Quality Management Plan

Transcription

1 September 8, 2015 NYNJ LINK DEVELOPER LLC Revision 0 Developer s Maintenance and Control Facility Elizabeth, NJ Parsons Project No.: &

2 This page intentionally left blank.

3

4 This page intentionally left blank. Parsons ii

5 REVISION LOG Rev. No. Date Change Description Pages Affected 0 09/08/2015 Original Issue All Parsons iii

6 This page intentionally left blank. Parsons iv

7 CONTENTS PROJECT DESCRIPTION QUALITY MANAGEMENT PLAN MANAGEMENT RESPONSIBILITY Quality Policy Integration of Quality Responsibilities Management Review QUALITY SYSTEM DESIGN CONTROL Construction Certification Shop Drawings PREVENTATIVE ACTIONS AND CONTROL OF NON-CONFORMING ITEMS Preventative Action Non-Conforming Reporting TESTING, SAMPLING AND CONTROL OF MATERIALS Inspection and Tests for Acceptance Control of Measuring and Test Equipment DOCUMENT CONTROL INSPECTION AND TEST PLANS INTERNAL AUDIT CERTIFICATION AND TRAINING... 8 FIGURE Figure 1-1: Organization Chart... 3 Parsons v

8 This page intentionally left blank. Parsons vi

9 ACRONYMS ACI AHJ ASCE ASNT AWS BCCNY CA CAP CEI CFR CQCP CQCP CQMP DIR DMCF EOR FP HVAC ICC IFC ITL ITP MURK NACE NCR NETTCP NICET NJSAT NYSDOT OSHA OSS PCI PE&I PM PQCM PQCP PTG American Concrete Institute Authority Having Jurisdiction American Society of Civil Engineers American Society for Nondestructive Testing American Welding Society Building Code for the City of New York Corrective Action Procedure Corrective Action Plan Construction Engineering and Inspection Code of Federal Regulations Construction Quality Control Procedures Contractor s Quality Control Plan Construction Daily Inspection Report Developer s Maintenance and Control Facility Engineer-of-Record fire protection heating, ventilation, and air-conditioning International Code Council issued for construction Inspection and Testing Laboratory Inspection and Test Plan Manual of Uniform Record Keeping NACE International (National Association of Corrosion Engineers) Nonconformance Report New England Transportation Technician Certification Program National Institute for Certificate in Engineering Technologies New Jersey Society of Asphalt Technologists New York State Department of Transportation Occupational Safety and Health Administration Operations Shared Services Pre-stressed Concrete Institute Parsons Environment and Infrastructure Project Manager Project Quality Control Manager Project Quality Control Plan Parsons Transportation Group Parsons vii

10 QA QAM QAP QC QMP ROW SQCP UG VRTIP Quality Assurance Quality Assurance Manager Quality Assurance Plan Quality Control RFI Request for Information right-of-way Subcontractor Quality Control Plan underground Verification, Review, Testing, and Inspection Plan Parsons viii

11 PROJECT DESCRIPTION The Developer s Maintenance and Control Facility (DMCF) project entails the construction of an approximately 6,000-square-foot building facility adjacent to the Replacement Goethals Bridge Project, which is currently under construction. The building will include office areas, basic equipment maintenance shops, storage areas, and outdoor parking areas. The construction start is scheduled for September 2015, with completion in August Construction activities are divided in the following work packages: H-Pile foundations Site work, concrete, and underground (UG) utilities Structural steel, framing, and miscellaneous steel Building envelope/exterior Mechanical/heating, ventilation, and air-conditioning (HVAC)/fire protection (FP)/plumbing Electrical 1 QUALITY MANAGEMENT PLAN The, (QMP), presents the Developer s approach to quality during construction of the DMCF. The QMP includes the Project Quality Control Plan, (PQCP), and the project Quality Assurance Plan, (QAP). This QMP has been developed for NYNJ Link Developer LLC (Developer) in order to: Satisfy the intent of the Construction Engineering and Inspection (CEI) requirements by utilizing a robust Quality Assurance (QA) oversight program. This in effect is accomplished by providing multiple levels of independent verification of work and certifying construction records and work is completed according to plan and spec as identified in the bullets listed below; Verification of inspection and testing reports of completed work is certified by the Subcontractor Quality Control Manager and the Subcontractors Independent Testing Laboratory (ITL) Verification of inspection and testing reports of completed work is certified by the Developers Independent Testing Laboratory (ITL) Verification of inspection and testing reports of completed work is certified by the PEI Project Quality Control Manager (PQCM) This information will be provided to the EOR and forms the basis for his review, acceptance, and certification of the works. Parsons 1

12 The Quality Assurance Manager (QAM) reviews, audits and confirms that the verification and certification process as described above is properly implemented. Implement a well designed quality program appropriate to the size and complexity of the DMCF with provision for continual improvement of all process as the project advances. Partner with the Authority to ensure construction and management process are open to inspection and oversight. Demonstrate our continued commitment to quality and to effectively communicate the QMP to the construction team to ensure its implementation throughout construction of the project. Empower quality personnel through support from upper management and the clear definition and communication of quality roles. Bring subcontractors and suppliers to the team who are committed to the construction of a superior end product which meets project quality requirements. Define the approach, policies and procedures to the management, oversight, reporting, auditing and monitoring of its activities sufficient to confirm its quality, continual improvement objectives and processes. The NYNJ Link Developer, LLC is the Developer. The lead designer is Parsons Environmental & Infrastructure (PEI) and the Project Manager is Parsons Environmental and Infrastructure, (PE&I). Project Quality Assurance is provided by Parsons Operations Shared Services (OSS). The Organization Chart provides the lines of responsibility and interrelationship of the responsibilities of the project executive, project management and project quality functions. Figure 1-1 shows the project organization chart. Parsons 2

13 Figure 1-1: Organization Chart Parsons 3

14 2 MANAGEMENT RESPONSIBILITY 2.1 Quality Policy The Developer s quality policy is to meet or exceed the requirements for quality management as defined in the QMP program that is compliant to the requirements in the RPW. It is incumbent on all Developer employees and subcontractors to understand the responsibility for the provision, pursuit and management of quality across all aspects of the project. The QMP is founded on three principles: Meet or exceed the Authority s expectations. Perform work right the first time. Strive for continuous improvement. 2.2 Integration of Quality Responsibilities The Developer organizational structure for the DMCF matches the size and complexity of construction project. The QMP tiered responsibilities are defined as follows: Quality Control is provide on two levels: o Level 1: Subcontractors are responsible for the quality of their works, including that of their Independent Inspection and Testing Laboratory (ITL). o Level 2: The Project Quality Control Manager, (PQCM) will develop, manage and maintain a quality control program. The Inspection and Testing requirements for this QC program will be provided by an Independent Inspection and Testing Laboratory (ITL), retained by the Developer. For the purpose of construction certification, the Engineer of Record (EOR) shall review and accept QC inspection and testing reports. Quality Assurance is provided by an independent Quality Assurance Manager, (QAM), provided by Parsons Operation Shared Services (OSS). Details of the QA and QC sampling, testing and inspection management controls are included in the Project Quality Control Plan, (PQCP) and Quality Assurance Plan, (QAP), respectively. 2.3 Management Review The PQCM and QAM are responsible for conducting surveillances and performing audits of their respective scope; surveillances and audits are conducted to ensure there is compliance to the PQP s and to identify any areas in need of improvement which would be the responsibility of the subcontractors and or suppliers. 3 QUALITY SYSTEM The QMP provides the framework and detail for quality implementation during the construction phase. The QMP focuses on appropriate staffing, training, coordinated inspections, reporting, documentation procedures and all project staff involvement. Parsons 4

15 The subcontractor quality control plans (SQCP) and the PQCP will outline quality procedures for construction operations. The project QAP outlines the review, audit and confirmation processes that will be utilized to validate the project QC and subcontractor QC testing and reports developed to demonstrate compliance to project requirements and project documents. Quality records provide objective evidence that the completed works meets project requirements. The process for identification, storage, protection, retrieval and disposition of quality records is defined in the document control plan. 4 DESIGN CONTROL Certifications made by the subcontractor quality control manager and project quality control manager to the EOR will be the basis for certification of partial and final completion. 4.1 Construction Certification Using the QMP, the Developer will coordinate the quality program with the PEI project manager, the independent inspection and testing laboratory (ITL), the subcontractor(s) quality control manager, and the EOR, so that written certification for partial and final construction are provided to the Authority. The subcontractor(s) will be responsible for implementing their own approved quality control program, (SCQP), which will include inspection and testing service from their own subcontracted ITL, and providing written certification that for their scope of work that the actual workmanship and material conform to project requirements. The ITL retained by the Developer will inspect and test the works in accordance with the PQCP and will be responsible for providing written certification that the workmanship and materials inspected and tested conform to the project requirements and are properly documented. In the unlikely event of a dispute between Subcontractors ITL test results and the Developer s ITL results, the Developer s ITL results will take precedence over the Subcontractors ITL results. The PEI PQCM will be responsible for implementing the PQCP plan and coordinating the efforts of the Developer s retained ITL when inspecting and testing materials. In addition, the PQCM will oversee the efforts of the SCQP. The PEI PQCM will be responsible for providing written certification of the completed works based on the observations and results from the PQCP reports, test data and certification from the Developer s ITL and SQCP quality reports. The EOR will review the test data and reports and certifications prepared by the SCQP, ITP and PQCP. This data will form the basis for certification by the EOR that the actual workmanship and materials conform to the project documents as identified in Section 1. Parsons 5

16 4.2 Shop Drawings The PQCM will monitor the shop drawing submittals process and ensure all the construction plans and shop drawings have been approved by the appropriate design engineers. 5 PREVENTATIVE ACTIONS AND CONTROL OF NON-CONFORMING ITEMS 5.1 Preventative Action The Developer and project manager strive to eliminate the causes of potential nonconformities in order to prevent their occurrence. Preventative actions include; work planning, access to information obtained and lessons learned. The process and procedure for inspection, tracking and reporting non conformances are detailed in the PQCP, QAP and the respective SCQPs. Checklists and refined procedures are developed to assist in identifying and eliminating, potential future non conformances. 5.2 Non-Conforming Reporting Non compliant materials, equipment, design, construction or procedural non compliance will be reported immediately and documented by an NCR. Our project quality assurance manager, project quality control manager, and the EOR individually or collectively, will develop and document a corrective action plan, (CAP). Details for the issuance, tracking and closure of NCR CAPs are detailed in the PQCP and QAP. 6 TESTING, SAMPLING AND CONTROL OF MATERIALS 6.1 Inspection and Tests for Acceptance Material receiving inspections are completed by both the subcontractor and project quality control manager, or designee to confirm that only undamaged, approved materials are incorporated into the work. In addition to physical inspections, received materials are verified using certificates of compliance (C of C) and/or certified material test report (CMTR s). Procedures for the handling, storage, and control of materials and equipment, and for the control of product identification and traceability, have been developed and are detailed in the PQCP. 6.2 Control of Measuring and Test Equipment The PQCP outline procedures to protect the integrity of inspection and testing results. Where specified or required by the contract documents, calibrated measuring and test equipment is used to verify and validate the work. The project PQCP includes detailed procedures for the control and documentation of equipment calibrations and procedures for equipment recalibration, Parsons 6

17 storage and protection. In addition, procedures for evaluation of the validity of previously calibrated results are provided. 7 DOCUMENT CONTROL The PQCP outlines proper documentation procedures for the QA and QC functions. Proper documentation facilitates auditing of the PQCP by the QAM and creates a road map and an example for future projects. A controlled inspection checklist based on the project specifications and testing requirements, including hold and witness points, will be included in the contractor-subcontractor developed work plans submittal. The subcontractors work plan is reviewed and accepted by the PQCM and EOR The QAM will review, audit and confirm that work plan and controlled inspection checklist are developed, maintained and managed by the PCQM and approved by the EOR. 8 INSPECTION AND TEST PLANS Inspection and test plans, (ITP), are essential quality records and include the following; Type and location of work Materials to be inspected and or tested Test/inspection frequency and which individual performed the inspection/test In addition, the ITPs include references to pertinent standards, specifications, witness, hold points and provide a definitive record of the status of the work item at that point in time: Accepted, Rejected or Accepted with comments. Detailed procedures for the development, maintenance and management of ITPs are provided in the PQCP and QAP. 9 INTERNAL AUDIT Procedures for planning, implementing, and follow up on internal quality audits to confirm compliance to the quality system and to measure the effectiveness of the system have been developed. Internal audits of subcontractors and suppliers are used to verify compliance to approved quality control plans and project documents. Refer to the audit procedures detailed in the PQCP and QAP. Qualified personnel independent of those responsible for the work are used as auditors. An audit schedule is prepared and updated periodically by the QAM. Parsons 7

18 Audit and surveillance results are documented and provided to those audited the Developer and the Authority. Corrective action on non conforming results is to be taken in a timely manner and follow up audits are completed to confirm implementation of the corrective action and the effectiveness of corrective action. 10 CERTIFICATION AND TRAINING The Developer is responsible for implementing a continuous improvement program. The methods and procedures used by the project team ensure that personnel who perform quality activities have the appropriate experience, qualifications, and quality training. Quality program personnel are selected based on their ability to satisfy job requirements. Those individuals responsible for implementing and executing the PQMP are indoctrinated and trained in the QMS system and associated quality procedures. Personnel qualifications are periodically evaluated to ensure that they are maintained current for their project work assignments. The qualifications of the personnel implementing the PQCM and QAM are documented and provided to the Developer/Authority. The Developer s QMP and the associated PQCP and QAP include programs for personnel project quality orientation, training, re-training. These programs help familiarize the personnel with the work and upgrade their qualifications whenever merited by job conditions. Training will include formal and informal sessions to ensure the understanding of and compliance with the PQCP and contract document requirements. Additional training is provided, as required, to cover newly assigned personnel and changes to procedures and to review lessons learned. Records are kept of the required training and certifications, including those from outside agencies. Personnel responsible for document control are trained in its use. Subconsultant and subcontractor contracts are required to address the elements of the PQCP which include the requirements for certification and training. Parsons 8