Quality Controle Plan
Quality Controle Plan
Quality Controle Plan
Earthworks
QA/QC Plan Sample
Selected pages (not a complete plan)
Part 1: Project‐Specific Quality Plan
Part 2: Quality Manual
Part 3: Submittal Forms
Part 4: Inspection Checklist Forms
Contact:
FirstTimeQuality
410‐451‐8006
Pat
[Pick the date]
Questions? Call First Time Quality (410) 451-8006
es
C. Project Quality Coordination and Communication..................................................................................13
D. Project QC Personnel................................................................................................................................17
ag
Project QC Job Position Assignments ....................................................................................................... 17
Project QC Organization Chart ................................................................................................................. 18
E. Duties, Responsibilities, and Authority of QC Personnel.........................................................................19
tP
F. Personnel Qualifications and Technical Certifications .............................................................................25
G. Qualification of Third Party Inspection/Testing Companies and Subcontractors and Suppliers ...........27
Qualification ............................................................................................................................................. 27
ec
es
Project Audit Plan ..................................................................................................................................... 65
Project Audit Requirements ..................................................................................................................... 65
ag
R. Additional Quality Control Requirements ...............................................................................................67
tP
l ec
Se
Questions? Call First Time Quality (410) 451-8006
Maintain a documented quality system consisting of a quality manual with policies and
procedures.
Tightly control exceptions to the quality system so company standards are applied uniformly to
every project
Systematically maintains quality system documents and records.
Quality Control Personnel. [CompanyName] fully integrates its quality management system
es
into the organizational structure and performance management systems for each project. We:
Appoint a Quality Manager, Superintendent, and Project Manager to each project, each with
well-defined quality responsibilities and the authority to carry them out.
ag
Have well-defined quality responsibilities for every employee with specific quality responsibilities
for key job positions.
Plan project quality records and documentation that will be maintained.
tP
Tightly control exceptions to the quality system so company standards are applied uniformly to
every project
Enforce policies that monitor work conditions before and during work so that quality results are
assured.
ec
Plan quality communications through meetings, reporting requirements, and points of contact.
Have a project startup meeting to communicate project goals and expectations.
Conduct preparatory meetings in advance of each scheduled work task to communicate
requirement details and coordinate work activities.
Audit the operation of the quality system on each project for conformance to the Project Quality
Assurance/Quality Control Plan and the [CompanyName] Quality System requirements.
Conduct annual company-wide audits to evaluate effectiveness of the [CompanyName] Quality
System and improve its operation.
Review ongoing employee qualifications and evaluate quality practices and performance as part
of the employee performance management process.
es
Supplement the contract and published standards with [CompanyName] quality standards as
required to reduce quality risks and assure quality results.
Inspections and Test Plan. [CompanyName] quality inspection processes ensure that all work
ag
activities comply with the documented standards and specifications. We:
Identify inspections and tests required by contract specifications and industry standards.
tP
Record the result of each quality inspection and test.
Use independent laboratories certified by nationally recognized accreditation agencies
Work Task Quality Inspections. [CompanyName] quality inspection processes ensure that
ec
all work activities comply with the documented standards and specifications. We:
Identify required quality inspections and tests at key milestones during the project.
l
Identify each work task that is subject to a series of quality inspections and quality control
Se
activities
Questions? Call First Time Quality (410) 451-8006
The Project Manager ensures that the information in customer contracts clearly defines customer
expectations and that the necessary details are provided to set requirements for construction.
[CompanyName] personnel and subcontractors and suppliers are accountable for compliance to
standards-based written specifications.
To achieve expectations reliably and consistently, specifications are clearly spelled out, not only for results
but also for processes. Specifications apply to materials, work steps, qualified personnel and
subcontractors and suppliers, safe work rules, and environmental work conditions.
Standards ensure that results are specified rather than left to discretionary practices.
All [CompanyName] construction activities comply with generally accepted good workmanship practices
es
and industry standards.
Local construction codes do not apply to this project. The project is not subjected to quality inspections
by local regulatory agencies. ag
tP
l ec
Se
Questions? Call First Time Quality (410) 451-8006
Reference
Division Description Reference Standard Title
Standard No.
31 Bedding for buried piping AWWA C600 Installation of Ductile-Iron Water Mains and Their Appurtenances
31 Welding lengths of pipe together for AWS D1.1/D1.1M Structural Welding Code - Steel
bore holes
31 Geotextile storing and handling ASTM D 4873 Identification, Storage, and Handling of Geosynthetic Rolls and Samples
es
31 Precast prestressed concrete pile PCI JR-382 Recommended Practice for Design, Manufacture and Installation of
installation Prestressed Concrete Piling
31 Drilled shaft foundation installation ACI 336.1 Specification for the Construction of Drilled Piers
ag
tP
l ec
Se
Questions? Call First Time Quality (410) 451-8006
Each inspection verifies compliance with full scope of the relevant specifications; not limited to inspection
form checkpoints.
The initial work task-ready inspection occurs when work is ready to start and ensures that work begins
only when it does not adversely impact quality results.
Incoming material inspections verify that materials are as specified and meet all requirements necessary
to assure quality results.
Work-in-process inspections continuously verify that work conforms to project specifications and quality
expectations. Work continues only when it does not adversely impact quality results.
At completion of the work task an inspection verifies that work has been completed in accordance with
project quality requirements.
es
Inspection results are recorded and maintained as part of the project files.
The Quality Manager identifies each Task that is a phase of construction that requires separate quality
ag
controls to assure and control quality results. Each Task triggers as set of requirements for quality control
inspections before, during and after work tasks.
tP
Independent quality audits are conducted to verify that the task quality controls are operating effectively.
Construction projects may execute a work task multiple times in a project, in which case a series of quality
inspections are required for each work task.
ec
Independent quality control audits are conducted to verify that the task quality controls are operating
effectively.
l
Se
TASK-READY INSPECTIONS
For each work task, the Superintendent or a qualified inspector performs job-ready quality inspections to
ensure that work activities begin only when they should begin. Job-ready quality inspections verify that
conditions conform to the project quality requirements.
es
ag
tP
l ec
Se
Questions? Call First Time Quality (410) 451-8006
QUALITY MANUAL
TABLE OF CONTENTS
1.1. Overview.............................................................................................................................................. 6
1.2. [CompanyName] Quality Policy ........................................................................................................... 6
1.3. Quality Duties, Responsibilities, and Authority ................................................................................... 6
1.4. Quality System Performance Measures .............................................................................................. 9
1.5. Customer Satisfaction Performance Measures ................................................................................... 9
1.6. Exceptions............................................................................................................................................ 9
2. Project Quality Assurance/Quality Control Plan......................................................................................10
2.1. Overview............................................................................................................................................ 10
2.2. [CompanyName] Project License and Qualification Requirements................................................... 10
es
2.3. Project Personnel and Qualifications ................................................................................................ 11
2.4. Project Quality Assurance/Quality Control Plan ................................................................................ 12
ag
2.5. Identification of Quality Controlled Work Tasks................................................................................ 12
2.6. Project Quality Inspection and Test Plan ........................................................................................... 12
2.7. Project Quality Communications Plan ............................................................................................... 12
tP
2.8. Project Quality Training Plan ............................................................................................................. 12
2.9. Customer Training On Operation and Maintenance ......................................................................... 13
2.10. Project Records and Documentation Plan ....................................................................................... 13
2.11. Project Audit Plan ............................................................................................................................ 13
ec
3.1. Overview............................................................................................................................................ 14
Se
4.1. Overview............................................................................................................................................ 18
4.2. Design Input Review .......................................................................................................................... 18
4.3. Project Design Quality Assurance/Quality Control Plan .................................................................... 18
4.4. Design Progress Reviews ................................................................................................................... 19
4.5. Design Output Verification and Approval .......................................................................................... 19
Page 2
Quality Manual
Copyright
Questions? Call First Time Quality (410) 451-8006
es
6.8. Project Purchase Order Approvals..................................................................................................... 26
7. Process Controls........................................................................................................................................27
ag
7.1. Overview............................................................................................................................................ 27
7.2. Project Startup and Quality Control Coordination Meeting .............................................................. 27
7.3. Preparatory Project Quality Assurance/Quality Control Plan Planning ............................................. 27
tP
7.4. Weekly Quality Planning and Coordination Meetings ....................................................................... 28
7.5. Process Control Standards................................................................................................................. 28
7.6. Daily Quality Control Report.............................................................................................................. 30
ec
8.1. Overview............................................................................................................................................ 31
Se
Page 3
Quality Manual
Copyright
Questions? Call First Time Quality (410) 451-8006
9.1. Overview............................................................................................................................................ 37
9.2. Nonconformances ............................................................................................................................. 37
9.3. Corrective Actions ............................................................................................................................. 38
11.1. Overview.......................................................................................................................................... 42
11.2. Project Quality System Audit ........................................................................................................... 42
11.3. Company-wide Quality System Audit .............................................................................................. 42
12. Record and Document Controls .............................................................................................................44
12.1. Overview.......................................................................................................................................... 44
12.2. Quality System Documents ............................................................................................................. 44
es
12.3. Document Controls.......................................................................................................................... 44
12.4. Record Controls ............................................................................................................................... 45
ag
13. Appendix .................................................................................................................................................47
13.1. Definitions of Terms ........................................................................................................................ 47
tP
l ec
Se
Page 4
Quality Manual
Copyright
Questions? Call First Time Quality (410) 451-8006
7. PROCESS CONTROLS
HOW WORK IS CARRIED OUT
7.1. OVERVIEW
The construction process plan defines how project work is to be done and approved for the overall
project. The construction process plan is communicated to all key personnel, subcontractors and suppliers
in a startup meeting. As the project proceeds, work task plans provide additional details of how each
individual work task is carried out. Work tasks planning meetings are used to communicate expectations
of the work task plan to key personnel responsible for carrying out the work task.
es
suppliers meet to review expectations for project quality results as well as quality assurance and quality
control policies and procedures including:
Key requirements of the project
ag
The Project Quality Assurance/Quality Control Plan
Required quality inspections and tests
tP
The project submittal schedule
Quality policies and heightened awareness of critical quality requirements
Project organization chart and job responsibilities
Methods of communication and contact information
ec
During the meeting, the Superintendent communicates the work task quality requirements and reinforces
heightened awareness for critical requirements. Topics for a work task quality plan meeting include:
es
Required quality documents and a verification of availability to personnel carrying out,
supervising, or inspecting the work task
Record keeping requirements and the availability of necessary forms
Review methods and sequences of installation ag
Special details and conditions
Standards of workmanship
Heightened awareness of critical quality requirements
tP
Quality risks
Work tasks quality inspection form
ec
The meeting is held on a nominal weekly schedule. During the meeting, the Superintendent facilitates
coordination among the participants, communication among the participants, and reinforces heightened
awareness for critical requirements.
The Superintendent maintains a record of the meeting event on the Daily Quality Control Report.
Copyright
Questions? Call First Time Quality (410) 451-8006
A nonconformance is any item that does not meet project specifications or [CompanyName] Quality
System requirements.
9.2. NONCONFORMANCES
es
9.2.2. CONTROL THE CONTINUATION OF WORK
After the item is marked, the Superintendent determines if work can continue in the affected area:
ag
CONTINUE WORK: When continuing work does not adversely affect quality or hide the defect, work may
continue in the affected area while the disposition of the item is resolved. The Superintendent may place
tP
limitations on the continuation of work.
STOP WORK ORDER: When continuing work can adversely affect quality or hide the defect, work must
stop in the affected area until the disposition of the item resolved. The Superintendent identifies the
ec
limits of the affected area. The Superintendent quickly and clearly identifies the boundaries of the stop
work area.
l
Se
es
Training Plan
Training Log
Regulatory Codes and Industry Standards ag
Project Regulatory Building Codes
Controlled Materials Form
tP
Metals Material Receiving Inspection Report
Material Inspection and Receiving Report
ec
[CompanyName][CompanySuffix]
Nonconformance Report
Version 20131125
Nonconformance Report
Control ID Project ID Project Name
[ProjectNumber] [ProjectName]
es
Disposition
Corrective Actions
Corrective actions completed Name/Date:_________________________
ec
Name/Date:_________________________
l
Se
Preventive Actions
FORMS:
es
Bored Piles
Caissons
Driven Piles ag
Excavating and Fill
Grading
tP
Clearing and Grubbing
l ec
Se
Questions? Call First Time Quality (410) 451-8006
es
production piles
inspection requirements
Do not place concrete near active pile placement to prevent
aggregate segregation
Compliance with Task completion inspection
requirements
Limit concrete placement rate and properly vibrate fill to
Quality 5 4 3 2 1 Notes:
On-Time 5 4 3 2 1 Notes:
Safety 5 4 3 2 1 Notes:
Quality Score 5 = 100% NO problems 4 = 1 minor problems 3 = Hotspot or 2-3 minor 2 = 6+ or major problems 1 = Excessive problems
On-Time Score 5 = On Time 4 = Late 3 = Late by 1 day 2 = Late by 2 days 1 = Late more than 2 days
Safety Score 5 = 100% NO problems 4 = 1 minor problem 3 = Hotspot or 2-3 minor 2= 4+ or major problem 1= Injury
Copyright 2012 First Time Quality
For More Information:
Contact: FirstTimeQuality
410-451-8006
www.FirstTimeQuality.com