Attachment_4.pdf

FA4803-14-R-0003

Attachment 4

CONSTRUCTION QUALITY PLAN

Air Combat Command United States Air Force Shaw Air Force Base Sumter, South Carolina

REPAIR FITNESS CENTER, B806

VLSB 10-0001

Shaw Air Force Base South Carolina

Approvals:

Project Manager

Quality Control Supervisor

TABLE OF CONTENTS

1.0 INTRODUCTION

1.1 Scope of Work

2.0 KEY PROJECT PERSONNEL

3.0 INSPECTIONS

3.1 Receiving Inspections

4.0 SUBMITTAL PROCESS

4.1 Planning

4.2 Submittal Register

4.3 Schedule

4.4 Transmittal Requirements

4.5 Tracking and Approval Process

5.0 THREE PHASE CONTROL PROCESS

5.1.1 Preparatory Phase Inspection

5.1.2 Initial Phase Inspection

5.1.3 Follow-Up Phase Inspection

5.1.4 Final Phase Inspections

5.2 Quality Audits

5.3 Completion Acceptance

6.0 MEETINGS

6.1 Preconstruction Conference

6.2 Project Kickoff Meeting

6.3 Weekly Status Reports

7.0 ENGINEERING AND CONSTRUCTION

7.1 Hold Point Compliance

7.2 As-Built Records

8.0 REPORTING AND RECORD KEEPING

8.1 Weekly Quality Control Report

8.2 Field Logbook

8.3 Photo Documentation

8.4 Inspection Reports

8.5 Project Files

9.0 SITE TRANSFER

9.1 Punch List Items

9.2 Pre-Final Inspection

9.3 Final Inspection

9.4 Warranty and Maintenance

9.5 REFERENCES AND GUIDANCE

5.1.1 Preparatory Phase Meeting

LIST OF APPENDICES

Construction QC Forms ………………………………………………………………… APPENDIX A

LIST OF ACRONYMS AND ABBREVIATIONS

AFCEC Air Force Civil Engineering Center

AECOM AECOM

CDRL Contract Data Requirements List CM Construction Manager CO Contracting Officer COR Contracting Officer’s Representative CQC Contractor Quality Control CQP Construction Quality Plan CTN Conditions and Notations CWP Conceptual Work Plan DFW Definable feature of work DOD Department of Defense DQCR Daily Quality Control Report HSP Health and Safety Plan IBC International Building Code IWP Implementation Work Plan NEC National Electrical Code NHT National Hose Thread NFPA National Fire Protection Association OSHA Occupational Safety Health Administration O&M Operation & maintenance PgM Program Manager PM Project Manager POC Point of Contact QA Quality assurance QC Quality control QCM Quality Control Manager REJ Reject R&R Revised and Resubmit SOR Statement of Requirement SOW Statement of Work TO Task order UFC Unified Facility Criteria USACE EM US Army Corps of Engineers Engineer Manual USAF United Stated Air Force WERC Worldwide Environmental Restoration and Construction WQCR Weekly Quality Control Report

1.0 INTRODUCTION

__________________________________________________ accepts this Construction Quality Plan (CQP) for the Air Force Base Civil Engineering under VLSB 10-0001 to perform the Statement of Work (SOW) entitled, “Repair B806” at Shaw AFB, South Carolina, SOW dated 20 December 2013.

Quality Control Objectives

The CQP establishes procedures to monitor project tasks utilizing the three phases of control process to help plan, modify, implement and complete all work in compliance with contract requirements. It establishes procedures for testing and inspection, documentation and reporting, and communication protocol to ensure all work meets the project specifications and conforms to contract requirements, project specifications, and applicable regulations.

The contractor performs the following functions:

• Provides a continuous program to examine the quality of materials, maintain standards of workmanship;

• Identifies/ corrects deficiencies, and furnishes work products that meet or exceed contract requirements; and

• Maintains qualified personnel, equipment, and facilities to complete the project.

1.1 Scope of Work

The work consists of the renovation of the existing Fitness Center at Shaw AFB, South Carolina. To ensure quality, the contractor will implement the Quality Control (QC) process including the three-phase inspection system for each definable feature of work (DFW). While specific timing and tests will be identified for each DFW during field activities, below are the general DFWs for which AECOM will assure proper installation and quality following its QC process. The specific elements of major DFWs are listed in Attachment 1.

1. Submittals

2. Permits

3. Mobilization

4. Site Preparation

5. Repair electrical equipment at pipe manifold pump pad rack facility 119 (Fac 111) and provide cover

6. Enclose building

7. Emergency eye wash & showers require repair by replacement B112 and B207.

8. Thermal relief valve evaluation, Facilities 9126 tank 27, 28, 29; Facility 119 pump pad; Facility

9129, diesel tank s1 & 2; Facility 9127 MOGAS; Facility 9300 railhead offload system

9. Pre-Final and Final Inspections

10. Demobilization

11. Final Reports

The contractor will document, record, and submit the testing, three-phase inspections, and any audits performed to CO for approval.

2.0 KEY PROJECT PERSONNEL

All work will be conducted under the supervision of the Senior Project Manager (PM), Construction Manager or the on-site Quality Control Manager (QCM), in accordance with ___ quality policies. The on-site QCM reports to the contractors corporate QC.

Subcontractors will abide by the procedures identified in project plans and documents, and follow all designated QC, safety, and security protocols. While subcontractors are required to ensure the quality of their work, the contractor will retain responsibility for supervision, inspection, and approval of subcontractor work.

Position Name Contact Information

3.0 INSPECTIONS

THE CONTRACTOR will routinely inspect completed work. Attachment A provides a list of QC forms and reports available to the QCM to document inspections and track progress. THE CONTRACTOR will supply checklists for the major DFWs, showing specific tests and inspections, as well as requirements that must be met prior to or during performance of that activity as required. THE CONTRACTOR will inform the AFCEC COR at least 5 working days, or as directed, in advance of any inspection.

3.1 Receiving Inspections

In the event the inspections reveal significant corrosion or faulty equipment, it may be necessary, after government approval of repairs, to fabricate or have materials delivered which may require government approval through the submittal process. All materials will conform to most recent applicable federal, state, and local statutes; DoD/Air Force instructions, manuals, handbooks, regulations, guidance, and policy letters, including but not limited to; International Building Code (IBC); Unified Facility Criteria (UFC); National Fire Protection Association (NFPA); National Electrical Code (NEC) prior to use, thus ensuring that quality products will be used throughout construction. The QCM or QC staff member will inspect all materials and equipment procured and delivered to the site to ensure they comply with applicable international/ regional codes and project plans as directed by the COR, as well as project specifications and application.

4.0 SUBMITTAL PROCESS

4.1 Planning

Prior to or upon award, the PM assembles contracts, scheduling, engineering, and quality control project personnel to:

• Develop the submittal register

• Identify required clarifications on the submittals from AFCEC

• Identify critical path submittal items to be incorporated into the schedule and procurement plan

• Identify the internal submittal review process for designs and materials

• Ensure that submittal requirements and the submittal process are communicated to the subcontractor as part of the RFP

• Ensure that the QCM understands their role in coordinating the submittal process and the required interfaces

4.2 Submittal Register

The QCM/Submittal Manager will maintain the AFCEC Master Submittal Register and updates the submittal register as necessary. The submittal register is linked to the project schedule and procurement plan.

THE CONTRACTOR maintains an updated submittal register on site.

4.3 Schedule

Submittals for materials are incorporated into the construction schedule. The project schedule “Dates” column identifies when submittals are required by AECOM, and when approval is needed. Submittals covering components forming a system or interrelated are scheduled to be submitted concurrently.

The QCM will monitor the schedule to ensure that the required procurement activities, meetings, inspections and submittals are reported and progressed accurately. The critical path activities will be monitored and evidence of schedule slippage will be discussed with project staff in order to plan for recovery of those activities.

4.4 Transmittal Requirements

A transmittal form accompanies each submittal. Appendix A contains a copy of the transmittal forms.

The submittal forms are properly completed by filling out all heading blank spaces and identifying each item submitted along with the applicable specification paragraph. Material submittals include a catalog data sheet and/or a picture of the material to be submitted, specification sheets, and/or other information to ensure that the materials meet the contract requirements.

4.5 Tracking and Approval Process

Submittals are managed on the contractor. The contractor will review and approve all submittals required from subcontractors and suppliers. The submittals shall then be forwarded to the contracting office for approval. The QCM assures that work is not started without Base CE approved submittals.

The following activities provide for appropriate control of submittals.

• All submittals have a unique identification number.

• Material submittals: Material submittals will receive a QC review at the project before being released for Base CE review.

• If any submittals are returned with as disapproved, the submittal and tracking dates are revised accordingly. Re-submittals must follow the same process as the original submittal.

• Re-submittals will be identified w i th t h e s a me su bmi t t a l n umb e r f o l l o w ed b y a letter designation, i.e. “2A” for the first revision, “2B” for the second revision, etc.

• The designated submittal manager will maintain the Master Submittal Register and coordinate all submittal activities to ensure proper reviews and timely submission of submittals.

The QCM assures that work is not started without Base CE approved submittals.

5.0 THREE PHASE CONTROL PROCESS

The Three-phase inspection process assures control of work at every stage of an activity, from planning through completion. The process entails the preparatory, initial, and follow-up inspections. Work will only begin on a DFW when a successful preparatory inspection is completed. An additional inspection may be conducted if a new crew or subcontractors are added to a feature of work. The CE inspector will be invited to attend all inspection.

5.1.1 Preparatory Phase Inspection

A preparatory phase inspection will be performed prior to beginning each major DFW to ensure that the applicable specifications and the necessary resources, supplies, conditions, and controls are in place before starting that activity. The QCM may meet with the Senior PM or Construction Manager and will meet with the subcontractors responsible for that activity to document the Preparatory Phase Inspection, which will ensure:

• Necessary plans and submittals have been prepared, approved, and are available

• Subcontractors are on site and ready to start the activity

• Appropriate field equipment is available, functional, and properly calibrated

• Necessary tests, verifications, and inspections have been performed to meet standards

• Responsibilities have been assigned and communicated

• Activity hazards analyses have been communicated, and safety measures are in place

• Personnel have the knowledge and expertise to perform their duties for the DFW

Deficiencies identified will be tracked and corrected to ensure all work meets applicable standards.

Discrepancies between existing conditions and approved plans and/or procedures will be resolved and corrective actions taken for unsatisfactory or nonconforming conditions identified. This will be verified by the QCM prior to granting approval for work to resume. Preparatory phase inspection results will be documented in the preparatory phase inspection checklist and summarized in the Weekly quality control report (WQCR).

5.1.2 Initial Phase Inspection

An initial phase inspection will be performed the first day a DFW is performed. The purpose of this inspection will be to do the following:

• Review the minutes of the Preparatory Phase Inspection to ensure they are incorporated into site activities

• Check the preliminary work for compliance with procedures and contract specifications;

• Verify inspection and testing

• Establish the acceptable level of workmanship

• Check and upgrade safety compliance

• Check for omissions and resolve differences in interpretation

The QCM or QC staff member will ensure the responsible party, such as Construction Manager or foreman, performs and records any equipment inspections to verify proper conditions. Calibration and equipment testing reports will be reviewed by the QCM. The QCM or QC staff member will ensure that discrepancies between site practices and approved specifications are identified and resolved before granting approval to proceed. He may coordinate this effort with the Senior PM, Senior Construction Manager or subcontractor’s foreman, if needed. The initial phase inspection results will be documented and summarized in the WQCR.

5.1.3 Follow-Up Phase Inspection

Follow-up inspections are conducted periodically on on-going work to ensure that the established standards of workmanship and procedures are being maintained. Follow-up Inspections shall be documented on the WQCR. If work fails to meet desired standards, a Stop Work Order will be issued and corrections made to improve a procedure or practice.

5.1.4 Final Phase Inspections

The contractor will complete a pre-final phase inspection and a final phase inspection.

Additional inspections may be conducted on the project DFW if any of the following occurs:

• QA representative determines that the quality of work is unacceptable

• QCM is changed

• Field conditions change

• PM is changed

• Fieldwork is resumed after a substantial period of inactivity

The Contracting Officer’s Designated Representative (COR) and the QCM shall review specifications and cut sheets prior to receiving material on site, and/or prior to installation on facilities, to avoid defective or inadequate materials/equipment. Documentation of the Engineer and/or QCM’s review and acceptance will be maintained on file to avoid controversy during inspection and acceptance by the client.

5.2 Quality Audits

Validation of compliance with Project Plans and SOW requirements is accomplished through periodic and random internal audits. The QCM will determine the type and method of audit prior to initiating an activity, and will recommend corrective actions to the Senior PM if any deficiencies are encountered.

5.3 Completion Acceptance

The QCM will invite the Senior PM, the contracting officer and the CE inspector to attend both Pre-final Inspection and Final inspection. This inspection will be formally scheduled by the contractor. This notice will be given at least 5 working days prior to the Final Inspection, and the contractor will provide assurances that all work is complete prior to this inspection. The Inspection will certify that all items of the plan have been implemented and that the construction is complete; and include a record of as-built drawings and specifications verifying standards have been met. A Final Inspection Report will be published.

6.0 MEETINGS

The contractor will attend and/or support monthly on-site progress meetings and teleconferences regarding project progress and status as required by the Contracting Officer. The following meetings are expected during project performance on an as needed basis:

• Preconstruction conference meeting

• Weekly QC meetings, and/or

• Other meetings necessary to support construction activities.

6.1 Preconstruction Conference

The CO, CE Inspector, CE project manager, QCM, Senior PM and major subcontractors will attend a preconstruction meeting conference call prior to starting the construction at the site to discuss the details of the QC process and documents, review the responsibilities of each organization, review the lines of authority and communication, and discuss the inspection program. The Senior PM will issue and sign the meeting minutes and acquire the signature of the CO for acceptance.

6.2 Project Kickoff Meeting

As part of the construction activities, a project kickoff meeting and initial inspection will be held with all stakeholders and subcontractors. This meeting will determine site coordination and access for the project.

6.3 Weekly Status Reports

The contractor shall provide weekly status report included with the Weekly Quality Control Report

(WQCR).

7.0 ENGINEERING AND CONSTRUCTION

The contractor will follow the design criteria, codes and standards established for the project and complete construction using locally available and accepted materials, construction techniques and quality standards appropriate. The contractor will incorporate existing plans and drawings to the fullest extent possible, available from the Shaw AFB Civil Engineering Squadron.

7.1 Hold Point Compliance

A review of any hold points will be conducted prior to beginning work on any new definable work feature. AECOM will place hold points on subcontractors at specific points in construction/installation, and direct subcontractors to postpone activities until a walk down and any required inspections are performed to verify that the preliminary work or activity has been completed according to the plans.

Hold points will be determined on a weekly basis. The QCM will identify the upcoming hold points on the daily work plan. The QCM will inform the Construction Manager or Project Manager of identified hold points and the sign-off requirements. The contractor will maintain an internal hold point tracking log to reflect which hold points have been signed off and which ones are pending.

7.2 As-Built Records

The as-built records contain actual construction details and approved field modifications. The QCM will ensure that all plans are red lined and marked appropriately to document as built conditions, field changes, and incorporate all client comments.

8.0 REPORTING AND RECORD KEEPING

The QCM will maintain documentation on the progress and quality of work. All reports required by the COR concerning project-related issues will be documented in the contractor’s schedule and submitted according to contract specifications.

8.1 Weekly Quality Control Report

The QCM will prepare a WQCR describing QC activities performed each week as well as the resources on site and activities performed, including work performed by subcontractors and offsite work. The report will present an accurate and complete picture of QC activities and site management. The QCM will report both conforming and deficient conditions in a precise, factual, legible, and objective manner.

Copies of supporting documentation such as checklists and surveillance reports will be attached. Work will be reported by terminology consistent with the work schedule.

8.2 Field Logbook

A field QC logbook will be assigned to the QCM for documenting details of field activities during QC tasks. The QCM will enter information in the logbook, such as daily activities, events, meetings and their results, personnel at the site, progress and rates of production (if appropriate), and other relevant information useful to recreate the site events. The QCM will sign and date the logbook at the end of his notes every day.

8.3 Photo Documentation

Digital photographs will be taken on a weekly basis to provide sufficient documentation to substantiate the progress of work. Photographs will be maintained in the project files. The following information will be recorded for each photograph:

• Photograph number

• Date of photograph

• Time of photograph

• Description of task and location

8.4 Inspection Reports

A draft field report will be submitted and presented to the CE inspector and Contracting Officer or Contracting Officer’s Representative prior to the departure from the work site. The report will include any mandatory findings and recommended repairs. The contractor will submit for approval a detailed work plan of repairs to include as a minimum drawings, details, and specifications indicating the repairs (recommended and mandatory) to be made by general notes and specific notes relative to the repair process.

8.5 Project Files

The contractor will maintain two distinct sets of files for project documentation: hard copy and electronic copy.

A file at the project office will be available for the COR’s review, containing all pertinent project information. The QCM will be responsible for maintaining the files, including all QC documents, inspections, meeting minutes, technical data, references, and submittals associated with the project. The files will be organized in the following order:

• Project correspondence

• Blank (contents based on the SOW)

• PM contract documents

• Plans and specifications

• Environmental site activity documents

• Project status

• Reports and submittals

• Reports from other sources

• Quality assurance reports and documents

• Photographs

• Regulatory documents, permits, and applications

• Health and safety documents

• Electronic media

9.0 PROJECT TRANSFER

Before the transfer of the project, the contractor will resolve any punch list items which may be identified during routine QC inspections or during the more formal pre-final and final inspections.

9.1 Punch List Items

The QCM will be responsible for maintaining an on-going list of work deficiencies referred to as the “Master Punch List” throughout fieldwork. When a deficiency is observed, it will be entered on the WQCR and the Rework Items List. If the deficiency is resolved by the end of the work day, it will be noted as completed on the WQCR. If the deficiency is not resolved by the end of the day, it will be recorded on a weekly summary sheet of deficiencies.

A copy of the Master Punch List will be reviewed at all progress meetings and included in the meeting minutes. A Rework Items List will be attached to the last WQCR of the month, and will identify:

• Items to be reworked

• Date originally discovered

• Date resolved

9.2 Pre-Final Inspection

The contractor will complete a pre-final inspection with the CE inspector near the end of fieldwork to identify final work items. The contractor will publish the findings in a report submitted to the CO including the punch list items identified and the schedule and responsibility for completion.

9.3 Final Inspection

Upon completion and final inspection, a report will be completed in accordance with the format specified at the preconstruction conference. The final inspection report will certify that all items of the plan are implemented and that construction is complete. A record of “signed and sealed” as-built specifications and drawings verifying that all development standards have been met will be included in that report. 15 days prior to the final inspection, the contractor will present a completed DD Form 1354, Transfer and Acceptance of Real Property, to the CE project manager and inspector for signature and acceptance.

A Take-Over-Certificate signed by the COR will be issued to the contractor after the following tasks have been completed:

• Final inspection of the sites by the COR

• Resolution and completion of final punch-list items

• Delivery to and acceptance by the COR of final as-built drawings and operation and maintenance manuals within two weeks after the Final Inspection.

9.4 Warranty and Maintenance

In order to ensure post-inspection and repair of systems, the contractor will provides the manufacturers’ information and recommendations for equipment operation and maintenance (O&M).

Training will be provided to site personnel on O&M of systems and equipment. The warranty period for this work is 12 months.

APPENDIX A

LIST OF QUALITY CONTROL FORMS AND REPORTS

Appendix A

Construction QC Forms QC Form Title Link Reference(s)

AF Transmittal Form 3000

AF Material Approval Submittal Form 3000

4.4 Transmittal Requirements

Corrective Action Request

Corrective Action Request

5.1.1 Corrective Action Report

Corrective Action Request Log

Corrective Action Request Log

5.1.1 Corrective Action Report

Daily Quality Control Report

(DCQR) and Checklist

Daily Quality Control Report (DQCR)

4.3 Follow-up Inspection

8.1 Daily Quality Control Report

Equipment Daily Checklist

Equipment Daily Checklist

7.1 Equipment Inspection

Follow-Up Phase Inspection

FOLLOW-UP PHASE

INSPECTION

5.1.3 Follow-up Inspection

Initial Phase Inspection Form

Initial Phase Meeting and Inspection Form

5.1.2 Initial Phase Meeting and Inspection

Materials Deliveries Storage

Materials Deliveries Storage Checklist

3.1 Material Receipt Inspections

Final Report Format

AECOM Final Report Format.docx

6.1 Final Report Format

Materials Inspection Form

Materials Inspection Form

Nonconformance Report

QC Form Title Link Reference(s)

Nonconformance Report

(NCR)

Non-Conformance Report (NCR)

Nonconformance Report

Non-Conformance Report Tracking Log

Non-Conformance Report Tracking Log

Preparatory Phase Checklist

Preparatory Phase

5.1.1 Preparatory Phase Meeting

Preparatory Phase Inspection

Preparatory Phase Inspection

Punch List

Punch List.doc

9.1 Follow up Inspection

9.1 Punch List Inspection

9.2 Pre-Final Inspection

9.1 Punch List

RFI’s

Request_For_Inform ation.doc

Request for Information

Safety Inspection Checklist for Construction Equipment

AECOM Safety

Inspection Sheet.doc

7.1 Equipment Inspection

Sign-in Sheets

5.1.2 Initial Phase Meeting / Inspection

6.0 Meetings

AECOM Sign In Sheet.doc

Suspension of Work

Suspension of Work Log

Log

Test Equipment List and Calibration Log

Test Equipment List and Calibration Log

5.1.2 Initial Phase Meeting / Inspection

QC Form Title Link Reference(s)

Transfer and Acceptance of Military Real Property- DD Form 1354

Transfer and Acceptance of Militaq

9.3 Department of Defense (DD) Form