NCD986187128_20010601_North Belmont PCE_FRBCERCLA LTRA_Construction Quality Control Plan-OCR

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CONSTRUCTION QUALITY CONTROL PLAN
NORTH BELMONT PCE SITE
WATER SYSTEM IMPROVEMENTS
BELMONT, GASTON COUNTY, NORTH CAROLINA
PreparedJ;1r:
Trans-State Construction
P.O. Box 545
Denver, North Carolina 28037
Prepared by:
Roy F. Weston, Inc.
5405 Metric Place, Suite 200
Norcross, Georgia 30092
[phone]
.JUNE 2001
WESTON WORK ORDER NO. 12720.001.001
SUPERFUND SECTION
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Section
2
3
4
5
6
7
8
9
TABLE OF CONTENTS
INTRODUCTION .............................................................................................. 1-1
1.1 Purpose .................................................................................................... 1-1
1.2 Scope ofWork ......................................................................................... 1-l
1.3 CQC Plan Document Structure ............................................................... 1-2
QA/QC ORGANIZATION ............................................................................... 2-1
2.1 Quality Control Organization .................................................................. 2-1
2.2 Project Manger ........................................................................................ 2-1
2.3 Field Supervisor ...................................................................................... 2-1
2.4 CQC Field Manager ................................................................................ 2-3
2.5 Inspectors and Technicians ..................................................................... 2-3
QUALITY ASSURANCE AUDITING ............................................................ 3-I
INSPECTIONS .................................................................................................. 4-1
TESTING POLICY ........................................................................................... 5-1
SUBMITTAL REVIE\V .................................................................................... 6-1
DOCUMENTATION AND REVIEW ............................................................. 7-1
NONCOMPLIANCE ......................................................................................... 8-1
CONSTRUCTION QUALITY CONTROL (QC) PROGRAM .................... 9-1
9.1
9.2
9.3
Introduction ............................................................................................. 9-1
General Pre-Construction Quality Control Measures ............................. 9-1
Water Main Extension and Residential Connections .............................. 9-2
9.3.1 !'reconstruction Quality Control Activities ....................................... 9-2
9.3.1.1
9.3.1.2
9.3.1.3
Final Water Main Alignment ................................................ 9-2
Survey Control ...................................................................... 9-2
Utilities Loci1tion ................................................................... 9-2
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Section
Figure
9.4
9.5
TABLE OF CONTENTS (Continued)
Title Page
9.3.2 Construction Quality Control Activities ............................................ 9-2
9.3.2.1
9.3.2.3
9.3.2.4
9.3.2.5
Water System Improvements ................................................ 9-2
Acceptance Procedures for Water System Improvements .... 9-4
Residential Carbon Filtration Units (RCFU) ......................... 9-4
Inspection Documentation ..................................................... 9-5
Vendor Data/Certificates ......................................................................... 9-5
Control of Subcontractors ....................................................................... 9-5
LIST OF FIGURES
Title
2-1 QA/QC Organization Structure ............................................................................ 2-2
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SECTION I
INTRODUCTION
Roy F. Weston Inc., (WESTON~) has been contracted by Trans-State Construction to perfonn
design services for the North Belmont PCE Site water system improvements. Trans-State
Construction will he installing 7,500 feet of water main to provide city water service to 65
residents, connecting individual residents desiring city water to the new or existing water main,
and installation and maintenance of 4 individual residential carbon filtration units. The project is
located in north Belmont, Gaston County, North Carolina.
I.I PURPOSE
The purpose of this Construction Quality Control (CQC) Plan is to ensure that the methods and
materials used to accomplish the scope of work meet the requirements of the Final 100% Design
Statement of Work For Extension of Existing Water Main, Connection of Individual Residences
to City Water, and Installation of Individual Residential Carbon Filtration Units, dated December
26, 2000. This CQC Plan outlines the required testing, inspection and record keeping
requirements to document that the scope of work is being pcrfonned as required. This plan
identifies the individuals who have responsibility to implement the CQC Plan and the respective
lines of communications.
1.2 SCOPE OF WORK
The CQC Plan will encompass the following scope items involved with the North Belmont PCE
Site project:
I. Water Main Extension and Residential Connections -The water main extension will be
designed according to the minimum standards provided by the City of Belmont (which
includes the applicable sections of the North Carolina Administrative Code), industry
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standards, and the sizes prescribed in the Statement of Work (SOW). Gastonia, North
Carolina's June I, I 997 Standard Details and Specifications will be used for this project.
Engineering speci lications will meet or exceed the minimum standards required by the City
of Belmont and will be modified to specify types and models of mechanical equipment (fire
hydrants, meters) requested.
2. Installation and Maintenance of the Residential Carbon Filtration Units (RCFUs) -The
RCFUs will be dcsigned for a maximum of IO gallons per minute (14,400 gallons per day
[gpd]) and a minimum of 450 gpd based on manufacturers recommendations to achieve the
desired watcr quality. Carbon tilters will be changed every six months during the first year of
operation. The efficiency of the RCFUs will be evaluated by collecting influent and cf!lucnt
samples of the water after the initial start-up and prior to the first filter change.
1.3 COC PLAN DOCUMENT STRUCTURE
The CQC Plan is comprised of the basic provisions and the Constrnctton Quality Control (CQC)
Program. The basic provisions delineate the administrative aspects of the project such as the
scope of work, the responsible parties and their roles and the general testing and inspection
procedures. The basic provisions specifically include:
• Purpose and Scope of the QCQ Plan
• CQC Program personnel, responsibilities and lines of communication
• Stop work authorization
• Quality assurance auditing
• Submittal Procedures
• Inspection and testing policies
• Documentation and review policies
• Noncompliance policies
The CQC Program outlines the specific quality control measures to be employed for each of the
major scope items (sec Section 9 of this report).
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SECTION 2
QA/QC ORGANIZATION
2.1 QUALITY CONTROL ORGANIZATION
This section identities the individuals and their responsibilities that arc associated with the
implementation of the Construction Quality Control (CQC) Plan. Figure 2-1 depicts the
reporting relationships of the individuals of the Trans-State team involved in CQC Plan for this
project. The chart shows the lines of communication from the project management level through
the CQC Field Manager to the field personnel including the relevant subcontractors. It is the
responsibility of the CQC Field Manager to ensure that the CQC Plan is being implemented
effectively. The Project Representative of CDM Federal Programs, the inspectors for the City of
Belmont, and the EPA shall conduct construction oversight and approve performance standards
achievement.
2.2 PRO.JECT MANGER
Mr. Troy Reeves of Trans-State Construction shall be the Project Manager and has overall
responsibility for the successful fulfillment of all Trans-State project contractual commitments to
CDM Federal Programs Corporation (CDM). He also has overall responsibility for project
implementation. Mr. Reeves is the fonnal point of contact for CDM.
2.3 FIELD SUPERVISOR
Mr. Todd Reeves will serve as the Field Supervisor and reports on a <lay-to-day basis to the
Project Manager. He is also acting as a Field CQC Manager. Mr. Reeves is responsible for the
day to day management of all aspects of executing the work including coordinating
subcontractor's activities. All site personnel report to Mr. Reeves. Mr. Reeves or his designated
alternate will be accessible at the site at all times that field activities arc in progress.
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FIGURE 2-1
QA/QC ORGANIZATION STRUCTURE
TRANS-STATE
Project Manager
COM
Project
Representative Troy Reeves
James Laforest
TRANS-ST ATE
Field Supervisor/
CQC Field Manager
Todd Reeves
Subcontractors
Material Vendors
Plumber
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ROY F. WESTON, INC.
Technical Advisor/
Lead Design Engineer
F.D. Mooney, P.E.
Subcontractors
Robinson & Sawyer, Inc.
Material Vendors
Plumber
EPA
_ Remedial Project
Manager
Giezelle Be1U1ett
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2.4 CQC FIELD MANAGER
Mr. Todd Reeves is the CQC Field Manager. He has the primary responsibility to ensure that the
CQC Plan is being properly implemented and are responsible for project quality at all levels.
This includes routine inspections and audits of field activities as well as reviewing all submittal
data prior to transmittal to CDM. Audits include inspection of field activities and testing
methods as well as reviewing test results and other documentation required to demonstrate
proper quality controls arc in place to ensure the quality of the work. Mr. Doug Mooney, P.E of
WESTON will serve as the technical advisor for the project.
2.5 INSPECTORS AND TECHNICIANS
Inspections and testing will be conducted by either the CQC Field Manager or qualified alternate
personnel acting under his direction. The person performing the inspection or test will be
qualified to do so through training or experience. Inspectors and test technicians will not inspect
or test their own work or work done under their direct supervision. Inspectors and test
technicians arc responsible for generating applicable signed documentation for their work using
standard forms/formats as specified in this plan.
An independent testing lab shall perform the analytical testing.
Scheduling of all testing and inspections shall be communicated by the CQC Field Manager or
his dcsigncc in a timely manner.
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SECTION 3
QUALITY ASSURANCE AUDITING
The Project Manager will conduct audits to document various activities of the project and their
conformance to the CQC Plan. In the event of a field audit, the Project Manager will meet with
the CQC Field Manager and review the records of inspection, testing, and other documentation
required by the CQC Plan. The Project Manger will also inspect the work in progress and, where
appropriate, laboratory and off~site fabrication sites. The work being conducted will be compared
to the requirements designated in the contract documents. The results of the audit will be kept on
site in the file for review by CDM at their request.
Audit notes will be recorded as a written repo11. The report will summarize the audit findings
and include the completed audit notes as backup documentation. Findings that require corrective
action will be clearly indicated. Whenever corrective action is required, the Project Manger shall
identify and verbally communicate the deficiency to the CQC Field Manager 8:l that the work or
work method can be immediately corrected. If the corrective measures arc extensive then the
Project Manager will be responsible for developing and implementing a plan of corrective action
complete with schedule and assigned responsibilities. Deficiencies shall be documented in an
audit report.
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SECTION 4
INSPECTIONS
Inspections are the documented ohservations used to ensure that the execution of the work meets
or exceeds all design criteria set forth in the contract documents. All activities affecting the
quality of work pcrfonncd in this project arc to undergo fomrnl inspection. The Project Manager
or the CQC Field Manager will conduct inspections, or another person appointed by him. The
individuals performing the inspection will ensure that the work complies with the specifications,
applicable standards, or good construction practices.
Construction inspections will document that the work is being perfonncd in accordance with the
contract documents. These inspections will include observations to ensure the proper
construction methods and materials being used, the proper test methods arc being performed at
the right frequency and that documentation is being generated and recorded properly. Punch list
inspections will be perfonned by the Design/Builder to verify that the work has been completed
in accordance to the contract requirements.
Inspections will be conducted as per those indicated in the Construction Quality Control Plan
(Section 9). All inspections will be recorded on a daily log. Documentation of these inspections
will be included in the field project files. Inspection records will include:
• Project Name and Number
• Project Location
• Date of test/inspection
• Applicable specification section and paragraph
• Name of Testing Agency
• Name of person performing the test and recording data
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• Type oftest or inspection
• Record of Field conditions encountered
• Testing location
• Sequential control number
• Observations regarding compliance
• Notation of non-compliance, if applicable, and name of person contacted regarding the
deficiency
• Actions taken by the contractor to correct any deficiencies
• Results of the test/inspection
• Signature of person perfom1ing the test/inspection
• Indication of the acceptability of the test results
All deficiencies noted shall be re-inspected and written confirmation will be made to document
corrective action was taken on a subsequent inspection form.
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SECTION 5
TESTING POLICY
The objective of this testing policy .is to ensure that the proper test method and frequency is
performed for all appropriate work tasks. The results of the testing provide the documentation
that the minimum design requirements have been achieved in the pcrfonnance of the work. This
policy also outlines the required information involved in this documentation. The required test
methods and test frequency is presented in Section 9 of this plan. Test methods shall conform to
the appropriate standards as specified Technical Specifications. The following requirements will
be followed for all testing associated with the work.
Tests will be conducted in accordance with a written, approved procedure and in compliance
with the contract documents and this CQC Plan.
• Tests will be conducted under appropriate conditions, including cleanliness and
orderliness.
• Test procedures will be consistent with recognized standards and regulations.
• Tests that cannot be readily perfonned in the field will be pcrfonned by an independent
testing laboratory.
• Tests will only be conducted by qualified, trained personnel.
• The Contracting Officer and regulatory agency representatives have the right to inspect
test equipment.
• Test equipment will be individually identified, calibrated and maintained at prescribed
intervals or as required by the test procedures.
• All tests will be recorded and the resulting documents retained.
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SECTION 6
SUBMITTAL REVIEW
The purpose of the submittal requirements is to provide CDM the opportunity to review the
actual materials, methods and testing which the design/builder is proposing to employ to
complete the project requirements. WESTON/Trans-State shall make submittals directly to the
CDM as required. The Project Manager will check and approve each submittal prior to
transmittal to the CDM. WESTON/Trans-State anticipates that CDM has 5 days to review and
approve submittals. WESTON/Trans State will have IO days from receipt of disapproved
submittals to resubmit. CDM will receive an original and one duplicate copy of each submittal.
Trans-State will maintain a copy of all submittals on site in the project constrnction trailer. A
complete set of all submittals shall also be kept at WESTON's Norcross, Georgia office as
maintained by the Lead Design Engineer.
The following is a listing of types ofsubmittals that will require review. Not all of the submittals
require approval in order to proceed with the work:
• Test Results/Certificates -This includes manufactures QA test results for materials
supplied to the job requiring approval of CDM.
• Manufacturers Literature/Data -This includes vendor cut sheets and technical and
performance specifications for equipment and materials to be used in the work. These
typically require review by the Lead Design Engineer and approval by the Project
Manager prior to shipment of the referenced materials to the job site.
• Shop Drawings -This includes vendor cut sheets and drawing diagramming dimensions
and/or schematic operation of a piece of equipment, design, critical materials, deviations,
equipment compatibility submittals requiring approval of CDM.
• Operation and Maintenance (O&M) Manuals -Vendor data regarding the operation and
maintenance of equipment. These submittals do not require the approval of COM to
continue the work and will be submitted at the end of the project.
• Samples and Test Specimens -Materials submittals such as, appliances, and fittings to be
used or offered for use in connection with the work.
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• Manuals and Plans -This submittal includes deliverables from the contractor
demonstrating the execution of the work.
• Administrative -Daily reports, pcm1its, notifications which do not require the approval
of COM in order to proceed with the work hut arc forwarded for information purposes.
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SECTION 7
DOCUMENTATION AND REVU:W
WESTON will maintain quality control documentation in accordance with this CQC Plan at the
work site. The purpose of this documentation is to ensure that the site personnel have the
infonnation required to carry out the timely execution of the work and to provide a record of
testing perfonned to date. Representatives of COM have the right to inspect this master file at
any time. The master CQC Plan tile will include the following documents:
• CQC Plan and all amendments
• Daily logbook entries
• Weekly CQC summaries
• Submittals which have been transmitted to COM
• Red Linc Drawings
• QA audit reports
• Change order correspondence
The CQC Field Manager will record CQC activities in the project log book. The CQC activities
will be summarized and submitted to the Project Manager and COM weekly. Trans-State will
also maintain a set of red line drawings at the job site. These drawings will be updated to show
any changes that have been made to the final design. The red line drawings will he updated
electronically and submitted at the end of the project.
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SECTION 8
NONCOMPLIANCE
There arc several mechanisms to identify services or activities that do not comply with the
contract requirements. These mechanisms include:
• CQC Plan inspections
• Acceptance testing
• Quality assurance audits
• Noli fication from the CDM
Normally if work-in-place or materials arc determined to be not in compliance with the contract
requirements, the deficiencies shall be corrected and/or compliant materials utilized as soon as
possible. In each case, any noncompliance issue will be specifically identified in the daily log
and documented in the weekly report. It will be the responsibility of the Project Manager to
notify the relevant parties of the noncompliance irrespective of the subsequent disposition of the
original report. At a minimum, the following persons will be notified of any identified
noncompliance condition:
• Field Supervisor/CQC Field Manager
• Project Manager
• Relevant Subcontractor or Vendor
The Project Manager has the authority and responsibility to stop work related to or affected by
the noncompliance condition until action can be taken to correct the noncompliance condition or
prevent it from affecting related or subsequent work. The Project Manager may at his discretion
require that the work be retested and/or re-inspected, if necessary, to confirm or disprove the
noncompliance condition. Documentation of the original inspections and/or test will be retained
as part of the project record. The Project Manager may not permit any subsequent work to
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continue if that work is, or may he, affected by the noncompliance condition until the work is
redone and subsequently retested and/or re-inspected and found to be in compliance.
The Project Manager will promptly complete a written report providing a determination of the
cause and effect of the noncompliance condition. This report will include a review of the CQC
Plan procedures, Scope of Work, specifications, and other relevant documents and procedures to
evaluate if the systems being utilized need to be amended. This report will also include, where
necessary, specific changes in procedures, work practices, or other actions taken to prevent
reoccurrence of the noncompliance condition. Finally, the report will include an assurance that
the noncompliance condition has not, and will not, adversely affect other work.
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SECTION 9
CONSTRUCTION QUALITY CONTROL (QC) PROGRAM
9.1 INTRODUCTION
The Construction Quality Control (CQC) Program outlines the schedule of testing and
inspections required to ensure that the execution of all phases of the work associated with this
project arc in compliance with the quality control standards set forth in the contract documents.
This section addresses the quality control measures involved with each item of the scope of work
including inspections, testing and the documentation and reporting requirements. The quality
control measures are discussed in this section are organized into the two major components of
the project; water main extension and residential connections, and residential carbon filtration
unit installation and maintenance.
9.2 GENERAL PRE-CONSTRUCTION QUALITY CONTROL MEASURES
These general pre-construction quality control measures presented 111 the section of the CQC
Program arc applicable to both major components of the work.
Survey Controls -A professional surveyor registered in the state of North Carolina (surveyor)
established project specific reference points to maintain horizontal and vertical control for all
relevant construction activities. The surveyor set the location and elevation of all the pertinent
clements of the work. The alignment of the water main will be finalized prior to construction.
The final alignment will be field staked by the surveyor to adequately control the installation of
the pipeline and associated structures.
Utilities Location -All utilities were requested to be located by the appropriate utility or utilities
location contractor prior to the finalization of the waterline design.
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9.3 WATER MAIN EXTENSION AND RESIDENTIAL CONNECTIONS
9.3.1 Prcconstruction Quality Control Activities
9.3.1.1 Final Water Main Alignment
Prior to construction, the final alignment for the water main will be field determined and
submitted to the City of Belmont for approval. This submittal will include the final location for
the water main, the location of connections to the pipeline, the location for the structures
associated with the pipeline work including the valves, and fire hydrants.
9.3.1.2 Survey Control
Once approval has been granted for the final alignment of the water main, the surveyor will
install sufficient horizontal control to guide the limits of clearing and the location of all the
aforementioned items. Survey control will be maintained as needed throughout the construction
period. If for any reason a discrepancy exists that affects the approved alignment, the
Design/Builder will notify COM immediately in writing .
9.3.1.3 Utilities Location
All utilities shall be located by the appropriate utility or utilities location contractor prior to
excavation of a portion of the trenching or coring activities.
9.3.2 Constrnction Quality Control Activities
9.3.2.1 Water System Improvements
Normal QA/QC procedures will consist of the Trans-State field supervisor visually and
physically inspecting the pipeline right-ol'-way clearing, pipeline trench excavation, pipeline
bedding, pipe laying, connections, taps, appurtenances, trench backfilling, trench closure, surface
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preparation, temporary cover, trench barricading, final cover installation (asphalt, gravel, or soil),
temporary and final seeding, replacement or repair of landscaping, and erosion control measure
management. After the line is completed and the service taps are added (street-by-street since
the project is not continuous and connects to existing waterlines) it will be hydrostatically tested
and disinfected. When the line passes both the pressure test and the sterilization requirements it
will be put in service.
In addition to compliance with the technical specifications (especially the hydrostatic testing and
disinfection procedures) Trans-State will address the following QA/QC concerns:
I) Perform work in a systematic manner to minimize inconvenience to the public due to
service interruptions and unnecessary traffic delays.
2) Install and maintain erosion control measures as required. Inspect measures weekly
and alter every significant rain event. Repair control measures within 48 hours of
inspection.
3) Backfill and close, cover, or barricade the trench at the end of each day.
4) Minimize, eliminate, and cleanup any residual excavated soil beside the trench at the
end of each day.
5) Maintain the red line drawings of any field changes for as-built generation.
6) Maintain daily QA/QC entries into the logbook of the superintendent for inspections,
City inspections, CDM oversight, testing, test results, and all follow-up corrective
activities.
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9.3.2.3 Acceptance Procedures for Water System Improvements
Acceptance testing and final inspection for watermains will be performed on a street by street
basis. Individual segments of the line will be hydrostatically tested according to the procedures
listed in Section 14.15 of the specifications and disinfected according to the procedures provided
in section 14.17 of the specifications. City Inspectors will have the opportunity to observe the
testing and disaffection procedures. Disinfection samples will be tested by an independent
laboratory. City Inspectors will have the opportunity to inspect the service tap, meter installation
and service line. At the completion of each work clement, Trans-State will schedule an
inspection of the work completed. Trans-State will infonn the appropriate City Inspector 24
hours prior to any required QC inspections or tests. This will include observation of any testing
as specified in the previous sections. A punch list of any items that do not conform to the
approved plans and specifications. A deficiency correction target date will be established and
provided to the CDM Project Manager and a subsequent completion inspection will be
conducted.
9.3.2.4 Residential Car·hon Filtration Units (RCFU)
The QA/QC on the RCFUs will consist of the following steps:
I) Inspection of the assembled unit(s).
2) Leak testing under pump developed pressure.
3) Inspection by licensed plumber.
4) Initial sampling of influent and cfllucnt water.
5) Review of operation and maintenance with homeowner/resident.
6) Compliance testing of influent and efllucnt after six months of operation.
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7) Review operation and maintenance with homeowner, replace carbon tilters, top
off softener brine tank, and turn over to homeowner.
9.3.2.5 Inspection Documentation
All inspection reports arc to be recorded and maintained in the project files. The documents
generated by these inspections are to be used to document and track deficiencies and corrective
actions, where necessary. The record of the inspections shall be reviewed by the CQC Project
Engineer or his dcsignec and the Project Manager.
9.4 VENDOR DATA/CERTIFICATES
Trans-State will utilize published vendor data and/or vendcr certification statements to
demonstrate and document compliance with material specifications and QC requirements.
Copies ofvender certificates, statements, etc. will be maintained in the CQC Plan project files.
9.5 CONTROL OF SUBCONTRACTORS
The CQC Plan outlines Trans-State's approach to ensuring the quality of work performed. This
approach includes a combination of inspections, tests, and documentation by qualified personnel,
applied to all phases of work. Subcontractors arc also subject to the provisions of this CQC Plan.
All subcontractors will work under the express direction of Trans-State supervisory staff and will
be expected to perform work to the quality standards of the contract.
The CQC Project Manager, the Lead Design Engineer or the CQC Field Manager will stop the
work of any subcontractor pending satisfactory resolution of noncompliance work noted by the
CQC Field Manager or by the COM Project Representative.
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