Inspection and Test Plan (ITP) - Civil Works
Qaremy Construction - NSW Solar Farm Project
Document Control
- Document No: QAR-ITP-CIV-001
- Revision: A
- Date: October 2025
- Discipline: Civil Works
1. Purpose and Scope
This Inspection and Test Plan (ITP) defines the inspection and testing requirements for civil works associated with the Solar Farm project.
Scope includes:
- Site preparation and earthworks
- Access roads and internal roads
- Drainage works
- Tracker foundation piles/footings
- Inverter station and substation foundations
- Cable trenches and conduits
- Site facilities and amenities
2. Inspection Point Definitions
2.1 Hold Point (H)
Work must stop and cannot proceed until the inspection is completed and documented approval is given by the designated party.
Symbol: 🛑 H
2.2 Witness Point (W)
The designated party must be given the opportunity to witness the activity. If they choose not to attend after notification, work may proceed.
Symbol: 👁️ W
2.3 Review Point (R)
Documentation must be submitted for review. Work may proceed while review is in progress unless stated otherwise.
Symbol: 📋 R
3. Inspection Parties
| Code | Party | Role |
|---|---|---|
| SC | Subcontractor | Self-inspection |
| QC | QC Inspector | Contractor quality control |
| QA | QA Manager | Client/independent quality assurance |
| ENG | Engineer | Engineer's representative |
| TP | Third Party | Independent certifier/testing laboratory |
4. ITP Table - Site Preparation and Earthworks
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Site Clearance | ||||||
| Pre-clearance survey | Heritage and environmental check | W | QA, ENV | DA Conditions | Clearance approved by environmental consultant | Survey report |
| Vegetation clearing | Compliance with clearing limits | W | QC, ENV | DA Conditions | Within approved boundaries | Site photos |
| Topsoil stripping | Depth and stockpile location | R | QC | DA Conditions | Min 100mm depth, designated stockpile area | Inspection checklist |
| Bulk Earthworks | ||||||
| Survey setout | Dimensional check | H | QC, ENG | AS 3798 | ±50mm horizontal, ±25mm vertical | Survey certificate |
| Stripping depth verification | Level survey | R | QC | Design specs | As per geotechnical report | Survey report |
| Compaction - subgrade | Density testing | H | QC, TP | AS 1289.5.8.1 | ≥95% Standard Maximum Dry Density (SMDD) | Test certificates |
| Moisture content | Laboratory test | W | TP | AS 1289.2.1.1 | Within ±2% of optimum moisture content | Test certificates |
| Cut/Fill Slopes | ||||||
| Batter slope verification | Dimensional check | R | QC | Design drawings | Within design tolerance (typically 1:3) | Inspection record |
| Erosion control measures | Visual inspection | R | QC | ESCP | Measures in place as per ESCP | Site photos |
5. ITP Table - Access Roads and Internal Roads
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Subgrade Preparation | ||||||
| Survey setout | Horizontal and vertical alignment | H | QC, ENG | AS 3798 | Per design drawings ±50mm | Survey certificate |
| Subgrade compaction | Field density test | H | QC, TP | AS 1289.5.8.1 | ≥98% SMDD | Test certificates (1 per 500m² or as specified) |
| Subgrade proof rolling | Heavy roller test | W | QC | AS 3798 | No pumping, rutting, or deflection | Inspection record |
| Base Course | ||||||
| Material certification | Material source approval | H | QA | AS 2758.1 | Complies with spec for grading, plasticity | Material certificates |
| Layer thickness | Measurement | R | QC | Spec drawings | ±20mm of design thickness (typically 150-200mm) | Inspection checklist |
| Compaction - base course | Field density test | H | QC, TP | AS 1289.5.8.1 | ≥98% SMDD (modified) | Test certificates (1 per 1000m² min) |
| Level and grade | Survey check | W | QC | Design drawings | Within tolerance ±25mm | Survey report |
| Wearing Course | ||||||
| Material certification | Gravel/seal specification | H | QA | AS 2758.1 | Complies with wearing course spec | Material certificates |
| Layer thickness | Core samples or measurement | R | QC | Spec drawings | Per specification (typically 50-75mm) | Test results |
| Compaction - wearing course | Field density test | H | QC, TP | AS 1289.5.8.1 | ≥98% SMDD | Test certificates |
| Surface finish | Visual and measurement | R | QC | Design spec | No loose material, smooth finish | Inspection checklist |
| Final survey | As-built survey | R | ENG | Design drawings | Within tolerance | As-built drawings |
Testing Frequency:
- Compaction tests: Minimum 1 per 500m² for subgrade, 1 per 1000m² for base course
- Additional tests at location changes or material changes
6. ITP Table - Drainage Works
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Drainage Channels | ||||||
| Survey setout | Line and level | H | QC | Design drawings | ±50mm horizontal, ±25mm vertical | Survey certificate |
| Excavation dimensions | Width, depth, batter slopes | R | QC | Design drawings | Per design specification | Inspection checklist |
| Erosion protection | Rock sizing and placement | W | QC | AS 3798, Design | Complies with rock sizing, filter layer requirements | Material cert, photos |
| Culverts | ||||||
| Bedding material | Grading and compaction | H | QC | AS 3725 | Complies with bedding spec | Test certificate |
| Pipe installation | Line, grade, joint integrity | H | QC | AS 3725 | Grade per design (min 0.5%), no deflection | Survey certificate |
| Backfill compaction | Density test | H | QC, TP | AS 1289.5.8.1 | ≥95% SMDD | Test certificates |
| Headwalls and endwalls | Dimensions and finish | R | QC | Design drawings | Per specification | Inspection record |
7. ITP Table - Tracker Foundation Piles
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Pre-Installation | ||||||
| Survey setout | Grid layout and elevation | H | QC, ENG | Design drawings | ±20mm horizontal position | Survey certificate |
| Pile specification review | Pile type, dimensions, steel grade | R | QA | Design drawings, AS 1163 | Complies with structural design | Material certificates |
| Pile delivery inspection | Visual inspection, quantity | R | QC | Purchase order | No damage, correct specification | Delivery docket |
| Pile Installation | ||||||
| Pile verticality | Plumb check | R | SC | Spec (typically 1:75) | Within 1° of vertical | Inspection checklist |
| Pile embedment depth | Measurement | H | QC | Geotechnical report | Minimum depth per geotech (typically 1.5-2.5m) | Installation log |
| Torque measurement | Drive torque or resistance | H | QC | Geotechnical report | Minimum torque value (e.g., 8-15 kNm depending on soil) | Torque log sheet |
| Top of pile level | Survey | W | QC | Design drawings | ±25mm from design level | Survey report |
| Load Testing | ||||||
| Pile load test (sample) | Compressive and lateral load test | H | TP, ENG | AS 2159 | Per structural design requirements | Load test certificate |
| Frequency | Test sample | - | - | Geotech report | Typically 1% of piles or min 3 per soil type | Test schedule |
| Post-Installation | ||||||
| Final alignment check | Grid verification | R | QC | Design tolerance | Row alignment within ±50mm | Survey report |
| Pile protection | Corrosion protection verification | R | QC | Specification | Galvanizing intact, no damage | Inspection checklist |
Hold Point Note: Pile installation must stop if:
- Refusal before minimum depth is reached
- Torque values fall below minimum threshold
- Pile deviates beyond acceptable tolerance
8. ITP Table - Concrete Foundations (Inverter Stations, Substation)
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Pre-Pour Activities | ||||||
| Survey setout | Foundation location and level | H | QC, ENG | AS 3600, Design | ±10mm horizontal, ±5mm vertical | Survey certificate |
| Excavation | Dimensions and base condition | H | QC, ENG | Design drawings | Correct size, firm undisturbed base | Inspection checklist |
| Formwork | Alignment, bracing, level | H | QC | AS 3600 | Secure, no movement, correct dimensions | Formwork checklist |
| Reinforcement | Bar size, spacing, cover, laps | H | QC | AS 3600 | Per structural drawings, 50mm cover min | Rebar inspection form |
| Reinforcement cleanliness | Visual check | R | QC | AS 3600 | Free from loose rust, oil, coatings | Inspection record |
| Embedments | Anchor bolts, conduits, inserts | H | QC | Design drawings | Correct location ±5mm, secured | Embedment checklist |
| Concrete Supply | ||||||
| Concrete mix design | Design approval | H | QA, ENG | AS 1379 | Approved mix design (typically N32 or N40) | Mix design certificate |
| Delivery docket | Batch details | R | QC | AS 1379 | Correct mix, slump, batch time | Delivery dockets |
| Slump test | Workability check | W | QC, TP | AS 1012.3.1 | Within specified range (typically 80-120mm) | Slump test record |
| Concrete Placement | ||||||
| Pour inspection | Placement method, compaction | W | QC | AS 3600 | No segregation, proper vibration | Pour record |
| Concrete samples | Compression test cylinders | H | TP | AS 1012.8.1 | 6 cylinders minimum per pour | Sample register |
| Surface finish | Level and finish | R | QC | Specification | Level to tolerance, smooth finish | Inspection checklist |
| Post-Pour | ||||||
| Curing | Curing method verification | R | QC | AS 3600 | Curing compound or wet curing for 7 days | Curing record |
| Concrete strength testing | 7-day and 28-day compressive strength | H | TP | AS 1012.9 | ≥N32 MPa (or as designed) at 28 days | Test certificates |
| Formwork removal | Timing and inspection | R | QC | AS 3600 | After sufficient strength gain (min 3 days) | Inspection record |
| As-built survey | Final dimensions and levels | R | QC | Design drawings | ±10mm tolerance | As-built drawings |
Concrete Testing Frequency:
- Slump test: Each pour or every 50m³
- Compression samples: Minimum 6 cylinders per pour (test at 7 and 28 days)
9. ITP Table - Cable Trenches and Conduits
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Excavation | ||||||
| Survey setout | Trench alignment and depth | H | QC | Design drawings | ±100mm horizontal, ±50mm depth | Survey certificate |
| Excavation dimensions | Width, depth, side walls | R | QC | AS 3000, Design | Min 600mm depth (per AS 3000 for burial) | Inspection checklist |
| Service clearance | Utility location verification | H | QC, ENG | Dial Before You Dig | No conflict with existing services | Service location plan |
| Trench bottom condition | Base preparation | R | QC | AS 3000 | Free from rocks, debris, firm base | Inspection record |
| Conduit Installation | ||||||
| Conduit material check | Material certification | R | QA | AS/NZS 2053 | Approved conduit type (PVC, HDPE) | Material certificates |
| Bedding material | Sand or approved bedding | H | QC | AS 3000 | 100mm min sand bedding below conduit | Inspection checklist |
| Conduit laying | Alignment and support | R | QC | AS 3000 | Straight runs, adequately supported | Inspection record |
| Warning tape installation | Marker tape placement | H | QC | AS 3000 | Installed 300mm above conduit | Inspection checklist |
| Backfill | ||||||
| Initial backfill | Material and compaction | H | QC | AS 3000 | Sand to 300mm above conduit, light compaction | Inspection record |
| Final backfill | Compaction | R | QC | AS 3798 | Compacted in layers, no voids | Inspection checklist |
| Documentation | ||||||
| As-built survey | Trench route and depth | H | QC | AS 3000 | Recorded before backfill | As-built drawings |
| Photographic record | Photos at key points | R | QC | - | Clear identification of route | Photo log |
10. Inspection Request and Notification
10.1 Notification Requirements
| Inspection Type | Advance Notice Required |
|---|---|
| Hold Point (H) | Minimum 48 hours |
| Witness Point (W) | Minimum 24 hours |
| Review Point (R) | As per document submittal schedule |
10.2 Inspection Request Process
- Subcontractor completes self-inspection
- Request for Inspection (RFI) submitted to QC Inspector
- QC Inspector schedules and conducts inspection
- QA or third-party notified for Hold/Witness points
- Inspection record completed and distributed within 24 hours
11. Non-Conformance Management
If an inspection identifies non-compliance:
- Stop work in affected area
- Document non-conformance (NCR form)
- Investigate root cause
- Propose corrective action
- Implement correction
- Re-inspect before proceeding
12. Testing Laboratory Requirements
All testing must be conducted by NATA-accredited laboratories (National Association of Testing Authorities, Australia).
Required Accreditation:
- Soil testing: NATA accreditation for AS 1289 series
- Concrete testing: NATA accreditation for AS 1012 series
13. Quality Records Retention
All inspection and test records shall be retained for minimum 7 years post-project completion or as per contractual requirements.
Records include:
- Inspection checklists and forms
- Test certificates
- Material certificates
- Survey reports
- Non-conformance reports
- Photographic records
14. Revision History
| Revision | Date | Description | Prepared By | Approved By |
|---|---|---|---|---|
| A | Oct 2025 | Initial Issue | Lead QC Inspector (Civil) | QA Manager |
END OF DOCUMENT