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HomeMy WebLinkAboutNCD980602163_20010423_Warren County PCB Landfill_SERB C_No. 113 - Construction Quality Assurance Project Plan-OCRTRANSMITTAL COVER PAGE WARREN COUNTY PCB LANDFILL DETOXIFICATION PROJECT IT Corp. Project #823851 Submitted By: IT Corporation -200 Horizon Center Boulevard, Trenton, New Jersey 08691 Transmittal Number (chronological sequence): 006 Transmittal Date: 04/23/01 Submittal Register Item Number: _ill Resubmittal : No_ll_ Yes Specification Section: H&SP 3.1 .1 Description: Construction Quality Assurance Project Plan Drawing/Detail Number: NIA Subcontractor/Supplier: N/ A Comments: NIA Number of Copies Submitted: _5_ Number of Copies to be Returned to Contractor _ _,__ Submitter's Name and Signature: Gary W. Duke, P.E. Earth Tech Engineer's Receipt Signature: ___________________ _ Comments: Receipt Date: Engineer's Approval Comments: Reviewer's Signature Project Manager's Signature D A. "Reviewed and approved, no exceptions taken" D B. "Reviewed and approved with comments D C. "Revise and Resubmit" ______________ Date ________ _ ______________ Date ________ _ ' f t l Warren County PCB Landfill Detoxification Construction Quality Assurance Plan April 20, 2001 '. Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE OF CONTENTS 1.0 INTRODUCTION ....................................................................................................... 1 1.1 Purpose ............................................................................................................ 1 1.2 Overview ......................................................................................................... 2 1.3 History ............................................................................................................. 2 1.4 Project Summary ofWork ............................................................................. -3 2.0 GENERAL ............................................................................................................. 4 2.1 Requirements ................................................................................................. 4 2.2 Testing Finns ................................................................................................... 4 2.3 Owner/ Agency Access .................................................................................... 4 2.4 Conformance ................................................................................................... 5 2.5 Acceptance by NCDENR ............................................................................... 5 3.0 PROJECT ORGANIZATION AND RESPONSIBILITIES 6 3.1 General ............................................................................................................. 6 3.2 Quality Control Supervisor ............................................................................ 6 Figure 1 -CQAP Organizational Chart ................................................. -7 3.3 Quality Control Technicians/Resident Inspectors ......................................... 9 3.4 Site Manager .................................................................................................. 9 4.0 SUBMITTAL MANAGEMENT ............................................................................. 10 4.1 General Requirements ................................................................................... I 0 4.2 Project Submittals ......................................................................................... 10 4.2.1 Shop Drawings ................................................................................. 11 4.2.2 Samples ............................................................................................. 11 4 .3 Project Records ............................................................................................. 12 4.4 Transmittals to NCDENR ............................................................................ 13 REV. 0. i-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE OF CONTENTS (Continued) 5.0 INSPECTION REQUIREMENTS ........................................................................... 14 5.1 5.2 5.3 5.4 5.5 5.6 General 14 ···-······--·-· .......................................................................................................................................... . Tes ting phases ............................................................................................... 14 5.2.1 Phase I Inspections ........................................................................... 14 5.2.2 Phase II Inspections ......................................................................... 15 5.2.3 Phase III Inspections ........................................................................ 15 Reporting ....................................................................................................... 15 Deficient work 16 ......... -..................... ····-----········ ........................... -............................. . Construction Quality Control Test Schedule ............................................... 16 Materials ........................................................................................................ 18 5.6.1 Storage ............................................................................................... 18 6.0 DOCUMENTATION ............................................................................................... 24 6.1 Record Keeping···························································································· 24 6.2 Daily Inspection Report ................................................................................ 24 6.3 Daily Test Reports ....................................................................................... 25 6.4 Notice of Non-Compliance .......................................................................... 26 LIST OFT ABLES AND FIGURES Figure 1-CQAP Organizational Chart ............. , ...................................... 7 Table I-Construction Quality Control Test Schedule ................................ .19 APPENDICES I. Forms Quality Control Daily Inspection Report Notice of Non-Compliance Submittal Register REV. 0. ii-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill AASHTO ASTM BCD BFA CFR CQAP CQC EM ENG ER ETG FVCSP NCAC NCDENR O&M PCB ppb ppm ppt QC RCRA Site TEQ TDU TSCA REV. 0. LIST OF ACRONYMS American Association of State Highway and Transportation Officials American Society for Testing and Materials Base Catalyzed Decomposition Barnes, Ferland & Associates, Inc. Code of Federal Regulations Construction Quality Assurance Plan Construction Quality Control Engineering Manual Engineering Form Engineering Regulation ETG Environmental Corporation Final Verification/Confirmation Sampling Plan North Carolina Administrative Code North Carolina.Department of Environment & Natural Resources Operations and Maintenance Polychlorinated Biphenyl part per billion part per million part per trillion Quality Control Resource Conservation and Recovery Act Warren County PCB Landfill Toxicity Equivalent Concentration Thermal Desorption Unit Toxic Substance Control Act iii-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 1.0 INTRODUCTION 1.1 Purpose The Construction Quality Assurance Plan (CQAP) describes the quality control (QC) organization and program for the detoxification activities of the Warren County PCB (polychlorinated biphenyls) Landfill (the Site). Chemical quality management aspects of this QC program are addressed in the Final Verification/Confirmation Sampling Plan (FVCSP). The CQAP and the requirements and systems established herein are relevant and applicable to the project work performed by the Contractor, and his subcontractors and suppliers. The objectives of this CQAP are to anticipate the specific operating requirements of the project, and to establish procedures to ensure that the construction quality meets technical design specifications and conforms to the requirements of the Contract. Specifically, this plan: • Identifies the project, QC organization and defines each individual's respective authority, responsibilities, and qualifications; • Defines project communication, documentation, and record keeping procedures; and • Establishes QC procedures, including the necessary supervision and tests, to ensure that work meets applicable specifications and drawings. REV.O 1-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 1.2 Overview The Warren County PCB Landfill is a closed Toxic Substances Control Act (TSCA) landfill. The detoxification of the landfill represents a voluntary closure of the facility. The State of North Carolina has selected Base Catalyzed Decomposition (BCD) technology to detoxify the PCB and dioxin contaminated materials at the Warren County PCB Landfill. The State of North Carolina legislature has incorporated the utilization of BCD for the landfill detoxification into law and has specified the appropriate treatment standards required for the detoxification of the landfill. The treatment standards for material are as follows: A) PCBs -200 parts per billion (ppb) and B) dioxins/furans -200 parts per trillion (ppt) Toxicity Equivalent Concentration (TEQ). 1.3 History The Warren County PCB Landfill is located in Warren County, North Carolina, approximately 50 miles north of Raleigh, North Carolina. The Site is situated within a tract of land owned by the State of North Carolina that covers 19.317 acres. The Site includes a 2.54 acre landfill cell (PCB Landfill) that contains materials with elevated levels of PCBs. A gravel road approximately 3,000 feet long provides access to the Site from State Road 1604. The PCB Landfill is approximately 250 feet wide (measured in an east to west direction) and 500 feet long and contains approximately 72,000 tons of materials that were deposited into the landfill from remediation of roadways throughout the state that were illegally sprayed with PCB contaminated oils. Approximately ten percent of the materials originated from the Fort Bragg Military Reservation near Southern Pines, North Carolina and are assumed to be of a similar nature to the balance of the contaminated materials. REV.O 2-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill The PCB concentrations in the materials range from 259 parts per million (ppm) to a high of 853 ppm, with an average concentration of 500 ppm. Dioxin/furan concentrations range from 147 ppt TEQ to 238 ppt, with an average concentration of200 ppt TEQ. The maximum depth of the PCB Landfill at the center is approximately 40 feet, which includes the lower liner and existing cover. The depth at the perimeter is approximately 20 feet. In addition to the PCB materials, a relatively small amount of kiln dust (less than 1 % of the total volume) occupies the northeast corner of the PCB Landfill. Approximately one-half of the PCB Landfill rises above the existing ground surface. The PCB Landfill was completed in 1983. 1.4 Project Summary of Work ETG Environmental, Inc./BF A Environmental Consultants, Inc. have developed the bid specifications for the detoxification of the PCB Landfill. The scope of work for the detoxification of the PCB Landfill is as follows: I. Mobilization and site preparation activities including clearing and grubbing, construction of staging areas, utilities, haul roads, support zones, sediment control/stormwater management facilities, fencing, and process pads and buildings; assembly/installation of full scale detoxification technology equipment; and temporary construction/support trailers. II. Landfill opening, excavation of contaminated materials, performance demonstration testing, detoxification of contaminated materials, verification and confirmation sampling and analysis, work area/perimeter air monitoring, process condensate treatment, and off-site recycling/disposal of solid and liquid residues. III. Landfill backfill and compaction, decontamination/demobilization of all equipment from the site, restoration and vegetation/planting of all work areas. REV.O 3-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 2.0 GENERAL 2.1 Requirements The CQAP defines the site personnel, procedures and protocols to be performed to ensure the quality of the work, at a minimum, satisfies the bid specifications. The CQAP focuses on the personnel organization and respective duties, and the quality assurance for the general construction activities to be performed at the site. Quality assurance issues regarding health and safety, air monitoring, verification and confirmation sampling and analysis, and performance determination are addressed within their respective plans that are included as part of the Bid Specifications. 2.2 Testing Firms The qualifications of testing firm(s), including laboratories used for air, water soil and personnel air monitoring, to be used for construction quality control tests will be ~ ..ieentifi:cct 30 days prior to their use. The selected testing firm(s) shall be experienced in · performing the work required. 2.3 Owner/ Agency Access Representatives of the North Carolina Department of Environment and Natural Resources (NCDENR) or their authorized agencies will have access to the work at all times for observations, inspection and testing. The Contractor will provide proper and safe conditions for such access. The Contractor will give NCDENR timely notice of readiness of all work that requires their inspection, tests, observations or approvals. REV.O 4-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 2.4 Conformance The Contractor will insure conformance of all items of work, including that undertaken by his subcontractors, to the applicable Drawings and Specifications with respect to materials and workmanship. 2.5 Acceptance by NCDENR Acceptance of this plan is conditional and will be predicated on satisfactory Contractor performance during the detoxification. The NCDENR reserves the right to require the Contractor to make changes in the CQAP including removal of personnel, as necessary, to obtain the quality specified. REV.O 5-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 3.0 PROJECT ORGANIZATION AND RESPONSIBILITIES 3.1 General The organization established for this project is depicted in Figure 1. This plan_ includes the project management, technical and QC staff. Additional QC staff may be added as necessary to meet QC requirements for each definable feature of work. The quality related responsibilities and authority of the key members of this organization are outlined below. 3.2 Quality Control Supervisor The on-site Quality Control Supervisor will be responsible for planning and executing QC oversight of project operations, and ensuring compliance with specified QC requirements. The QC Supervisor will be employed by the Contractor and will be accountable to the Contractor's Site Manager. The position of QC Supervisor may be held by different individuals during different stages of the project; the qualifications and experience of each such individual will be relevant to the project activities taking place during his/her tenure. For example, during the construction-related phases of the project (site preparation and closeout), the QC Supervisor shall have qualifications and experience pertinent to the construction-related phases of the project. During the BCD Detoxification phase of the project, the QC Supervisor shall have qualifications and experience pertinent to verifying performance of the BCD Detoxification process. The QC Supervisor and designated alternates are subject to NCDENR approval. REV.O 6-April 20 200 I .. Construction Quality Assurance Plan -BCD Detoxification Quality Control Techs (As Needed) Project Manager Site Manager Quality Control Supervisor Warren County PCB Landfill Outside Inspectors (As Required) Figure 1. CQAP Organization Chart REV.O 7-April 20 200 I .. . Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill Specifically, the QC Supervisor will be responsible for: 1) developing, assessing the effectiveness of, and maintaining this CQAP and related procedures; 2) reviewing and approvmg the qualifications of proposed technical staff and subcontractors; Figure 1 3) planning and ensuring the performance of preparatory, initial, follow-up, and completion inspections for each definable feature of work; 4) identifying quality problems and verifying that appropriate corrective actions are implemented; 5) ensuring that the requisite QC records including submittals are generated and retained as prescribed by this CQAP; 6) verifying that subcontracted laboratories have appropriate certifications and operate under a documented QC that complies with the CQAP and applicable requirements of the contract; and 7) notifying the NCDENR representative 48 hours prior to beginning any actions required of the preparatory and initial phases. The QC Supervisor shall also prepare QC reports upon completion of each of the three phases of the project (site preparation, BCD Detoxification, and closeout). In each QC report, the QC Supervisor shall verify compliance with the Plans and Specifications. REV.O 8-April 20 2001 .. Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill The QC Supervisor or his designated alternate will be physically on-site whenever project-related field work is in progress. During periods that coincide with project- related field work when the QC Supervisor is not present (e.g.: vacation) the site manager will assume the duties of the QC supervisor. 3.3 Quality Control Technicians/Resident Inspectors As needed the QC Supervisor will assign quality control technicians and resident inspectors to adequately implement the CQAP. These personnel will be engineers, engineering technicians, or experienced craftsman with qualifications in the appropriate fields of construction materials and/or hazardous waste remediation. The quality control technicians report directly to the QC Supervisor ( e.g. concrete field tests, soil compaction tests, etc.). 3.4 Site Manager The Site Manager will be responsible for all daily site operations. He will ensure the implementation of the CQAP and support the efforts of the QC Supervisor and his staff. REV.O 9-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 4.0 SUBMITTAL MANAGEMENT 4.1 General Requirements The QC Supervisor has the sole responsibility of ensuring submittals fully comply with project requirements. Each project submittal shall be signed and sealed by the PE in responsible charge of the submittal, where required by the statutes governing the practice of engineering in North Carolina. Submittal control is required to regulate the timely flow of materials and work, to ensure problem prevention and to demonstrate that materials and work are in compliance with applicable specifications. Project submittal procedures will be implemented in accordance with the project procedures prescribed herein and in accordance with the project Submittal Register form provided in Appendix I of this CQAP. The Project Manager will be responsible for overall management and control of project submittals. The Site Manager will be responsible for submittal scheduling and tracking. The QC Supervisor will be responsible for ensuring, through detailed review, that submittals, as well as the materials and the work they represent are in full compliance with applicable contract specifications. The QC Supervisor will also be responsible for ensuring that a project file is established and maintained. 4.2 Project Submittals Submittals will be listed and tracked using the referenced submittal register. Submittals are defined in the submittal register. The QC Supervisor will review the list to ensure its completeness and may expand general category listings to show individual entries for each item. REV.O 10-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill REV.O 4.2.1 Shop Drawings Shop drawings from subcontractors and suppliers will be initially screened by the subcontractor's / supplier's in-house QC personnel. Shop drawings approved by the subcontractors and suppliers will be forwarded to the QC Supervisor for review to ensure that the items represented are in accordance with the contract drawings and specifications. Shop drawings not in compliance will be returned to the subcontractor or supplier for review and correction. Shop drawings in compliance will be signed by the QC Supervisor and forwarded as listed on the submittal register for that particular item. As the material/equipment arrives on the job site, the shop drawings and other pertinent data will be consulted to perform the receiving inspection and ascertain that the material/ equipment conforms to contract specifications. 4.2.2 Samples Samples being provided by subcontractors, manufacturers and suppliers will be checked by the QC Supervisor for conformance with the contract specifications. Conformance samples will be stored for future comparison with the project materials as they arrive at the construction site. 11-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 4.3 Project Records The QC Supervisor is to establish and maintain an on-site project file for document control. The purpose of this file is to maintain a complete set of all documents, reports, certifications and other records that provide information on project plans, contract agreements, and project activities. The initial file will be structured to include a record copy of the following documents: • Construction schedule and progress reports • Technical specifications, including addenda and modifications thereof • Change orders and other contract modifications • Engineer field orders • Manufacturer's certificates • Daily work activity summary reports, including: • Daily QC report (including QC log) • Daily Health and Safety Report • Daily Superintendent Report (including activity log) • Reports on any emergency response actions • Test records * Record of site work * Chain-of-custody records • Reports on any spill incidents • Truckload and tickets and shipping papers * Laboratory results • Records of quantities of soil treated * Noted Deficiencies (master deficiency log submitted monthly) * Landfill excavation and sampling map (weekly) • Other items required by the NCDENR • Conversation logs • Meeting minutes and agenda • Inspection logs and schedules REV.O 12-April 20 200 I . . Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill • Photo documentation • Site maps • As-built drawings 4.4 Transmittal to NCDENR Submittals that require NCDENR approval will be reviewed and approved by the QC Supervisor before submission with proper listings of the specifications, paragraph, and/or sheet number of the plans pertinent to the data submitted for each item requiring approval. REV.O 13-April 20 200 l Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 5.0 INSPECTION REQUIREMENTS 5.1 General Quality control inspection functions are organized to provide inspections for all definable features of work as detailed below. All inspections will be documented by the Contractor as specified in Section 6.0 "Documentation" of the CQAP. Inspection shall be performed daily to ensure continuing compliance with contract requirements until completion of the particular feature of work. 5.2 Testing Phases The CQAP includes three phases of inspections and tests for each feature of the work to insure that work is carried out in accordance with the Drawings and Specifications. The Contractor will not conceal any feature of work containing uncorrected defects. The NCDENR will be notified at least 48 hours in advance of each test and inspection. REV.O 5.2.1 Phase I Inspections Phase I Inspections will be performed prior to beginning each feature of construction work. Phase I inspections for the applicable feature of work include: a. A review of submittal requirements and all other contract requirements with the foreman or supervisor directly responsible for the performance of the work. b. Checks to assure that provisions have been made to provide required field control testing. 14-April 20 2001 . . Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill c. Examination of the work area to ascertain that all preliminary work has been completed. d. Verification of all field dimensions and advise the NCDENR of any discrepancies. e. Physical examination of materials and equipment to assure that they conform to approved shop drawings or submittal data and that all material and/or equipment are on hand. 5.2.2 Phase II Inspections Phase II Inspections will be performed as soon as work begins on a representative portion of the particular feature of work and include examination of the quality of workmanship as well as a review of control testing for compliance with Contract Requirements (e.g. soil compaction test, concrete testing, etc.). 5.2.3 Phase III Inspections Will be performed continuously as any particular feature of work progresses, to assure compliance with Contract requirements including control testing, until completion of that feature of the work. 5.3 Reporting All inspections and test results shall be recorded daily. The "Quality Control Daily Inspection Report" and any "Daily Test Report" (see Section 6.0 "Documentation") shall be reproduced and fully executed to show all inspections and tests and shall be submitted to the NCDENR on the first work day following the date covered by the report. REV.O 15-April 20 200 I . . , Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 5.4 Deficient Work The Contractor shall stop work on any item or feature, pending satisfactory correction of any deficiency noted by his quality control staff or by the NCDENR. Construction shall not proceed upon any feature of work containing uncorrected work. If recurring deficiencies in an item or items indicate that the quality control system is inadequate, corrective action shall be taken as directed by the NCDENR. If the Contractor refuses or fails to comply promptly, the NCDENR may issue an order stopping all or part of the work until satisfactory corrective action has been taken. 5.5 Construction Quality Control Test Schedule As part of the overall CQAP the Contractor will implement a construction quality control test schedule Q. The testing schedule includes the minimum tests and frequencies required by each technical specification item, as well as any additional quality control tests that the Contractor deems necessary to adequately control production and/or construction processes. The testing schedule is shown in Table 1 on pages following Section 5.6.1. The elements of construction to which the testing schedule applies include construction of the water main, electrical services, haul roads, erosion control/storm water management facilities, process pads and buildings, and backfill and compaction of the landfill following successful detoxification of the PCB-contaminated materials. Construction of the water and stormwater mains will involve Excavating, Backfilling and Compaction (Spec. 02220), Cast-in-Place Concrete (Spec. 03300), and Designation and Testing of Piping Materials (Spec. 15044). REV.O 16-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill Electrical services construction will conform to the North Carolina State Building Code, Volume 4 (National Electrical Code). Applicable specifications include Excavating, Backfilling & Compaction (Spec. 02220), Cast-in-Place Concrete (Spec. 03300), and Electrical (Spec. 16050). Elements of the erosion control/stormwater management facility are the stormwater collection system, new lined pond, pump station and forced main, and wet pond. Applicable specifications are Earthwork (Spec. 02200), Excavation, Backfilling and Compaction (Spec. 02220), HDPE Liner (Spec. 02750), Cast-in-Place Concrete (Spec. 03300), Designation and Testing of Piping Materials (Spec. 15044), and Electrical (Spec. 16050). Haul road construction will involve Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02200), Aggregate for Non-Asphalt Flexible Type Base (Spec. 01010), Road Base (Spec. 02232), and Stabilized Subgrade (Spec. 02240). Specifications applicable to construction of process pads include Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02220), and Cast-in-Place Concrete (Spec. 03300). Construction of the storage containment area will involve Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02220), Stabilized Subgrade (Spec. 02240), Pavement Base (Spec. 02232). Construction of the pole barn will involve Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02220), Cast-in-Place Concrete (Spec. 03300), and Structural Steel (Spec. 05120). Backfilling and compaction of the landfill following successful detoxification of the PCB-contaminated material will involve Earthwork (Spec. 02200) and Excavating, Backfilling and Compaction (Spec. 02220). REV.O 17-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 5.6 Materials All materials and equipment, except as otherwise provided in the contract documents will be of good quality and condition. All materials and equipment will be applied, installed, connected, erected, used, cleaned and conditioned in accordance with the bid specifications and recommendations of the applicable supplier. Where the bid specification and manufacturer recommendations differ, the more stringent requirement will apply. REV .O 5.6.1 Storage Materials will be shipped, delivered and stored in the manufacturer's undamaged crating and packaging. Material will be stored off the ground on blocking, appropriately covered, and be protected from sunlight, weather and vandalism. 18-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLEl CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 010IO Aggregate for • Gradation test Two random samples per 1,000 As specified in NCDOT Non-Asphalt tons or fraction thereof requirement IO I 0 Flexible Type Bases • Liquid limits plasticity index 02200 Earthwork • In place soil density detennined by Load-Bearing Areas: 95 percent either the Sand Replacement (ASTM modified Proctor Method (ASTM D 1556), Nuclear (ASTM D2922), or D-1557). Drive Sleeve (ASTM D2937) Methods. Non-Load Bearing Areas: 90% Modified Proctor Method. Area One (I) Test per 2,500 Sq. Ft. per -Beneath and around all structures Lift or Min. of two (2) tests, whichever is greater One (I) test per I 0,000 Sq. Ft. per -Beneath paved areas lift. One (I) test per I 00 linear feet -Wall Footings One (I) test per I 00 linear feet for -Pipes yard piping. Min. one (I) test per lift for pipes under structures As directed by Engineer -Other Areas REV.O 19-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill I, TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE ~ Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 02220 Excavating, • In place soil density detennined by Reference Spec. Section 02200 Backfilling Nuclear Density Meter per (ASTM & Compaction D2922) or Drive Sleeve Method per (ASTM D2937) Area Material -Utility Trenches, Structural Fill 8 inch lifts Compaction to 95% of modified Backfill beneath Proctor Method (ASTM D-1557) structures and roadways " -Around structures Structural Fill 8 inch lifts Compaction to 95% of modified Proctor Method (ASTM D-1557) -From cleared Common Fill 12 inch lifts Compaction to 95% of modified existing surface Proctor Method (ASTM D-1557) to subgrade for paved and gravel -Non-load bearing Common Fill 12 inch lifts Compaction to 90% of modified Proctor Method (ASTM D-1557) 02232 Road Base • Modified Proctor I 00 ft. of roadway, on center Compaction to 2:: 98% Modified (ASTM D 1557) Proctor 02240 Stabilized Subgrade • Modified Proctor Test Density every Compaction to 2:: 98% Modified (ASTM D 1557) 300 feet or less, on center, Proctor of roadways REV.O 20-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill -I, TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE .. Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 02750 PE Liner • Thickness (ASTM D75 I) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Density (ASTM D792) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Melt Index (ASTM Dl238) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Carbon Black Content Random samples of each shipment, Spec. 02750, Table I (ASTM Dl603) as specified PE Liner • Tensile Properties (ASTM D638) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Tear Resistance (ASTM DI004) Random samples of each shipment, Spec. 02750, Table I as specified PE Seams • Peel (ASTM D4 l 3) Test seams, twice or more daily As specified in Spec. 02750, PE Seams • Shear (ASTM D3083) per machine, + I sample/seamer para. 3.048 PE Seams • Vacuum or Pressure Test Entire length, each field seam As specified in Spec. 02750, para. 3.04C. l or 2 PE Seams • Destructive testing of seams Every 500 feet As specified in Spec. 02750, para. 3.04C.3 Anchor Trench Backfill • Standard Proctor (ASTM D698) One (I) test/I 00 lineal feet 90% maximum dry density 03300 Cast-in-Place • Slump (ASTM 39) Perform @ Concrete 3" -4" Concrete • Temperature Placement for Each Load 68° ± 2° F • Air Content (ASTM C 173) Every other truck 6%±½% or (ASTM C231) • Compressive Strength (ASTM C39) I Set per Day or 50 CY 3000 PSI @ 28 Day Set of (5) Cylinders (ASTM C31) (Max.) [Test (2)@ 7 days, (2) @ 28 Days, (I) Reserve] REV.O 21-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill r. TABLE! CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 03483 Precast Concrete • Slump Perform @ concrete placement for 3" -4" Structures -each load Cement Mortar • Temperature 68° ± 2° F used for Repairs • Air Content (ASTM Cl73) or Every other truck 6%±½% (ASTM C23I) 4,000 psi @ 7 days I Set per Day or 50 CY (Max.) • Compressive Strength (ASTM C39) (Test (2) @ 7 days, 2 @ (28) days, 5,000 psi @ 28 days Set of (5) Cylinders (ASTM C3 I) ( I ) Reserve) 03610 Floor Grouting • Compressive Strength (ASTM C39) I Set per 75 CY or per day if See Section 03300 Set of (5) Cylinders (ASTM C3 I) < 45 CY/Day. Test in accordance with Section 03300 11190 ASTs • Visual At delivery As specified • Leak monitoring As specified by NCAC As specified by NC AST regulations 13200 Process Tanks • Visual At delivery No visible defects • Hydrostatic Test At installation Watertight at 24 hours REV.O 22-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE .. Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 15044 Piping Materials, • Hydrostatic Test, as specified Each piping installation Check for leaks and correct until Designation and no Testing leaks • Pneumatic Test, as specified Each piping installation Check for leaks and correct until no • lnfiltration/Exfiltration Tests, as Each piping installation leaks specified Leaks ~25 gal.fin. -mile of pipe per 24 hours 16050 ·Electrical • Protective relays Prior to energizing Meet manufacturer's specifications and requirements ofN.C. Building • Operation of circuit breakers and Code, Vol. 4 (NEC) interrupters • Switchgear, switches, power and control panels REV.O 23-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 6.0 DOCUMENTATION 6.1 Record Keeping The Contractor will maintain current quality control records of all inspections and tests performed. These records include factual evidence that the required inspections or tests have been performed, including the individuals and organization performing inspections or tests, type and number of inspections or tests involved; results of inspections or tests; nature of defects, deviations, causes for rejection, etc.; proposed remedial action; and corrective action taken. These records cover both conforming and defective or deficient features, and include a statement that all supplies and materials incorporated in the work are in full compliance with the terms of the contract. Legible copies of these records shall be furnished to the NCDENR daily. The records will cover all work placed subsequent to the previously furnished records and reviewed and approved by the QC Supervisor. 6.2 Daily Inspection Report Each Contractor quality control technician will maintain a daily log of all inspections performed for both Contractor and subcontractor operations on a form acceptable to the NCDENR. These technician's daily reports provide factual evidence that continuous quality control inspections have been performed and include the following: a. Technical specification item number and description b. Compliance with approved submittals c. Proper storage of materials and equipment REV.O 24 April 20 2001 , , , Construction Quality Assurance Plan • BCD Detoxification Warren County PCB Landfill d. Proper operation of all equipment e. Adherence to plans and technical specifications f. Review of quality control tests g. Safety inspection h. Names and signatures of the technician and QC Supervisor. The daily inspection reports identify inspections conducted, results of inspections, location and nature of defects found, causes for rejection, and remedial or corrective actions taken or proposed. The daily inspection reports will be signed by the responsible quality control technician and the Quality Control Supervisor. The NCDENR will be provided at least one copy of each daily inspection report on the work day following the day of record. 6.3 Daily Test Reports The Quality Control Supervisor will establish a system which will record all quality control test results. Daily test reports shall document the following information: a. Technical Specification item number and description; b. Test designation; c. Location; REV.O 25 April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill d. Date of test; e. Control requirements; f. Test results; g. Causes for rejection; h. Recommended remedial actions; and 1. Retest. Test results from each day's work period shall be submitted to the NCDENR the following day. When required by the technical specifications, the Contractor will maintain statistical quality control charts. The daily test reports will be signed by the responsible quality control technician and the QC Supervisor. 6.4 Notice of Non-Compliance The QC Supervisor shall notify the Site Manager in writing of any deficiency in workmanship and/or materials documenting the corrective action taken by Contractor to correct situation. This notice shall include the following information: a. Date b. Specification section and/or drawing number c. Description of deficiency REV.O 26 April 20 200 l .) Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill d. Corrective action taken by Contractor e. Signature of technician and Contractor. If there is no resolution or deficiency or continued reoccurrences, the Site Manager shall notify NCDENR immediately. See attached sample form for reporting noncompliance in Appendix I. REV.O 27 April 20 200 I · Construction Quality Assurance Plan -BCD Detoxification REVO Appendix I Forms Warren County PCB Landfill Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill PAGE 1 OF3 L QUALITY CONTROL DAILY INSPECTION REPORT I GENERAL INFORMATION Regort No: Contract No. Date: Project: Weather: Prime Contractor: CLEAR CLOUDY RAIN SNOW Temgerature Range: Subcontractors: F to F ---- DAILY WORKFORCE AND EQUIPMENT MAJOR TRADE NO. OF PERSONS MAJOR EQUIPMENT TOT AL PERSON: YES NO (IF YES PREP ARE A NOTICE OF NON-COMPLIANCE FOR EACH ITEM) REVO April 20 2001 . . Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill PAGE 2OF3 Lass . QUALITY CONTROL DAIL y INSPECTION REPORT I CONTRACTORS WORK SUBCONTRACTOR(S) WORK REVO April 202001 .. I I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill PAGE 30F3 L QUALITY CONTROL DAIL y INSPECTION REPORT I INSPECTIONS & TESTS INSTRUCTIONS RECEIVED & REMARKS SIGNATURE QUALITY CONTROL TECHNICIAN: (SIGNATURE) (PRINTED NAME) (DATE) I CERTIFY THAT THE ABOVE REPORT IS COMPLETE AND CORRECT AND THAT I, OR MY AUTHORIZED REPRESENTATIVE, HA VE INSPECTED THE WORK PERFORMED THIS DAY BY THE PRIME CONTRACTOR AND EACH SUBCONTRACTOR AND HA VE DETERMINED THAT ALL MATERIALS, EQUIPMENT, AND WORKMANSHIP ARE IN STRICT COMPLIANCE WITH THE CONTRACT DOCUMENTS EXCEPT AS NOTED ABOVE. (SIGNATURE) (PRINTED NAME) (DATE) REVO April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill PAGE 1 OF 1 L NOTICE OF NON-COMPLIANCE • GENERAL INFORMATION !DATE: PROJECT: !NOTICE NUMBER: CONTRACTOR: !SPECIFICATION NUMBER(S): NOTICE ISSUED TO: DESCRIPTION OF DEFICIENCY IN WORKMANSHIP AND/OR MATERIAL CORRECTIVE ACTION ACCOMPLISHED SIGNATURES CQAP TECHNICAN: DATE ISSUED: CONTRACTOR: DA TE ISSUED: REVO April 202001 No. I 2 3 4 5 6 7 8 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill [ SUBMITTAL REGISTER FORM Submittal Date Projected Due Date Section Item Submitted Use Date Status Date: Approved: Resubmit: Date: Approved: Resubmit: Date: Approved: Resubmit: Date: Approved: Resubmit: Date: Approved: Resubmit: Date: Approved: Resubmit: Date: Approved: Resubmit: Date: Approved: Resubmit: REVO April 20 2001 I Comments/Date/Initial .. .. ..., JI TRANSMITTAL COVER PAGE WARREN COUNTY PCB LANDFILL DETOXIFICATION PROJECT IT Corp. Project #823851 Submitted By: IT Corporation -200 Horizon Center Boulevard, Trenton, New Jersey 08691 Transmittal Number (chronological sequence): 006 Transmittal Date: 04/23/01 Submittal Register Item Number: _l11 Resubmittal: No_x_ Yes Specification Section: H&SP 3.1.1 Description: Construction Oualitv Assurance Project Plan Drawing/Detail Number: NIA Subcontractor/Supplier: NI A Comments: NI A Number of Copies Submitted: _5_ Number of Copies to be Returned to Contractor _ _,__ Submitter's Name and Signature: Gary W. Duke, P.E. Earth Tech Engineer's Receipt Signature: -------------------- Comments: Receipt Date: Engineer's Approval Comments: Reviewer's Signature Project Manager's Signature □ A. "Reviewed and approved, no exceptions taken" D B. "Reviewed and approved with comments □ C. "Revise and Resubmit" _______________ Date ________ _ _______________ Date. ________ _ Warren County PCB Landfill Detoxification Construction Quality Assurance Plan April 20, 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 1.0 TABLE OF CONTENTS INTRODUCTION 1 I.I 1.2 1.3 1.4 Purpose ............................................................................................................ ! Overview 2 ........................................................................................................................................................................................ History·············································································································2 Project Summary of Work .............................................................................. 3 2.0 GENERAL ............................................................................................................. 4 2.1 Requirements ................................................................................................... 4 2.2 Testing Firms .................................................................................................. 4 2.3 Owner/ Agency Access .................................................................................... 4 2.4 Conformance ................................................................................................... 5 2.5 Acceptance by NCDENR ............................................................................... 5 3.0 PROJECT ORGANIZATION AND RESPONSIBILITIES 6 3 .1 General ............................................................................................................. 6 3.2 Quality Control Supervisor.~ ........................................................................... 6 Figure 1 -CQAP Organizational Chart ................................................. -7 3.3 Quality Control Technicians/Resident Inspectors ........................................ 9 3.4 Site Manager .................................................................................................. 9 4.0 SUBMITTAL MANAGEMENT 4 .1 General Requirements .................................................................................. 10 4.2 Project Submittals ......................................................................................... 10 4.2.1 Shop Drawings .................................................................................. 11 4.2.2 Samples ............................................................................................. 11 4 .3 Project Records ............................................................................................. 12 4.4 Transmittals to NCDENR ............................................................................ 13 REV. 0. i-April 20 200 l . ·' Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE OF CONTENTS (Continued) 5. 0 INSPECT! ON REQUIREMENTS ........................................................................... 14 5.1 5.2 5.3 5.4 5.5 5.6 General 14 ............................................................................................................................... Testing phases ............................................................................................... 14 5.2.1 Phase I Inspections ........................................................................... 14 5.2.2 Phase II Inspections .......................................................................... 15 5.2.3 Phase III Inspections ........................................................................ 15 Reporting······································································································· l 5 Deficient work 16 ................................................................................................................ Construction Quality Control Test Schedule .............................................. 16 Materials ........................................................................................................ 18 5 .6.1 Storage ............................................................................................... 18 6.0 DOCUMENTATION ................................................................................................ 24 6.1 Record Keeping ............................................................................................ 24 6.2 Daily Inspection Report ................................................................................ 24 6.3 Daily Test Reports ........................................................................................ 25 6.4 Notice of Non-Compliance .......................................................................... 26 LIST OF TABLES AND FIGURES Figure 1-CQAP Organizational Chart .................................................... 7 Table I-Construction Quality Control Test Schedule ................................. 19 APPENDICES I. Forms Quality Control Daily Inspection Report Notice of Non-Compliance Submittal Register REV. 0. ii-April 20 200 l ., Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill AASHTO ASTM BCD BFA CFR CQAP CQC EM ENG ER ETG FVCSP NCAC NCDENR O&M PCB ppb ppm ppt QC RCRA Site TEQ TDU TSCA REV. 0. LIST OF ACRONYMS American Association of State Highway and Transportation Officials American Society for Testing and Materials Base Catalyzed Decomposition Barnes, Ferland & Associates, Inc. Code of Federal Regulations Construction Quality Assurance Plan Construction Quality Control Engineering Manual Engineering Form Engineering Regulation ETG Environmental Corporation Final Verification/Confirmation Sampling Plan North Carolina Administrative Code North Carolina.Department of Environment & Natural Resources Operations and Maintenance Polychlorinated Biphenyl part per billion part per million part per trillion Quality Control Resource Conservation and Recovery Act Warren County PCB Landfill Toxicity Equivalent Concentration Thermal Desorption Unit Toxic Substance Control Act iii-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 1.0 INTRODUCTION 1.1 Purpose The Construction Quality Assurance Plan (CQAP) describes the quality control (QC) organization and program for the detoxification activities of the Warren County PCB (polychlorinated biphenyls) Landfill (the Site). Chemical quality management aspects of this QC program are addressed in the Final Verification/Confirmation Sampling Plan (FVCSP). The CQAP and the requirements and systems established herein are relevant and applicable to the project work performed by the Contractor, and his subcontractors and suppliers. The objectives of this CQAP are to anticipate the specific operating requirements of the project, and to establish procedures to ensure that the construction quality meets technical design specifications and conforms to the requirements of the Contract. Specifically, this plan: • Identifies the project, QC organization and defines each individual's respective authority, responsibilities, and qualifications; • Defines project communication, documentation, and record keeping procedures; and • Establishes QC procedures, including the necessary supervision and tests, to ensure that work meets applicable specifications and drawings. REV.O 1-April 20 200 l Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 1.2 Overview The Warren County PCB Landfill is a closed Toxic Substances Control Act (TSCA) landfill. The detoxification of the landfill represents a voluntary closure of the facility. The State of North Carolina has selected Base Catalyzed Decomposition (BCD) technology to detoxify the PCB and dioxin contaminated materials at the Warren County PCB Landfill. The State of North Carolina legislature has incorporated the utilization of BCD for the landfill detoxification into law and has specified the appropriate treatment standards required for the detoxification of the landfill. The treatment standards for material are as follows: A) PCBs -200 parts per billion (ppb) and B) dioxins/furans -200 parts per trillion (ppt) Toxicity Equivalent Concentration (TEQ). 1.3 History The Warren County PCB Landfill is located in Warren County, North Carolina, approximately 50 miles north of Raleigh, North Carolina. The Site is situated within a tract of land owned by the State of North Carolina that covers 19 .317 acres. The Site includes a 2.54 acre landfill cell (PCB Landfill) that contains materials with elevated levels of PCBs. A gravel road approximately 3,000 feet long provides access to the Site from State Road 1604. The PCB Landfill is approximately 250 feet wide (measured in an east to west direction) and 500 feet long and contains approximately 72,000 tons of materials that were deposited into the landfill from remediation of roadways throughout the state that were illegally sprayed with PCB contaminated oils. Approximately ten percent of the materials originated from the Fort Bragg Military Reservation near Southern Pines, North Carolina and are assumed to be of a similar nature to the balance of the contaminated materials. REV.O 2-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill The PCB concentrations in the materials range from 259 parts per million (ppm) to a high of 853 ppm, with an average concentration of 500 ppm. Dioxin/furan concentrations range from 147 ppt TEQ to 238 ppt, with an average concentration of 200 ppt TEQ. The maximum depth of the PCB Landfill at the center is approximately 40 feet, which includes the lower liner and existing cover. The depth at the perimeter is approximately 20 feet. In addition to the PCB materials, a relatively small amount of kiln dust (less than 1 % of the total volume) occupies the northeast comer of the PCB Landfill. Approximately one-half of the PCB LandfiUrises above the existing ground surface. The PCB Landfill was completed in 1983. 1.4 Project Summary of Work ETG Environmental, Inc./BF A Environmental Consultants, Inc. have developed the bid specifications for the detoxification of the PCB Landfill. The scope of work for the detoxification of the PCB Landfill is as follows: I. Mobilization and site preparation activities including clearing and grubbing, construction of staging areas, utilities, haul roads, support zones, sediment control/stormwater management facilities, fencing, and process pads and buildings; assembly/installation of full scale detoxification technology equipment; and temporary construction/support trailers. II. Landfill opening, excavation of contaminated materials, performance demonstration testing, detoxification of contaminated materials, verification and confirmation sampling and analysis, work area/perimeter air monitoring, process condensate treatment, and off-site recycling/disposal of solid and liquid residues. III. Landfill backfill and compaction, decontamination/demobilization of all equipment from the site, restoration and vegetation/planting of all work areas. REV.O April 20 200 I Construction Quality Assurance Plan • BCD Detoxification Warren County PCB Landfill 2.0 GENERAL 2.1 Requirements The CQAP defines the site personnel, procedures and protocols to be performed to ensure the quality of the work, at a minimum, satisfies the bid specifications. The CQAP focuses on the personnel organization and respective duties, and the quality assurance for the general construction activities to be performed at the site. Quality assurance issues regarding health and safety, air monitoring, verification and confirmation sampling and analysis, and performance determination are addressed within their respective plans that are included as part of the Bid Specifications. 2.2 Testing Firms The qualifications of testing firm(s), including laboratories used for air, water soil and personnel air monitoring, to be used for construction quality control tests will be ..idefttifiect 30 days prior to their use. The selected testing firm(s) shall be experienced in performing the work required. 2.3 Owner/ Agency Access Representatives of the North Carolina Department of Environment and Natural Resources (NCDENR) or their authorized agencies will have access to the work at all times for observations, inspection and testing. The Contractor will provide proper and safe conditions for such access. The Contractor will give NCDENR timely notice of readiness of all work that requires their inspection, tests, observations or approvals. REV.O 4-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 2.4 Conformance The Contractor will insure conformance of all items of work, including that undertaken by his subcontractors, to the applicable Drawings and Specifications with respect to materials and workmanship. 2.5 Acceptance by NCDENR Acceptance of this plan is conditional and will be predicated on satisfactory Contractor performance during the detoxification. The NCDENR reserves the right to require the Contractor to make changes in the CQAP including removal of personnel, as necessary, to obtain the quality specified. REV.O 5-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 3.0 PROJECT ORGANIZATION AND RESPONSIBILITIES 3.1 General The organization established for this project is depicted in Figure 1. This plan_ includes the project management, technical and QC staff. Additional QC staff may be added as necessary to meet QC requirements for each definable feature of work. The quality related responsibilities and authority of the key members of this organization are outlined below. 3.2 Quality Control Supervisor The on-site Quality Control Supervisor will be responsible for planning and executing QC oversight of project operations, and ensuring compliance with specified QC requirements. The QC Supervisor will be employed by the Contractor and will be accountable to the Contractor's Site Manager. The position of QC Supervisor may be held by different individuals during different stages of the project; the qualifications and experience of each such individual will be relevant to the project activities taking place during his/her tenure. For example, during the construction-related phases of the project (site preparation and closeout), the QC Supervisor shall have qualifications and experience pertinent to the construction-related phases of the project. During the BCD Detoxification phase of the project, the QC Supervisor shall have qualifications and experience pertinent to verifying performance of the BCD Detoxification process. The QC Supervisor and designated alternates are subject to NCDENR approval. REV.O 6-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Quality Control Techs (As Needed) Project Manager Site Manager Quality Control Supervisor Warren County PCB Landfill Outside Inspectors ( As Required) Figure 1. CQAP Organization Chart REV.O 7-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill Specifically, the QC Supervisor will be responsible for: 1) developing, assessing the effectiveness of, and maintaining this CQAP and related procedures; 2) rev1ewmg and approving the qualifications of proposed technical staff and subcontractors; Figure 1 3) planning and ensunng the performance of preparatory, initial, follow-up, and completion inspections for each definable feature of work; 4) identifying quality problems and verifying that appropriate corrective actions are implemented; 5) ensuring that the requisite QC records including submittals are generated and retained as prescribed by this CQAP; 6) verifying that subcontracted laboratories have appropriate certifications and operate under a documented QC that complies with the CQAP and applicable requirements of the contract; and 7) notifying the NCDENR representative 48 hours pnor to beginning any actions required of the preparatory and initial phases. The QC Supervisor shall also prepare QC reports upon completion of each of the three phases of the project (site preparation, BCD Detoxification, and closeout). In each QC report, the QC Supervisor shall verify compliance with the Plans and Specifications. REV.O 8-April 20 200 l Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill The QC Supervisor or his designated alternate will be physically on-site whenever project-related field work is in progress. During periods that coincide with project- related field work when the QC Supervisor is not present (e.g.: vacation) the site manager will assume the duties of the QC supervisor. 3.3 Quality Control Technicians/Resident Inspectors As needed the QC Supervisor will assign quality control technicians and resident inspectors to adequately implement the CQAP. These personnel will be engineers, engineering technicians, or experienced craftsman with qualifications in the appropriate fields of construction materials and/or hazardous waste remediation. The quality control technicians report directly to the QC Supervisor ( e.g. concrete field tests, soil compaction tests, etc.). 3.4 Site Manager The Site Manager will be responsible for all daily site operations. He will ensure the implementation of the CQAP and support the efforts of the QC Supervisor and his staff. REV.O 9-April 20 200 I Construction Quality Assurance Plan • BCD Detoxification Warren County PCB Landfill 4.0 SUBMITTAL MANAGEMENT 4.1 General Requirements The QC Supervisor has the sole responsibility of ensuring submittals fully comply with project requirements. Each project submittal shall be signed and sealed by the PE in responsible charge of the submittal, where required by the statutes governing the practice of engineering in North Carolina. Submittal control is required to regulate the timely flow of materials and work, to ensure problem prevention and to demonstrate that materials and work are in compliance with applicable specifications. Project submittal procedures will be implemented in accordance with the project procedures prescribed herein and in accordance with the project Submittal Register form provided in Appendix I of this CQAP. The Project Manager will be responsible for overall management and control of project submittals. The Site Manager will be responsible for submittal scheduling and tracking. The QC Supervisor will be responsible for ensuring, through detailed review, that submittals, as well as the materials and the work they represent are in full compliance with applicable contract specifications. The QC Supervisor will also be responsible for ensuring that a project file is established and maintained. 4.2 Project Submittals Submittals will be listed and tracked using the referenced submittal register. Submittals are defined in the submittal register. The QC Supervisor will review the list to ensure its completeness and may expand general category listings to show individual entries for each item. REV.O 10-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill REV.O 4.2.1 Shop Drawings Shop drawings from subcontractors and suppliers will be initially screened by the subcontractor's / supplier's in-house QC personnel. Shop drawings approved by the subcontractors and suppliers will be forwarded to the QC Supervisor for review to ensure that the items represented are in accordance with the contract drawings and specifications. Shop drawings not in compliance will be returned to the subcontractor or supplier for review and correction. Shop drawings in compliance will be signed by the QC Supervisor and forwarded as listed on the submittal register for that particular item. As the material/equipment arrives on the job site, the shop drawings and other pertinent data will be consulted to perform the receiving inspection and ascertain that the material/ equipment conforms to contract specifications. 4.2.2 Samples Samples being provided by subcontractors, manufacturers and suppliers will be checked by the QC Supervisor for conformance with the contract specifications. Conformance samples will be stored for future comparison with the project materials as they arrive at the construction site. 11-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 4.3 Project Records The QC Supervisor is to establish and maintain an on-site project file for document control. The purpose of this file is to maintain a complete set of all documents, reports, certifications and other records that provide information on project plans, contract agreements, and project activities. The initial file will be structured to include a record copy of the following documents: • Construction schedule and progress reports • Technical specifications, including addenda and modifications thereof • Change orders and other contract modifications • Engineer field orders • Manufacturer's certificates • Daily work activity summary reports, including: * Daily QC report (including QC log) * Daily Health and Safety Report * Daily Superintendent Report (including activity log) * Reports on any emergency response actions * Test records * Record of site work * Chain-of-custody records * Reports on any spill incidents * Truckload and tickets and shipping papers * Laboratory results * Records of quantities of soil treated * Noted Deficiencies (master deficiency log submitted monthly) * Landfill excavation and sampling map (weekly) * Other items required by the NCDENR • Conversation logs • Meeting minutes and agenda • Inspection logs and schedules REV.O 12-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill • Photo documentation • Site maps • As-built drawings 4.4 Transmittal to NCDENR Submittals that require NCDENR approval will be reviewed and approved by the QC Supervisor before submission with proper listings of the specifications, paragraph, and/or sheet number of the plans pertinent to the data submitted for each item requiring approval. REV.O 13-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 5.0 INSPECTION REQUIREMENTS 5.1 General Quality control inspection functions are organized to provide inspections for all definable features of work as detailed below. All inspections will be documented by the Contractor as specified in Section 6.0 "Documentation" of the CQAP. Inspection shall be performed daily to ensure continuing compliance with contract requirements until completion of the particular feature of work. 5.2 Testing Phases The CQAP includes three phases of inspections and tests for each feature of the work to insure that work is carried out in accordance with the Drawings and Specifications. The Contractor will not conceal any feature of work containing uncorrected defects. The NCDENR will be notified at least 48 hours in advance of each test and inspection. REV.O 5.2.1 Phase I Inspections Phase I Inspections will be performed prior to beginning each feature of construction work. Phase I inspections for the applicable feature of work include: a. A review of submittal requirements and all other contract requirements with the foreman or supervisor directly responsible for the performance of the work. b. Checks to assure that provisions have been made to provide required field control testing. 14-April 20 200 l Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill c. Examination of the work area to ascertain that all preliminary work has been completed. d. Verification of all field dimensions and advise the NCDENR of any discrepancies. e. Physical examination of materials and equipment to assure that they conform to approved shop drawings or submittal data and that all material and/or equipment are on hand. 5.2.2 Phase II Inspections Phase II Inspections will be performed as soon as work begins on a representative portion of the particular feature of work and include examination of the quality of workmanship as well as a review of control testing for compliance with Contract Requirements ( e.g. soil compaction test, concrete testing, etc.). 5.2.3 Phase III Inspections Will be performed continuously as any particular feature of work progresses, to assure compliance with Contract requirements including control testing, until completion of that feature of the work. 5.3 Reporting All inspections and test results shall be recorded daily. The "Quality Control Daily Inspection Report" and any "Daily Test Report" (see Section 6.0 "Documentation") shall be reproduced and fully executed to show all inspections and tests and shall be submitted to the NCDENR on the first work day following the date covered by the report. REV.O 15-April 20 200 l Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 5.4 Deficient Work The Contractor shall stop work on any item or feature, pending satisfactory correction of any deficiency noted by his quality control staff or by the NCDENR. Construction shall not proceed upon any feature of work containing uncorrected work. If recurring deficiencies in an item or items indicate that the quality control system is inadequate, corrective action shall be taken as directed by the NCDENR. If the Contractor refuses or fails to comply promptly, the NCDENR may issue an order stopping all or part of the work until satisfactory corrective action has been taken. 5.5 Construction Quality Control Test Schedule As part of the overall CQAP the Contractor will implement a construction quality control test schedule (). The testing schedule includes the minimum tests and frequencies required by each technical specification item, as well as any additional quality control tests that the Contractor deems necessary to adequately control production and/or construction processes. The testing schedule is shown in Table 1 on pages following Section 5.6.1. The elements of construction to which the testing schedule applies include construction of the water main, electrical services, haul roads, erosion control/stormwater management facilities, process pads and buildings, and backfill and compaction of the landfill following successful detoxification of the PCB-contaminated materials. Construction of the water and storm water mains will involve Excavating, Backfilling and Compaction (Spec. 02220), Cast-in-Place Concrete (Spec. 03300), and Designation and Testing of Piping Materials (Spec. 15044). REV.O 16-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill Electrical services construction will conform to the North Carolina State Building Code, Volume 4 (National Electrical Code). Applicable specifications include Excavating, Backfilling & Compaction (Spec. 02220), Cast-in-Place Concrete (Spec. 03300), and Electrical (Spec. 16050). Elements of the erosion control/stormwater management facility are the stormwater collection system, new lined pond, pump station and forced main, and wet pond. Applicable specifications are Earthwork (Spec. 02200), Excavation, Backfilling and Compaction (Spec. 02220), HDPE Liner (Spec. 02750), Cast-in-Place Concrete (Spec. 03300), Designation and Testing of Piping Materials (Spec. 15044), and Electrical (Spec. 16050). Haul road construction will involve Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02200), Aggregate for Non-Asphalt Flexible Type Base (Spec. 01010), Road Base (Spec. 02232), and Stabilized Subgrade (Spec. 02240). Specifications applicable to construction of process pads include Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02220), and Cast-in-Place Concrete (Spec. 03300). Construction of the storage containment area will involve Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02220), Stabilized Subgrade (Spec. 02240), Pavement Base (Spec. 02232). Construction of the pole barn will involve Earthwork (Spec. 02200), Excavating, Backfilling and Compaction (Spec. 02220), Cast-in-Place Concrete (Spec. 03300), and Structural Steel (Spec. 05120). Backfilling and compaction of the landfill following successful detoxification of the PCB-contaminated material will involve Earthwork (Spec. 02200) and Excavating, Backfilling and Compaction (Spec. 02220). REV.O 17-April 20 200 l Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 5.6 Materials All materials and equipment, except as otherwise provided in the contract documents will be of good quality and condition. All materials and equipment will be applied, installed, connected, erected, used, cleaned and conditioned in accordance with the bid specifications and recommendations of the applicable supplier. Where the bid specification and manufacturer recommendations differ, the more stringent requirement will apply. REV.O 5.6.1 Storage Materials will be shipped, delivered and stored in the manufacturer's undamaged crating and packaging. Material will be stored off the ground on blocking, appropriately covered, and be protected from sunlight, weather and vandalism. 18-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 01010 Aggregate for • Gradation test Two random samples per 1,000 As specified in NCDOT Non-Asphalt tons or fraction thereof requirement IO 10 Flexible Type Bases • Liquid limits plasticity index 02200 Earthwork • In place soil density determined by Load-Bearing Areas: 95 percent either the Sand Replacement (ASTM modified Proctor Method (ASTM D 1556), Nuclear (ASTM 02922), or D-1557). Drive Sleeve (ASTM 02937) Methods. Non-Load Bearing Areas: 90% Modified Proctor Method. Area One ( 1) Test per 2,500 Sq. Ft. per -Beneath and around all structures Lift or Min. of two (2) tests, whichever is greater One ( 1) test per I 0,000 Sq. Ft. per -Beneath paved areas lift. One ( 1) test per I 00 1 in ear feet -Wall Footings One (I) test per 100 1 in ear feet for -Pipes yard piping. Min. one (I) test per lift for pipes under structures As directed by Engineer -Other Areas REV.O 19-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 02220 Excavating, • In place soil density determined by Reference Spec. Section 02200 Backfilling Nuclear Density Meter per (ASTM & Compaction D2922) or Drive Sleeve Method per (ASTM D2937) Area Material -Utility Trenches, Structural Fill 8 inch lifts Compaction to 95% of modified Backfill beneath Proctor Method (ASTM D-1557) structures and roadways -Around structures Structural Fill 8 inch lifts Compaction to 95% of modified Proctor Method (ASTM D-1557) -From cleared Common Fill 12 inch lifts Compaction to 95% of modified existing surface Proctor Method (ASTM D-1557) to subgrade for paved and gravel -Non-load bearing Common Fill 12 inch lifts Compaction to 90% of modified Proctor Method (ASTM D-1557) 02232 Road Base • Modified Proctor I 00 ft. of roadway, on center Compaction to ~ 98% Modified (ASTM D 1557) Proctor 02240 Stabilized Subgrade • Modified Proctor Test Density every Compaction to ~ 98% Modified (ASTM D 1557) 300 feet or less, on center, Proctor of roadways REV.O 20-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 02750 PE Liner • Thickness (ASTM D751) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Density (ASTM D792) Random samples of each shipment, Spec. 02750, Table 1 as specified PE Liner • Melt Index (ASTM Dl238) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Carbon Black Content Random samples of each shipment, Spec. 02750, Table I (ASTM Dl603) as specified PE Liner • Tensile Properties (ASTM D638) Random samples of each shipment, Spec. 02750, Table I as specified PE Liner • Tear Resistance (ASTM Dl004) Random samples of each shipment, Spec. 02750, Table I as specified PE Seams • Peel (ASTM D4l3) Test seams, twice or more daily As specified in Spec. 02750, PE Seams • Shear (ASTM D3083) per machine, + I sample/seamer para. 3.04B PE Seams • Vacuum or Pressure Test Entire length, each field seam As specified in Spec. 02750, para. 3.04C. l or 2 PE Seams • Destructive testing of seams Every 500 feet As specified in Spec. 02750, para. 3.04C.3 Anchor Trench Backfill • Standard Proctor (ASTM D698) One (I) test/JOO lineal feet 90% maximum dry density 03300 Cast-in-Place • Slump (ASTM 39) Perform @ Concrete 3"-4" Concrete • Temperature Placement for Each Load 68° ± 2° F • Air Content (ASTM Cl73) Every other truck 6%±½% or (ASTM C23 l) • Compressive Strength (ASTM C39) I Set per Day or 50 CY 3000 PSI @ 28 Day Set of (5) Cylinders (ASTM C3 l) (Max.) [Test (2)@ 7 days, (2) @ 28 Days, (I) Reserve] REV.O 21-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 03483 Precast Concrete • Slump Perform @ concrete placement for 3"-4" Structures -each load Cement Mortar • Temperature 68° ± 2° F used for Repairs • Air Content (ASTM Cl73) or Every other truck 6%±½% (ASTM C23 l) 1 Set per Day or 50 CY (Max.) 4,000 psi @ 7 days • Compressive Strength (ASTM C39) (Test (2) @ 7 days, 2 @ (28) days, 5,000 psi @ 28 days Set of (5) Cylinders (ASTM C3 l) ( 1) Reserve) 03610 Floor Grouting • Compressive Strength (ASTM C39) 1 Set per 75 CY or per day if See Section 03300 Set of (5) Cylinders (ASTM C3 l) < 45 CY/Day. Test in accordance with Section 03300 11190 ASTs • Visual At delivery As specified • Leak monitoring As specified by NCAC As specified by NC AST regulations 13200 Process Tanks • Visual At delivery No visible defects • Hydrostatic Test At installation Watertight at 24 hours REV.O 22-April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill TABLE 1 CONSTRUCTION QUALITY CONTROL TEST SCHEDULE Specification Section Item Required Test(s) Frequency of Testing Acceptance Criteria/Other 15044 Piping Materials, • Hydrostatic Test, as specified Each piping installation Check for leaks and correct until Designation and no Testing leaks • Pneumatic Test, as specified Each piping installation Check for leaks and correct until no • lnfiltration/Exfiltration Tests, as Each piping installation leaks specified Leaks ::;25 gal./in. -mile of pipe per 24 hours 16050 Electrical • Protective relays Prior to energizing Meet manufacturer's specifications and requirements ofN.C. Building • Operation of circuit breakers and Code, Vol. 4 (NEC) interrupters • Switchgear, switches, power and control panels REV.O 23-April 20 200 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill 6.0 DOCUMENTATION 6.1 Record Keeping The Contractor will maintain current quality control records of all inspections and tests performed. These records include factual evidence that the required inspections or tests have been performed, including the individuals and organization performing inspections or tests, type and number of inspections or tests involved; results of inspections or tests; nature of defects, deviations, causes for rejection, etc.; proposed remedial action; and corrective action taken. These records cover both conforming and defective or deficient features, and include a statement that all supplies and materials incorporated in the work are in full compliance with the terms of the contract. Legible copies of these records shall be furnished to the NCDENR daily. The records will cover all work placed subsequent to the previously furnished records and reviewed and approved by the QC Supervisor. 6.2 Daily Inspection Report Each Contractor quality control technician will maintain a daily log of all inspections performed for both Contractor and subcontractor operations on a form acceptable to the NCDENR. These technician's daily reports provide factual evidence that continuous quality control inspections have been performed and include the following: a. Technical specification item number and description b. Compliance with approved submittals c. Proper storage of materials and equipment REV.O 24 April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill d. Proper operation of all equipment e. Adherence to plans and technical specifications f. Review of quality control tests g. Safety inspection h. Names and signatures of the technician and QC Supervisor. The daily inspection reports identify inspections conducted, results of inspections, location and nature of defects found, causes for rejection, and remedial or corrective actions taken or proposed. The daily inspection reports will be signed by the responsible quality control technician and the Quality Control Supervisor. The NCDENR will be provided at least one copy of each daily inspection report on the work day following the day of record. 6.3 Daily Test Reports The Quality Control Supervisor will establish a system which will record all quality control test results. Daily test reports shall document the following information: a. Technical Specification item number and description; b. Test designation; c. Location; REV.O 25 April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill d. Date of test; e. Control requirements; f. Test results; g. Causes for rejection; h. Recommended remedial actions; and 1. Retest. Test results from each day's work period shall be submitted to the NCDENR the following day. When required by the technical specifications, the Contractor will maintain statistical quality control charts. The daily test reports will be signed by the responsible quality control technician and the QC Supervisor. 6.4 Notice of Non-Compliance The QC Supervisor shall notify the Site Manager in writing of any deficiency in workmanship and/or materials documenting the corrective action taken by Contractor to correct situation. This notice shall include the following information: a. Date b. Specification section and/or drawing number c. Description of deficiency REV.O 26 April 20 200 l Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill d. Corrective action taken by Contractor e. Signature of technician and Contractor. If there is no resolution or deficiency or continued reoccurrences, the Site Manager shall notify NCDENR immediately. See attached sample form for reporting noncompliance in Appendix I. REV.O 27 April 20 2001 Construction Quality Assurance Plan -BCD Detoxification REVO Appendix I Forms Warren County PCB Landfill Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill PAGE 1 OF3 QUALITY CONTROL DAILY INSPECTION REPORT I GENERAL INFORMATION Re12ort No: Contract No. Date: Project: Weather: Prime Contractor: CLEAR CLOUDY RAIN SNOW Tem12erature Range: Subcontractors: F to F ---- DAILY WORKFORCE AND EQUIPMENT MAJOR TRADE NO. OF PERSONS MAJOR EQUIPMENT TOT AL PERSON: YES NO (IF YES PREP ARE A NOTICE OF NON-COMPLIANCE FOR EACH ITEM) REVO April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill PAGE 2OF3 l. QUALITY Cz?NTROL EzAIL y INSPECTION REPORT I CONTRACTORS WORK SUBCONTRACTOR(S) WORK REVO April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill PAGE 3OF3 QUALITY CONTROL DAILY INSPECTION REPORT INSPECTIONS & TESTS INSTRUCTIONS RECEIVED & REMARKS SIGNATURE QUALITY CONTROL TECHNICIAN: (SIGNATURE) (PRINTED NAME) (DATE) I CERTIFY THAT THE ABOVE REPORT IS COMPLETE AND CORRECT AND THAT I, OR MY AUTHORIZED REPRESENTATIVE, HA VE INSPECTED THE WORK PERFORMED THIS DAY BY THE PRIME CONTRACTOR AND EACH SUBCONTRACTOR AND HA VE DETERMINED THAT ALL MATERIALS, EQUIPMENT, AND WORKMANSHIP ARE IN STRICT COMPLIANCE WITH THE CONTRACT DOCUMENTS EXCEPT AS NOTED ABOVE. (SIGNATURE) (PRINTED NAME) (DATE) REVO April 202001 I Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill PAGE 1 OF 1 ' .£ NOTICE OF NON-COMPLIANCE a • GENERAL INFORMATION !DATE: PROJECT: !NOTICE NUMBER: CONTRACTOR: !SPECIFICATION NUMBER(S): NOTICE ISSUED TO: DESCRIPTION OF DEFICIENCY IN WORKMANSHIP AND/OR MATERIAL CORRECTIVE ACTION ACCOMPLISHED SIGNATURES CQAP TECHNICAN: DATE ISSUED: CONTRACTOR: DATE ISSUED: REVO April 20 2001 Construction Quality Assurance Plan -BCD Detoxification Warren County PCB Landfill SUBMITTAL REGISTER FORM -_, -I No. Submittal Date Projected Due Date Section Item Submitted Use Date Status Comments/Date/Initial 1 Date: Approved: Resubmit: 2 Date: Approved: Resubmit: 3 Date: Approved: Resubmit: 4 Date: Approved: Resubmit: 5 Date: Approved: Resubmit: 6 Date: Approved: Resubmit: 7 Date: Approved: Resubmit: 8 Date: Approved: Resubmit: REVO April 20 2001