Your Company Name CONSTRUCTION PROJECT CQC PLAN Origination Date: (month year) Document Identifier: Name, Number, Unique ID Date: Latest Revision Date Project: Customer, Unique ID, Part Number Document Status: Draft, Redline, Released, Obsolete (Your Project Description) CONTRACT NO. XXXXXXXXXXX Under the Supervision of (Your Customer Name) Abstract: This document describes the quality control plan for xxxxxx. Page 1 of 21 PROPRIETARY INFORMATION This document expires 30 days after printing unless marked "Issued". Date Printed: 25-Jan-12 Form Rev: Orig
Transcript
Your Company Name
CONSTRUCTION PROJECTCQC PLAN
Origination Date: (month year)
Document Identifier:
Name, Number, Unique ID
Date: Latest Revision DateProject: Customer, Unique ID, Part Number
Document Status:
Draft, Redline, Released, Obsolete
(Your Project Description)
CONTRACT NO. XXXXXXXXXXX
Under the Supervision of
(Your Customer Name)
Abstract:This document describes the quality control plan for xxxxxx.
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Date Printed: 25-Jan-12Form Rev: Orig
Your Company NameQuality Program
TBD Rev: Orig
REVISION LOGIssue Date Comment Author
0-0
DOCUMENT CHANGE RECORDIssue Item Reason for Change
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Date Printed: 25-Jan-12Form Rev: Orig
Your Company NameQuality Program
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1.0 SCOPEThe Company’s quality system has been fully documented and implemented and is maintained as needed to meet the requirements of the Company vision and governing policies.
The Company has adopted a process-oriented method of management. This approach emphasizes the importance of:
a) continuous improvement of processes based on objective measurement and analysis.
b) need to consider processes in terms of added value,
c) obtaining results of process performance and effectiveness and
d) understanding, meeting and integrating Customer, statutory and regulatory requirements,
The sequence and interaction of processes has been determined and are controlled by specific criteria and methods. Objectives are set for each process and then measured and monitored with appropriate data gathered and analyzed to ensure process effectiveness. During Management Review, process resources are discussed and allocated by management, as applicable. Corrective and preventive action is taken to ensure the processes achieve the desired results and continually improve.
2.0 RESPONSIBILITY AND AUTHORITYAll employees are empowered to request corrective or preventive action to prevent the occurrence of nonconformities relating to the construction process or the quality management system. The CQC Systems Manager oversees this effort and makes sure that such issues are identified and recorded, that solutions are transmitted to and resolved by the proper functions, and that the solutions are verified for effectiveness.
Project Superintendent
The Project Superintendent oversees all aspects of the job - responsibilities include:
• Request and attend bi-weekly progress meetings
• Request monthly partnering meetings to be attended by the Company, Customer and other local agencies.
• Serve as alternate CQC Systems Manager
• Supervise the CQC Systems Manager• Ultimately responsible for both production and quality of the project
The Project Superintendent has the authority to direct all work, subcontractors and project personnel, initiate and negotiate change orders, approve and disapprove any and all submittals, issue purchase orders and subcontracts or cancel them for noncompliance with contract documents, issue stop work orders and require corrective action on any deficiencies.
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CQC Systems ManagerThe Company’s Superintendent/Contractor Quality Control Systems Manager (CQC) verifies conformance to all Plans and Specifications - responsibilities include but are not limited to:
• Approve submittals not requiring Customer approval• Attend all scheduled progress meetings
• Complete and maintain Daily Report and copy to Project Superintendent
• Conduct and report preliminary, initial and follow-up inspections
• Conduct daily quality control inspections, report deficiencies, monitor progress and coordinate corrective actions with the Project Superintendent• Conduct weekly QC Meetings• Ensure all materials comply with the Plans and Specifications for the project
• Ensure approval and delivery of required submittals
• Ensure all tests are conducted according to the applicable procedure(s)
• Report all deficiencies to the President and Project Superintendent• Review all construction for compliance with the Plans and Specifications as well as quality workmanship
• Stop work and require corrective action on any deficiencies
Project Superintendent/CQC Systems Manager has the authority to direct all work, subcontractors and project personnel, approve and disapprove any and all submittals, issue stop work orders, require corrective action on any deficiencies and submit Requests for Information. See attached letter signed by a responsible authority of the Company that outlines responsibilities of the CQC Systems Manager, which includes authority to stop work that is not in compliance with the contract.
Alternative Contractor Quality Control RepresentativeIn the event the CQC Systems Manager is not present at the jobsite, the Alternative Quality Control Representative assumes all responsibilities and authorities. See attached letter signed by a responsible authority of the Company that outlines responsibilities of the Alternative Quality Control Representative, which includes authority to stop work that is not in compliance with the contract.
See Attachment 1 organization chart that shows lines of authority with the CQC Systems Manager reporting to the Project Superintendent. See Attachment 2 qualifications in resume format for the duties, responsibilities and authorities of each person assigned a CQC function.
3.0 SUBMITTALSAll submittals are scheduled, reviewed, certified and managed to include submittals from subcontractors, offsite fabricators, suppliers, purchasing agents, designers of record, consultants, architect engineers (AE) and offsite fabricators.
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Contractor Prepared Submittal RegisterThe Submittal Register is tailored to meet project schedules and is used as a checklist to assure all material and equipment requiring submission is submitted. A preliminary submittal register will be submitted for approval at the preconstruction conference. Additional details will be submitted according to the construction schedule within 30 days after Notice to Proceed.
General Submittal ProcedurePrior to submittal, all items shall be checked and approved by the QC representative and each item shall be stamped, signed and dated by the QC representative indicating action taken. Submittals will include items such as: Contractor’s, manufacturer’s or fabricator’s drawings; descriptive literature including but not limited to catalog cut sheets, diagrams, operating charts or tables, certifications, warranties and other such required submittals according to the requirements of the Plans and Specifications.
The Submittal Register may not be all-inclusive and additional submittals may be required. The approved submittal register will become the scheduling document and will be used to control the submittals throughout the life of the project. The submittal register and the progress schedules will be coordinated. A transmittal form will be used for submitting both Customer-approved and information-only submittals. Scheduling ProcedureThe Company uses software program (your software name) to assure delivery of submittals according to requirements of (your Customer doc) and upon completion of construction according to requirements of (your Customer doc).
4.0 INSPECTION SYSTEMThe engineering drawing, other technical documentation and identified critical items including key characteristics provides the requirements for all construction work. In all cases, this must include criteria for acceptance/rejection; where this is not clear the CQC Systems Manager oversees clarification of these criteria with the Project Superintendent.
Incoming materials are inspected by Quality to ensure they meet requirements before use and as a means of monitoring ongoing Supplier quality.
Inspection consists of Preparatory, Initial and Follow-up Inspections and applicable records for each Inspection.
Preparatory Inspections
This inspection will be conducted prior to beginning all definable segments of work as well as at the beginning of all of the Phases of the Contract. The Customer/Inspector and other involved personnel will be notified twenty-four (24) hours in advance of this inspection.
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Preparatory Inspections may include:
• PREPARATORY INSPECTION SHOULD BE POSTPONED UNTIL APPLICABLE SUBMITTALS ARE COMPLETED.
• Review requirements for quality control and/or performance testing during this phase of work. Emphasize testing methods and frequency. Establish who will be doing the testing and verify that testing personnel will be present as needed.• Review the contract drawings and specifications for this phase of work in detail. Discuss the construction procedures, tolerances, workmanship standards and repetitive deficiencies.• Review the requirement for special items and verify all samples have been submitted and approved.
• Verify all mobile construction equipment has been inspected for safety using US Army Corp of Engineers form number SAD Form 1666-R.• Verify all preliminary work required to start this phase of construction has been completed and the work to be built upon has no deficiencies.
• Verify all required materials and equipment are onsite, as specified, submitted and approved and properly stored.
• Verify all required submittals have been approved (review them as required). • Verify all work clearance permits have been obtained.
• Verify MSDS for all material to be used are readily available on the jobsite.
RECORD THE RESULTS OF THIS INSPECTION ON SEPARATE SHEETS AND ATTACH THEM TO THE DAILY REPORT.
Initial Inspections
This inspection will be held after a representative portion of the work has been accomplished. The Customer/Inspector and other involved personnel will be notified twenty-four (24) hours in advance of this inspection.
Initial Inspections may include:
• Determine necessary corrections if the work is not in compliance.• Record the exact location where the initial inspection was held for future reference and comparison during follow-up inspections.
• Review the records of the preparatory inspection and verify that all action items have been completed.• Verify all required quality control inspections and test are being performed.
• Verify that the work being performed is in full compliance with contract requirements, including acceptable level of workmanship. Compare with approved samples as appropriate.
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RECORD THE RESULTS OF THIS INSPECTION ON SEPARATE SHEETS AND ATTACH THEM TO THE DAILY REPORT.
Follow-up Inspections
This inspection will be performed as required. The Customer/Inspector and other involved personnel may arrange with the CQC Systems Manager to be present for this inspection.
Follow-up Inspections may include:
• Compliance with safety requirements.
• Documentation of this inspection will be noted on the Daily Report.
• Records of the Follow-up Inspection will be submitted to the Customer/Inspector not more than one (1) working day after the inspection.
• Review Noncompliance Tracking Log and ensure all deficiencies have been corrected or are being scheduled for corrective action.
• Review previous Inspection Reports to verify compliance with Contract requirements.
Documentation and Control
• All Inspections will be documented on a separate form and submitted with the Daily Report (attach your sample form).
• All reports for inspection and applicable records will be electronically maintained by the Project Superintendent in a document management program (your name; for instance, Constructware).
• Inspections will be conducted, controlled and tracked for each definable feature of work and sub-element identified herein using a project management program (your software name; for instance, Oracle’s Primavera SureTrak, USACE QCS System, etc.)
Completion Inspection
Punch-Out Inspection:
The Project Superintendent and CQC Systems Manager shall conduct an inspection of the work and develop a punch list of items that do not conform to the approved drawings and specifications. The Responsible Authorities will document and include the estimated date by which the deficiencies will be corrected and make a second inspection to ascertain all deficiencies have been corrected. Once this is accomplished, the CQC Systems Manager and Project Superintendent will sign-off the punch list then notify the Customer that the project is ready for Customer Pre-Final Inspection.
Pre-Final Inspection
The Customer will perform this inspection to verify the construction is complete and ready to be operated. A Customer Pre-Final Punch List may be developed as a result of this
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inspection. The CQC Systems Manager shall ensure that all items on this list have been corrected to schedule a Final Inspection with the Customer.
Final Acceptance Inspection
The CQC Systems Manager or other primary management personnel and the Customer Representative shall be in attendance at this inspection. The final acceptance inspection will be formally scheduled by the Project Superintendent based upon results of the Pre-Final Inspection. Notice shall be given by the Project Superintendent at least 14 days prior to the final acceptance inspection and shall include the Company’s assurance that all specific items previously identified under the contract will be complete and acceptable by the date scheduled for the final acceptance inspection.
5.0 TESTINGThe Testing Plan for the (your project name) is as follows:
• Test reports will be attached to the Daily Report by the CQC Systems Manager
• Test reports will include the date, time and type of test to be performed, test name, specification paragraph requiring testing, feature of work to be tested, test frequency and person responsible for each test. (Laboratory facilities will be approved by the Purchasing.)
• The CQC Systems Manager will notify the Customer/Inspector twenty-four (24) hours in advance of any scheduled test.
Control, verification and acceptance testing procedures for each specific test will include the test name, specification paragraph requiring test, feature of work to be tested, test frequency and person responsible for each test. Customer-directed laboratory facilities will be used when specified by Contract.
6.0 DOCUMENTS AND RECORDSRecords are controlled to provide evidence of conformity to requirements. Documents are controlled so that the information on them is accessible, legible and suitably maintained. Documents are reviewed and approved prior to release and only the latest versions are available to users. Previous versions are stamped “Superseded” and legacy documents are segregated and retained for historical purposes.
7.0 CONTROL OF NONCONFORMANCESConstruction design and construction deficiencies that are found to be nonconforming against specified requirements are identified, documented, segregated (if possible), evaluated and dispositioned to prevent unintended use or delivery. Necessary corrective and preventive actions are taken to contain the effect of the nonconformity on other products or processes and actions are verified to confirm that deficiencies have been corrected. This applies to incoming product or services (vendor-supplied), in-process product or services, final product or services and Customer returned products.
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REWORK PROCEDURES
The Company has a long standing successful Noncompliance Management Program to ensure all deficiencies are recorded, logged and pursued from identification through acceptable corrective action. Upon identification of a construction deficiency, a noncompliance report will be initiated by the CQC Systems Manager and forwarded to the appropriate subcontractor and Resident Engineer for notification of construction deficiency.
A narrative will be provided describing the construction deficiency, its proposed corrective action, time frame for correction, required testing and follow-up inspections to be taken.
The construction deficiency will be noted on the Daily Report and tracked daily until corrective action has been completed. The CQC Systems Manager will insure corrective action is accomplished according to the contract Plans and Specifications with approval of the Project Superintendent.
The Noncompliance Program will be maintained throughout the life of the project. Copies of all noncompliance reports will be available for review by the Customer/Inspector as well as any Subcontractor involved in the deficiency.
The Noncompliance Log will be updated monthly or as requested by the Project Superintendent.
8.0 DOCUMENTATIONProcedure
All reportable records shall include names of attendees.
All submittals of records will be maintained at the job site field office.
Test Reports will be attached to the Daily Report as they are received by the CQC Systems Manager.
The CQC Systems Manager will submit all Inspection Reports not more than one (1) working day after each inspection.
Registers / Files Maintained at Company Field Offices
• As-Built Drawings• Contract Documents (Plans, Specifications and Amendments)• Control Testing Schedule• Correspondence Files (Owner, Subcontractor, Supplier, etc)• Daily Report• Equipment and Material Delivery Schedule and Tracking Log• Field Survey Log• Inspection Reports (Preparatory, Initial and Follow-up)
• Material / Equipment Delivery Receipts• Modifications
• Noncompliance Management Program• Requests for Information (RFI) and RFI Log• Safety Plan
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• Subcontract and Purchase Order Registers• Submittal Data• Submittal Register and Submittal Log
9.0 WORKMANSHIPThe Company plans and carries out construction activities that include workmanship requirements for:
• Approval of work according to supporting documentation that includes the requirements of any applicable reference standards, regulatory codes, quality plans and other documented procedures.
• Completion of initial, follow-up, pre-final and final inspection activities.
• Construction work instructions or procedures that identify all necessary work steps (flowcharts, travelers, tickets).
• Designation of unapproved equipment, utilities and supplies with proper signage to prevent use.
• Documented work instructions where the lack of such instructions would affect conformity to requirements.
• Engineering documents for all construction characteristics (drawings, part lists, materials and specifications)
• Monitoring and measurement procedures.
• Monitoring and measuring devices.
• Skilled maintenance personnel and proper training of operators.
10.0LIST OF DEFINABLE FEATURES OF WORK(Tailor this section to address key elements of the project. A definable feature of work is a task that is separate and distinct from other tasks, has separate control requirements and may be identified by different trades or disciplines or it may be work by the same trade in a different environment. This list should be agreed upon during the coordination meeting.)
For instance – breakdown each work element from your contract Plans and Specifications:
General Requirements
01050 Field EngineeringEngineering ServicesSurvey Records/Cross-SectionsSurveyor Information
01320 Construction Video and Photographs01410 Testing and Quality Control01510 Temporary Utilities and Facilities01520 Temporary Pumping01530 Temporary Barriers and Controls01570 Traffic Control
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02370 RipRap SystemHandling and Storage of MaterialsMaterial Compliance
02401 Dewatering and Cofferdam
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Dewatering PlanStructural Certification
02431 Catch Basins, Frames and GratesHandling and Storage of MaterialsInstallationMaterial Compliance
02433 Storm Drainage System - Reinforced Concrete PipeHandling and Storage of MaterialsMaterial CompliancePlacement of Concrete PipeTesting
02435 Turbidity Control & Monitoring02436 Environmental Protection
02451 GuardrailHandling and Storage of MaterialsInstallationMaterial Compliance
02455 Round Timber PilingInspect for Preservation TreatmentInstallationMaterial CompliancePile Driving Equipment
02486 GrassingInstallationMaintenanceWatering02780 Floating Trash BarrierHandling and Storage of MaterialsInstallationMaterial Compliance
02781 Staff GaugesHandling and Storage of MaterialsInstallationMaterial Compliance
Concrete
03100 Concrete Formwork and AccessoriesHandling and Storage of MaterialsInstallationMaterial Compliance
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03200 Concrete ReinforcementHandling and Storage of MaterialsInstallationMaterial ComplianceShop Drawings
03300 Cast in Place ConcreteConcrete MixtureConstruction ToleranceCuring and ProtectionDesign RequirementsEquipmentFinishingGovernment TestingMaterial CompliancePlacingPreparation and PlacingTests and Inspection
03410 Precast Concrete Products for Below-Grade ConstructionDeliveryHandling and Storage of MaterialsInstallationMaterial ComplianceTests and Inspections
03600 GroutHandling and Storage of MaterialsInstallationMaterial Compliance
Metals
05060 WeldingCertifications
05070 Bolted FastenersHandling and Storage of MaterialsInstallationMaterial Compliance
05100 Structural SteelHandling and Storage of MaterialsInstallationMaterial ComplianceShop Drawings
05521 Handrails, Railings and GuardpostsHandling and Storage of Materials
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InstallationMaterial ComplianceShop Drawings
05550 Fabricated Metalwork and CastingsHandling and Storage of MaterialsInstallationMaterial ComplianceShop Drawings
Thermal and Moisture Protection
07920 Sealants and CaulkingsHandling and Storage of MaterialsInstallationMaterial ComplianceTests and Inspections
07921 Joint SealantsInstallationMaterial ComplianceTests and Inspections
Doors and Windows
08110 Hollow Metal Doors and FramesInspectionInstallationMaterial Compliance
08700 Finish Hardware and AccessoriesInspectionInstallationMaterial Compliance
Finishes
09805 Coal-Tar Epoxy Coating Systems for Steel Tie Rods and AccessoriesApplicationInspectionMaterial Compliance
15101 Valves and AppurtenancesHandling and StorageInstallationMaterial Compliance
15510 FansHandling and StorageInstallationMaterial Compliance
Electrical
16050 Basic Materials and MethodsFactory Test ReportsField Test ReportsHandling and StorageInstallationMaterial ComplianceOperating Tests
16061 Cathodic Protection SystemHandling and StorageInstallationMaterial ComplianceTests and Inspections
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16110 Raceways, Boxes, Fittings, SupportsHandling and StorageInstallationMaterial ComplianceTests and Inspections
16120 Wires and CableHandling and StorageInstallationMaterial ComplianceTests and Inspections
16140 Wiring DevicesHandling and StorageInstallationMaterial ComplianceTests and Inspections
16150 MotorsHandling and StorageInstallationMaterial ComplianceTests and Inspections
16155 Motor StartersHandling and StorageInstallationMaterial ComplianceTests and Inspections
16160 Panelboards & General Purpose Dry Type TransformersHandling and StorageInstallationMaterial ComplianceShop DrawingsTests and Inspections
16289 Transient Voltage Surge SuppressorsHandling and StorageInstallationMaterial ComplianceTests and Inspections
16440 Disconnect Safety SwitchHandling and StorageInstallationMaterial ComplianceTests and Inspections16450 Grounding
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Handling and StorageInstallationMaterial ComplianceTests and Inspections
16500 Lighting DevicesHandling and StorageInstallationMaterial ComplianceTests and Inspections
16620 Propane Fueled Generator and Transfer SwitchHandling and StorageInstallationMaterial ComplianceShop DrawingsTests and Inspections
16621 Diesel Fueled Generator and Transfer SwitchHandling and StorageInstallationMaterial ComplianceShop DrawingsTests and Inspections
16670 Lightning Protection SystemHandling and StorageInstallationMaterial ComplianceTests and Inspections
16910 Structure Remote Terminal Unit (RTU)Handling and StorageInstallationMaterial ComplianceShop DrawingsTests and Inspections
16920 Portable Water SamplersHandling and StorageInstallationMaterial ComplianceShop DrawingsTests and Inspections
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ATTACHMENT 1 - ORGANIZATION CHART
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PROJECT SUPERINTENDENT
CQC SYSTEMS MANAGER
FACILITIES MANAGER
PROJECT FOREMAN
PROJECT ENGINEER
ADMINISTRATIVE ASSISTANT
ACCOUNTING MANAGER
ENVIRONMENTAL HEALTH & SAFETY
RECEIVING
Maintenance
INSPECTORS
PRODUCTION SUPERVISOR
Contracts
PURCHASING
HR
PRODUCTION CREW
SHIPPING
Your Company NameQuality Program
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ATTACHMENT 2 - CQC RESUMES
(your CQC Systems Manager)
Mr/Mrs xxxxx is in charge of inspections and will verify that the contractors are in compliance with the project specifications & engineering design drawings. In addition, Mr/Mrs xxxxx is responsible for ensuring that the project is constructed, tested, inspected, and documented according to project specifications. Mr/Mrs xxxxx will also be responsible for quality control in the following areas: materials management, subcontractors, document controls, discrepancy control, system acceptance and turnover.
(your CQC Inspector)
Mr/Mrs xxxxx performs inspections to ensure conformance to quality, performance, safety and/or code requirements. Inspector assists with general guidance to other inspectors and provides QA/QC reports to supervisor for approval and maintains inspection records.
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