Atch01SOOItem05QualityControl.doc

CXTFC CSS Section 01440

DEFENSE THREAT REDUCTION AGENCY

Test Directorate, Engineering Division (TDTOE)

1680 Texas Street, Southeast

Kirtland AFB, NM 87117

SPECIFICATIONS FOR CONSTRUCTION AND SUPPORT SERVICES

SECTION 01440

QUALITY CONTROL

28 August 2007

1. GENERAL

1.1 REFERENCES - The AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.

ASTM D 3740

(1992) Evaluation of Agencies Engaged in the Testing and/or Inspection of Soil and Rock as Used in Engineering Design and Construction

ASTM E 329

(1993b) Agencies Engaged in the Testing and/or Inspection of Materials Used in Construction

1.2 QUALITY CONTROL - The Contractor is responsible for quality control and shall establish and maintain an effective Quality Control program. The Quality Control program shall consist of plans, procedures, and organization necessary to produce an end product that complies with the contract’s requirements for quality workmanship. The system shall cover all construction operations, both on-site and off-site, and shall be keyed to the proposed construction sequence. The Site Superintendent will be held responsible for the quality of work on each delivery order and contract line item and is subject to removal by the Contracting Officer for non‑compliance with quality requirements specified in the contract and individual task orders and delivery orders. Site Superintendent in this context shall mean the individual with the responsibility for the overall management of the contract including quality and production.

1.3 PAYMENT - Separate payment will not be made for providing and maintaining an effective Quality Control program.

2. PRODUCTS - Not used in this Section.

3. CONTRACTOR SUBMITTALS - The Contractor shall furnish for review and acceptance by the COR, not later than 15 working days after receipt of contract notice to proceed, the Contractor’s Quality Control Plan (QCP). The plan shall identify Contractor Quality Control (CQC) personnel, procedures, control, and instructions to be used. Performance will be permitted to begin only after acceptance of the QCP or acceptance of an interim plan. Work outside of the features of work included in an accepted interim plan will not be permitted to begin until acceptance of a QCP.

4. EXECUTION

4.1 QUALITY CONTROL PLAN

4.1.1 Content - The QCP shall include, as a minimum, the following to cover all construction and test support operations, both on-site and off-site, including work by subcontractors, fabricators, suppliers, and purchasing agents:

(1) A description of the quality control organization, including a chart showing lines of authority and acknowledgment that the CQC staff shall implement the three phase control system for all aspects of the work specified. The staff shall include a CQC Manager who shall report to the site superintendent.

(2) The name, qualifications (in resume format), duties, responsibilities, and authorities of each person assigned a CQC function.

(3) Procedures for scheduling, reviewing, certifying, and managing submittals, including those of subcontractors, off-site fabricators, suppliers, and purchasing agents.

(4) Procedures for tracking construction deficiencies from identification through acceptable corrective action. These procedures will establish verification that identified deficiencies have been corrected.

(5) Reporting procedures, including proposed reporting formats and daily QC reports.

(6) A list of the definable features of work. A definable feature of work is a task that is separate and distinct from other tasks and has separate control requirements. The task(s) could be identified by different trades or disciplines or it could be work by the same trade in a different environment. Although each section of the specifications may generally be considered as a definable feature of work, there are frequently more than one definable feature under a particular section. This list will be agreed upon during the coordination meeting.

4.1.2 Acceptance of Plan - Acceptance of the Contractor's QC Plan is required prior to the start of construction. Acceptance is conditional and will be predicated on satisfactory performance during the construction. The Government reserves the right to require the Contractor to make changes in his QCP and operations including removal of personnel, as necessary, to obtain the quality specified.

4.1.3 Notification of Changes - After acceptance of the QCP, the Contractor shall notify the COR in writing of any proposed change and allow a minimum of three working days for the COR to review. Proposed changes are subject to acceptance by the COR.

(1) Specific delivery orders may require the Performer to prepare an annex to the QCP that addresses any unique requirements for that delivery order.

(2) Prior to beginning work on each delivery order, the Performer's QC Manager shall conduct a Quality Control planning meeting with the Superintendent, Foreman, the Government's Project Engineer, and QA Inspector in attendance. The QC Manager shall review the scope of work and the three phases of Quality Control. The Government's Project Engineer shall identify the required testing to be accomplished by the Government.

4.2 COORDINATION MEETING - The Contractor shall meet with the COR to discuss the Contractor's quality control program and QCP. The QCP shall be submitted for review a minimum of 10 calendar days prior to the Coordination Meeting. During the meeting, a mutual understanding of the QCP details shall be developed, including the forms for recording the CQC operations, control activities, administration of the system for both on-site and off-site work, and the interrelationship of Contractor's Management and CQC program with the Government's Quality Assurance program. There may be occasions when subsequent conferences will be called by either party to reconfirm mutual understandings and/or address deficiencies in the CQC program or procedures which may require corrective action by the Contractor.

4.3 QUALITY CONTROL ORGANIZATION - The requirements for the CQC organization are a CQC Manager and sufficient number of additional qualified personnel to ensure contract compliance. The Contractor shall provide a CQC organization that shall be at the site at all times during progress of the work and with complete authority to take any action necessary to ensure compliance with the task order. All CQC staff members shall be subject to acceptance by the COR.

4.3.1 CQC Manager - The Contractor shall identify as CQC Manager an individual within his organization at the site of the work who shall be responsible for overall management of the CQC Program and have the authority to act in all CQC matters for the Contractor. The CQC Manager shall have a minimum of two years construction experience on construction similar to this contract. The CQC Manager shall also have completed training in concrete placement and inspection, concrete field sampling, earth compaction testing, and general construction inspection; courses typically offered by the American Concrete Institute, the Portland Cement Association, or other comparable agencies. Certificates or proof of successful course completion shall be included in the CQC Manager's resume. The CQC Manager shall be on the site as required to ensure requirements of the contract, task orders and delivery orders are met. The CQC Manager's primary duties shall be the overall management of the CQC organization and CQC program. The CQC Manager shall be assigned no other duties, without COR approval. An alternate for the CQC Manager will be identified in the plan to serve in the event of the CQC Manager's absence. The requirements and qualifications for the alternate will be the same as for the designated CQC Manager.

4.3.2 CQC Staff - A staff shall be maintained under the direction of the CQC Manager to perform all QC activities. The staff must be of sufficient size to ensure adequate QC coverage of all work phases, work shifts and work crews involved with the construction. These personnel may perform other duties, but must be fully qualified by experience and technical training to perform their assigned QC responsibilities and must be allowed sufficient time to carry out these responsibilities.

4.3.3 Organizational Changes - The Contractor shall maintain his CQC staff at full strength at all times. When it is necessary to make changes to the CQC staff the Contractor shall revise the QCP to reflect the changes and submit the changes to the COR for acceptance.

4.4 PROJECT SUBMITTALS - Submittals shall be made as specified in Section 01305 SUBMITTAL PROCEDURES. The CQC Manager shall be responsible for certifying that all submittals are in compliance with the contract requirements.

4.5 CONTROL - Contractor Quality Control is the means by which the Contractor ensures that the construction, to include that of subcontractors and suppliers, complies with the requirements of the contract. At least three phases of control shall be conducted by the CQC Manager for each definable feature of work as follows:

4.5.1 Preparatory Phase - This phase shall be performed prior to beginning work on each definable feature of work and shall include:

(1) A review of each paragraph of applicable specifications.

(2) A review of the task order drawings.

(3) A check to assure that all materials and/or equipment have been submitted and approved.

(4) Review of provisions that have been made to provide required control and inspection.

(5) Examination of the work area to assure that all required preliminary work has been completed and is in compliance with the task order.

(6) A physical examination of required materials, equipment, and sample work to assure that they are on hand, conform to approved shop drawings or submitted data, and are properly stored.

(7) A review of the appropriate activity hazard analysis to assure safety requirements are met.

(8) Discussion of procedures for controlling quality of the work including repetitive deficiencies. Document construction tolerances and workmanship standards for that feature of work.

(9) A check to ensure that the portion of the plan for the work to be performed has been accepted by the COR.

(10) Discussion of the initial control phase.

(11) The Government shall be notified at least 3 working days in advance of beginning the preparatory control phase. This phase shall include a meeting conducted by the CQC Manager and attended by the Site Superintendent, other CQC personnel (as applicable), the foreman responsible for the definable feature, and the Government On-site Inspector. The results of the preparatory phase actions shall be documented. The Contractor shall instruct applicable workers as to the acceptable level of workmanship required in order to satisfy contract specifications.

4.5.2 Initial Phase - This phase shall be accomplished at the beginning of a definable feature of work. The following shall be accomplished:

(1) A check of work to ensure that it is in full compliance with task order requirements. Review minutes of the preparatory meeting.

(2) Verify adequacy of controls to ensure full contract compliance. Verify required control inspection and testing.

(3) Establish level of workmanship and verify that it meets minimum acceptable workmanship standards. Compare with required sample panels as appropriate.

(4) Resolve all differences.

(5) Check safety to include compliance with and upgrading of the safety plan and activity hazard analysis. Review the activity analysis with each worker.

(6) The Government shall be notified at least 24 hours in advance of beginning the initial phase. Separate minutes of this phase shall be prepared by the CQC. Exact location of initial phase shall be indicated for future reference and comparison with follow‑up phases.

(7) The initial phase should be repeated for each new crew to work on-site, or any time acceptable specified quality standards are not being met.

4.5.3 Follow‑up Phase - Daily checks shall be performed to assure control activities are providing continued compliance with task order requirements, until completion of the particular feature of work. The checks shall be made a matter of record in the CQC daily report. Final follow‑up checks shall be conducted and all deficiencies corrected prior to the start of additional features of work that may be affected by the deficient work. The Contractor shall not build upon or conceal non‑conforming work.

(1) The Government shall conduct final acceptance inspections of all rebar and formwork prior to concrete placement. The Performer shall not place any concrete before obtaining Government approval and shall incorporate time for inspections into the construction progress schedule.

4.5.4 Additional Preparatory and Initial - Additional preparatory and initial phases shall be conducted on the same definable features of work if the quality of on‑going work is unacceptable, if there are changes in the applicable CQC staff, on-site production supervision or work crew, if work on a definable feature is resumed after a substantial period of inactivity, or if other problems develop.

4.6 TESTS

4.6.1 Testing Procedure - The Government shall perform specified or required tests to verify that the product or item provided by the Contractor conforms to contract requirements. Typical Government tests include soil compaction and concrete strength. The Government shall sample a minimum of three sets for each sampled item. For cast-in-place concrete, five samples shall be taken for each set. Testing includes sampling and laboratory operation and/or acceptance tests when specified. The Government's on-site inspector, in coordination with the Government's Laboratory personnel and Contractor's CQC Manager shall perform the following activities and maintain the following data:

(1) Verify that testing procedures comply with contract requirements.

(2) Verify that facilities and testing equipment are available and comply with testing standards.

(3) Check test instrument calibration data against certified standards.

(4) Verify that recording forms and test identification control number system, including all of the test documentation requirements, have been prepared.

(5) Verify that field sampling was conducted in accordance with applicable ASTM Standards.

(6) Results of all tests taken, both passing and failing tests, will be recorded on the QC report for the date taken. Specification paragraph reference, location where tests were taken, and the sequential control number identifying the test will be given. If approved by the Project Engineer and/or COR, actual test reports may be submitted later with a reference to the test number and date taken. An information copy of tests performed will be provided directly to the Project Engineer and/or COR.

4.7 COMPLETION INSPECTION

4.7.1 Pre‑Final Inspection - At the completion of all work or any increment thereof, and or stated elsewhere in the specifications, the CQC Manager shall conduct an inspection of the work and develop a "punch list" of items which do not conform to the approved drawings and specifications. Such a list of deficiencies shall be included in the CQC daily report and shall include the estimated date by which the deficiencies will be corrected. Once this is accomplished, the Contractor shall notify the Government On-site Inspector that the facility is complete and is ready for the Government's "Pre-final" inspection. The Government will perform this inspection to verify that the facility is complete and ready for acceptance. A Government "Pre-final Punch List" will be developed as a result of this inspection. The Contractor's CQC Manager shall ensure that all items on this list have been corrected and notify the Government so that a "Final" inspection with the Project Engineer and or COR can be scheduled. Any items noted on the "Final" inspection shall be corrected in a timely manner. These inspections and any deficiency corrections required by this paragraph will be accomplished within the time stated for completion of the entire work or any particular increment thereof if the project, task order or delivery order is divided into increments by separate completion dates.

4.7.2 Final Acceptance Inspection - The Contractor's Quality Control Inspection personnel, his superintendent or other primary management person and the Government’s On-Site Inspector, Project Engineer and/or COR will be in attendance at this inspection. Additional Government personnel including, but not limited to, those from the Test Team may also be in attendance. The final acceptance inspection will be formally scheduled by the COR based upon notice from the Contractor. This notice will be given to the COR at least 4 working days prior to the final acceptance inspection and must include the Contractor's assurance that all work is complete and acceptable by the date scheduled for the final acceptance inspection. Failure of the Contractor to have all contract work acceptably complete for this inspection will be cause for the COR to bill the Contractor for the Government's additional inspection cost in accordance with the contract clause entitled "Inspection of Construction".

4.8 DOCUMENTATION

4.8.1 Contractor - The Contractor shall maintain current records providing factual evidence that required quality control activities have been performed. These records shall include the work of subcontractors and suppliers and shall be documented on Air Force Form 1477 (form provided in Section J on the base contract) or an acceptable form that includes, as a minimum, the following information:

(1) Contractor/subcontractor and their area of responsibility.

(2) Work performed each day, giving location, description, and by whom.

(3) Quality Control activities performed with results and references to specifications, drawings or requirements. The control phase should be identified (Preparatory, Initial, Follow‑up). List deficiencies noted along with corrective action.

(4) Quantity of materials received at the site with statement as to acceptability, storage, and reference to specifications, drawings or requirements.

(5) Submittals reviewed, with contract reference, by whom, and action taken.

(6) Off‑site surveillance activities, including actions taken.

(7) Sampling evaluations stating what was checked, results, and instructions or corrective actions.

(8) Instructions given/received and conflicts in plans and/or specifications.

(9) Description of sample(s) taken and testing and inspecting.

a) Complete test or inspection data.

b) Ambient conditions at time of sample taking and testing and inspecting.

c) Test and inspection results and an interpretation of test results.

(10) Comments or professional opinion on whether tested or inspected Work complies with the Contract Document requirements.

(11) Contractor's verification statement.

(12) These records shall indicate a description of trades working on the project; the number of personnel working; weather conditions encountered; and any delays encountered. These records shall cover both conforming and deficient features and shall include a statement that equipment and materials incorporated in the work and workmanship comply with the task order. The original and one copy of these records in report form shall be furnished to the Government's on-site inspector on a daily basis. All calendar days shall be accounted for throughout the life of the contract. Report shall be signed and dated by the CQC Manager and the Site Superintendent.

4.8.2 Government - The Government On-Site Inspector shall maintain a daily record, using Air Force Form 1477, providing factual evidence that required project execution and quality control activities and/or tests have been performed. This record shall include the work of subcontractors and suppliers and shall include, as a minimum, the following information:

(1) Contractor/subcontractor and their area of responsibility.

(2) Work performed each day, giving location, description, and by whom.

(3) Test activities performed with results and references to specifications/drawings requirements. The control phase should be identified (Preparatory, Initial, Follow‑up). List deficiencies noted along with corrective action.

(4) Quantity of materials received at the site with statement as to acceptability, storage, and reference to specifications/drawings requirements.

(5) Submittals reviewed, with contract reference, by whom, and action taken.

(6) Off‑site surveillance activities, including actions taken.

(7) Job safety evaluations stating what was checked, results, and instructions or corrective actions.

(8) Instructions given/received and conflicts in plans and/or specifications.

(9) Inspector’s verification by signature.

(10) Daily reports shall indicate a description of trades working on the project; the number of personnel working; weather conditions encountered; and any delays encountered. These records shall cover both conforming and deficient features and shall include a statement that equipment and materials incorporated in the work and workmanship comply with the task order. Consolidated copies of these records in report form shall be forwarded to the Project Engineer.

4.9 NOTIFICATION OF NONCOMPLIANCE - The COR will notify the Contractor of any detected noncompliance with the foregoing requirements or unacceptable products or workmanship. The Contractor shall take immediate corrective action, at no additional cost to the Government, after receipt of such notice. If the Contractor fails or refuses to comply promptly, the COR may notify the Contracting Officer to issue an order stopping all or part of the work until satisfactory corrective action has been taken. No part of the time lost due to such stop orders shall be made the subject of claim for extension of time or for excess costs or damages by the Contractor.

5. TESTING – Not used in this Section.

- END OF SECTION -

CSS--01440-1

Attachment 6

CSS-01440-7

Attachment 6