Section 153 — Contractor Quality Control

Description

153.01This work consists of planning and implementing a construction quality process to ensure work conforms to the contract. This work also includes inspection and documentation, and process control sampling and testing. See FAR Clause 52.246-12 Inspection of Construction.

Construction Requirements

153.02Qualifications. At least 14 days before starting work, submit documentation of the following for approval:

(a)QCM. Provide a QCM with documented authority to stop non-compliant work or work that results in non- compliance with contract requirements. Provide a QCM with at least 3 years’ experience in areas of material testing, inspection, management, supervision, and QC on highway construction projects of similar type and scope;

(b)Alternate QCM. Provide an alternate QCM, meeting QCM qualifications ;

(c)Inspectors. Provide inspectors with at least 2 years’ experience inspecting work of similar type and scope ; and

(d)Testers. Provide testers with at least 1 year’s experience in the type of sampling a nd testing required, and with one of the following for the type of sampling and testing performed:

(1)National Institute for Certification in Engineering Technologies (NICET ) Level II certification in construction materials testing for similar material types or equivalent state or industry certification;

(2)Certification by a state or regional certification program, such as Western Alliance for Quality Transportation Construction or Northeast Transportation Technician Certification Program; or

(3)At least 1 year of employment by an AASHTO accredited laboratory performing equivalent sampling and testing with competence according to AASHTO R 18.

153.03Quality Control Plan. Develop and submit a QCP for approval at least 14 days before starting a Section of work. Include the work of subcontractors, material suppliers, and technical services suppliers. Include the work required under Section 154. Do not perform work unless the QCP for that Section is approved. Approval does not imply that the QCP will result in contract compliance. For each Section of work, include the following:

(a)QC personnel. Provide the name, authority, responsibilities, and qualifications of the QCM and other personnel directly involved in inspection and testing. 70 (b) QC procedures. Describe the inspection, testing, and other activities to be performed for each phase of work in Subsection 153.06. Include methods, schedules, equipment, and laboratory facilities. Include the following for materials to be tested:

(1)Pay item;

(2)Brief operational work plan including, but not limited to, the locations, crews, equipment, and proposed methods to complete the work. Describe the plan for staging, disposal, and storage areas. Include the following in the plan for each Section of work:

(a)The process to ensure the completed work conforms to contract requirements.

(b)The inspection and testing frequency to e nsure the process remains valid or work is being performed according to the established process.

(3)Sampling, testing, and acceptance requirements including the location of sampling, and the frequency of testing. At a minimum, perform testing according to the requirements in each applicable Section;

(4)Personnel responsible for performing the inspection, sampling, and testing;

(5)Laboratory testing facilities to be used for process control and project acceptance testing; and

(6)Proposed reporting formats.

(c)Records. Describe the reporting format for inspection, testing, certification, and daily reports. Revise the QCP if contract quality requirements are not achieved, or changes occur in the contract, work processes, or personnel.

153.04Quality Control Manager. Provide a QCM who is on site while contract work is being performed. Provide a QCM with no responsibilities for managing or superintending the project or performing operations other than managing QC. Do not use an alternate QCM for more than 3 consecutive days unl ess approved.

153.05Certifications and Submittals. The QCM is required to review certifications and submittals to ensure compliance with the contract requirements. Provide a copy of the reviewed submittals and certifications signed by the QCM . Submit mat erial certifications and submittals at least 7 days before the applicable work starts , unless otherwise specified.

153.06Prosecution of Work. Complete the following:

(a)Preparatory and start- up phase.

(1)Before starting each Section of work, hold a preparatory phase meeting. Include the project superintendent, work foreperson, CO, QCM, inspectors, testers, and appropriate subcontractors. Discuss the following :

(a)Contract requirements for the work including, but not limited to, acceptance procedures, schedule, and control strip;

(b)Process and equipment for constructing the work; and

(c)Plan for inspection, process control, testing, measuring, and reporting the work.

(2)Review and coordinate certifications, submittals, plans, drawings, and permits.

(3)Verify the capabilities of equipment, material, and personnel. Provide training as necessary.

(4)Establish a detailed testing schedule based on the production schedule.

(5)Report the required preparatory testing, calibra tion, and inspection results.

(6)Review accuracy of the surveying and staking.

(7)Explain procedures to be followed if defective work is identified.

(8)Describe the plan for staging, disposal, and storage areas.

(9)Provide a brief operational work plan including, but not limited to, the locations, crews, equipment, and proposed methods to complete the work.

(b)Production phase.

(1)Inspect, test, and report according to the QCP and evaluate the acceptability of the work produced. Meet with the CO weekly, or as requested, to d iscuss the status and effectiveness of the QC process. (2) Identify and correct deficiencies. Identify root causes and make changes to work processes to prevent repeated deficiencies.

(3)Request Government inspection. Allow 24 hours for inspection of the completed work after the Government has been notified.

153.07Sampling and Testing. At least 45 days before project use, ensure laboratory test equipment has been checked, calibrated, standardized, and verified according to AASHTO and ASTM standards by an individual qualified to perform the work. Keep laboratory facilities clean and maintain equipment in proper working condition. Certify that equipment conforms to testing requirements and submit evidence of current calibrations. Inspect and calibrate mobile labora tory equipment after the laboratory is moved to the project, before using equipment, and every time it is moved thereafter. Allow the CO unrestricted access to the laboratory for inspection and review. P rovide additional inspections and tests to demonstra te sampling and testing proficiency if requested. Submit proficiency sample test results within 48 hours of sample receipt. 72 Perform QC sampling and testing according to the QCP and the Sampling, Testing, and Acceptance Requirements tables included at the end of each applicable Section. If no sampling frequencies are specified, submit the proposed sampling and testing frequencies. Allow the CO the opportunity to witness all sampling and testing. If requested, sample and split QC samples according to AASHTO or other acceptable procedures. Deliver and label split QC samples according to Subsection 154.03. Sample and test material that appears defective or inconsistent with similar material being produced, unless such material is voluntarily removed and replaced or otherwise corrected according to Subsection 106.01.

153.08Records and Control Charts. Maintain records and control charts by pay item.

(a)QC and construction operations reports. Submit written QC and construction operations reports daily according to the QCP. Document meetings, work locations, labor and equipment used. Include actual hours worked, testing and measurement activities, inspection results, deficiencies observed, corrective actions tak en, and process changes. Use Form FHWA 1413, Inspector’s Daily Record of Construction Operations or approved alternate forms. Include the following certification signed by the QCM on all reports: "I certify that the information contained in this record is accurate and that work documented herein complies with the contract. Exceptions to this certification are documented as a part of this record."

(b)Test Results. Label test results according to Subsection 154.03. Attach workshe ets used to determine test values to the test result forms when submitted.

(c)Control charts. Maintain linear control charts that identify the test number, test parameter, upper and lower specification limit applicable to each test parameter, and test results for applicable material. Use the control charts to document variability of the process, to identify production and equipment problems, and to identify actions to improve processes or quality. Update and post control charts daily in a location accessible t o the CO. Stop production and correct the process when problems are evident.

153.09Acceptance. The Contractor’s QC process will be evaluated under Subsections 106.02 and 106.04 based on it s demonstrated effectiveness to ensure work conforms to the contract. Performance of the work may be stopped according to Subsection 108.06 , either in whole or in part, for failure to comply with the requirements of this Section.

Measurement

153.10Measure the Section 153 pay items listed in the bid schedule according to Subsection 109.02 .

Payment

153.11The accepted quantities will be paid at the contract price per unit of measurement for the Section 153 pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section. See Subsection 109.05 .