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USACE‐NAVFAC Sample QA/QC Plan  
       20 selected pages (out of ϭϮϱ) 

     Part 1:  Project‐Specific Quality Plan 
     Part 2:  Quality Manual 
     Part 3:  Submittal Forms      
 
 
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      410‐451‐8006 
                                                  
 

 
 
 
 
 

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PROJECT-SPECIFIC QUALITY PLAN

TABLE OF CONTENTS
The Project Quality Control Plan contents correspond with USACE / NAVFAC / AFCESA / NASA UFGS-01 45
00.00 20 (November 2011) Construction Quality Control (QC) Plan requirements.

Background Information .......................................................................................................................... 6

Project Name .............................................................................................................................................. 6

Project Number .......................................................................................................................................... 6
Project Location .......................................................................................................................................... 6
Project Description ..................................................................................................................................... 6
Project Scope .............................................................................................................................................. 6

A. QC Organization................................................................................................................................... 7

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B. Names and Qualifications .................................................................................................................... 8
C. Duties, Responsibilities, and Authority of QC Personnel .................................................................... 10

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Quality Responsibilities ............................................................................................................................ 10
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D. Outside Organizations ....................................................................................................................... 13

Qualification of Subcontractors and Suppliers ......................................................................................... 13

Purchase Order Approval ......................................................................................................................... 13
Qualification of Testing Laboratories ....................................................................................................... 14
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E. Appointment Letters .......................................................................................................................... 16

F. Submittals Procedures and Submittal Register ................................................................................... 20
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G. Testing Laboratory Information ......................................................................................................... 21

Qualification of Testing Laboratories ....................................................................................................... 21

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H. Quality Testing Plan and Log .............................................................................................................. 23

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Preparation of Inspection and Test Plan .................................................................................................. 23

I. Procedures Completion of Rework Items ............................................................................................ 25

Nonconformance Controls ....................................................................................................................... 25

Nonconformance Corrective Actions ....................................................................................................... 26
Nonconformance Preventive Actions ....................................................................................................... 26

J. Documentation Procedures ................................................................................................................ 29

K. List of Definable Features................................................................................................................... 31
L. Procedures for Performing the Three Phases of Control ..................................................................... 33

Phase 1: Preparatory Phase ...................................................................................................................... 33

Phase 2: Initial Phase ................................................................................................................................ 34
Phase 3: Follow-up Phase ......................................................................................................................... 35

M. Personnel Matrix .............................................................................................................................. 42

N. Procedures for Completion Inspection............................................................................................... 43
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Punch-Out QC Inspection ......................................................................................................................... 43

Pre-Final Customer Inspection ................................................................................................................. 43
Final Acceptance Customer Inspection .................................................................................................... 43

O. Training Procedures and Training Log ................................................................................................ 47

Project Quality Training ............................................................................................................................ 47

P. Organization and Personnel Certifications ......................................................................................... 50

Company Qualifications............................................................................................................................ 50
Personnel Certifications ........................................................................................................................... 50

Q. Design Controls ................................................................................................................................. 53

Design Reviews ......................................................................................................................................... 53

Design Review Plan ................................................................................................................................... 54

R. Additional Quality Control Requirements .......................................................................................... 57

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I. PROCEDURES COMPLETION OF REWORK ITEMS

Should a nonconformance be identified by an inspection, a systematic method will be used to control the
item, correct it, and ensure that project quality is not adversely impacted by the event.

Nonconformances and their resolution are recorded on a Nonconformance Report form. A

Nonconformance Report form exhibit is included in this subsection.

NONCONFORMANCE CONTROLS
Should a nonconformance be identified by an inspection there is a systematic method to control the item,
correct it, and ensure that project quality is not adversely impacted by the event.

A nonconformance is any item that does not meet project specifications or [CompanyName] Quality
System requirements.

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MARKING OF NONCONFORMANCES AND OBSERVATIONS
When the QC Manager, Superintendent, inspector, or customer identifies a nonconformance or an

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observation, the item is quickly and clearly marked by paint, tape, tag, or other easily observable signal to
prevent inadvertent cover-up.

CONTROL THE CONTINUATION OF WORK

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After the item is marked, the Superintendent determines if work can continue in the affected area:

CONTINUE WORK: When continuing work does not adversely affect quality or hide the defect, work may
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continue in the affected area while the disposition of the item is resolved. The Superintendent may place
limitations on the continuation of work.
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STOP WORK ORDER: When continuing work can adversely affect quality or hide the defect, work must
stop in the affected area until the disposition of the item resolved. The Superintendent identifies the
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limits of the affected area. The Superintendent quickly and clearly marks the stop work area.

RECORDING OF NONCONFORMANCES
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If nonconformances or observed items exist by the feature of work completion inspection, the
Superintendent or inspector records the nonconformances on a nonconformance report.

The Superintendent sends the nonconformance report to the QC Manager.

QC MANAGER DISPOSITION OF NONCONFORMANCE REPORTS

When the QC Manager receives a Nonconformance Report, he or she makes an assessment of the affect
the reported nonconformance has on form, fit, and function. The QC Manager may assign a disposition of
either:

REPLACE: The nonconformance can be brought into conformance with the original specification
requirements by replacing the nonconforming product or material with a conforming product or material.

REPAIR: The nonconformance can be brought into conformance with the original requirements through
re-machining, reassembly, reprocessing, reinstallation, or completion of the required operations.

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L. PROCEDURES FOR PERFORMING THE THREE

PHASES OF CONTROL
Three phases of control and a feature of work completion inspection will be performed for each defined
feature of work.

The controls and the forms that will be used to record control activities are included on table L-1.

Table L-1

Control Form

Phase 1: Preparatory Phase Preparatory Phase Checklist

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Phase 2: Initial Phase Initial Phase Checklist

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Phase 3: Follow-up Phase Contractor Quality Control Report

Feature of Work Completion Inspection

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Three Phases of Control and FOW Completion Inspection forms exhibits are included as an exhibit in this
subsection.
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PHASE 1: PREPARATORY PHASE

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Phase 1 is the Preparatory Phase that plans quality for an upcoming feature of work. It includes a
requirements review, site inspection, and a preparatory meeting. Records of the preparatory phase of
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control are recorded on the Preparatory Phase Checklist included as exhibits in this subsection.

Procedures that will be used on this project to conduct the Phase I preparatory phase of control are as
follows.

PREPARATORY FEATURE OF WORK QUALITY CONTROL PLANNING

In preparation for the start of an upcoming feature of work, the Superintendent reviews an integrated
and coordinated set of documents that collectively define quality requirements for the feature of work
including:

 Objectives and acceptance criteria of the feature of work

 Quality standards that apply to the feature of work
 Work instructions, process steps, and product installation instructions that apply to the feature
of work
 Shop drawings
 Submittals
 Tools and equipment necessary to perform the work
 License, certification, or other qualification requirements of personnel assigned to work

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[CompanyName]
Nonconformance Report
Version April 7, 2012

Nonconformance Report
Control ID Project ID Project Name
[ProjectNumber] [ProjectName]
Preparer Signature/ Submit Date QC Manager Signature / Disposition Date

Description of the requirement or

specification

Description of the nonconformance,

location, affected area, and marking

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Replace Repair Rework Use As-is

Disposition

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Approval of disposition required by customer representative? Yes No
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Customer approval signature /date: ___________________________________
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Corrective Actions
Corrective actions completed Name/Date:_________________________
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Customer acceptance of corrective actions required? Yes No

Name/Date:_________________________
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Preventive Actions

Preventive actions completed Name/Date:_________________________

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SPEC SECTION DATE

INITIAL PHASE CHECKLIST

CONTRACT NO DEFINABLE FEATURE OF WORK SCHEDULE ACT NO. INDEX #

GOVERNMENT REP NOTIFIED _____ HOURS IN ADVANCE: YES NO

NAME POSITION COMPANY/GOVERNMENT
PERSONNEL
PRESENT
COMPLIAN

IDENTIFIY FULL COMPLIANCE WITH PROCEDURES IDENTIFIED AT PREPARATORY. COORDINATE PLANS, SPECIFICATIONS, AND SUBMITTALS.
PROCEDU
RE

CE

COMMENTS:

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ENSURE PRELIMINARY WORK IS COMPLETE AND CORRECT. IF NOT, WHAT ACTION IS TAKEN?
PRELIMI

WORK
NARY

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ESTABLISH LEVEL OF WORKMANSHIP.

WHERE IS WORK LOCATED?

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WORKMANSHIP

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IS SAMPLE PANEL REQUIRED? YES NO

WILL THE INIITAL WORK BE CONSIDERED AS A SAMPLE? YES NO

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(IF YES, MAINTAIN IN PRESENT CONDITION AS LONG AS POSSIBLE AND DESCRIBE LOCATION OF
SAMPLE)
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RESOLVE ANY DIFFERENCES.

RESOLUTI

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COMMENTS:
ON

REVIEW JOB CONDITIONS USING EM 385-1-1 AND JOB HAZARD ANALYSIS

SAFETY
CHECK

COMMENTS:

OTHER ITEMS OR REMARKS

OTHER

QC MANAGER DATE

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Q. DESIGN CONTROLS
Design controls are in place to assure the quality of designs for this project.

A design plan is used to document the design control process. The Design Plan is included as an exhibit in
this subsection.

The first control point will be of the review of design inputs. The Design Manager will assure that all
necessary information is available to perform the required design work. The Design Manager will also
assure that expectations for design outputs are well defined.

Intermediate reviews will be carried out as indicated on the design control plan. The last review is the
design output review.

A record of all reviews will be recorded on the Design Review form. A Design Review form exhibit is
included in this subsection.

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The Owner has appointed [DesignManagerName] as the Design Manager. [DesignManagerName] will
control the design process with specific quality responsibilities, duties, and the authority to carry them
out.

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DESIGN REVIEWS Pa
DESIGN INPUT REQUIREMENTS REVIEW
The Quality Manager ensures that the information in design inputs clearly defines customer expectations
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and that the necessary details are provided to set requirements for design.

The Quality Manager obtains design specifications from the customer and conducts a customer design
input review to ensure that:
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• Customer design input requirements and specifications are complete

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• Design process review milestones are specified when necessary

• Customer design output requirements and specifications are complete for review milestones as
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well as the completed design

• Customer design requirements and specifications are compatible with the relevant regulations,
[CompanyName] quality standards, and Quality System requirements
• [CompanyName] has the capability to deliver the completed design in the time allotted
The Quality Manager identifies supplemental design specifications that supplement customer
specifications when they are needed to ensure a quality design.

Before design work begins, the Quality Manager makes sure that all design requirements are clearly
understood, all discrepancies are resolved, and all requirements are agreed upon. Once these
requirements are met, the Quality Manager approves the design input.

The Quality Manager ensures that design input documents are verified by qualified personnel. The
person responsible must verify:

• Design input specification are approved by a customer authority

• Design input specifications are complete
• Design input requirements and specifications are compatible with the relevant regulations,
[CompanyName] quality standards, and Quality System requirements
 Questions? Call First Time Quality 410-451-8006

[CompanyName]
Project Design Review Plan
Version 20131016

Project ID Project Name Preparer Date

[ProjectNumber] [ProjectName]

Design Appointments

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Design Manager

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Designer(s)

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Design QC Reviewer

Design Review Milestones

Output required for

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Ref# Work Task review Scheduled date/milestone Review participants
Design Input Review

Work in Process
Review:
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Work in Process
Review:
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Final Design Review:

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QUALITY MANUAL
TABLE OF CONTENTS

1. Quality System Management and Responsibilities ............................................................................. 11

1.1. Overview ............................................................................................................................................ 11

1.2. [CompanyName] Quality Policy ......................................................................................................... 11
1.3. Quality Duties, Responsibilities, and Authority ................................................................................. 11
1.4. Quality System Performance Measures ............................................................................................ 14
1.5. Customer Satisfaction Performance Measures ................................................................................. 14
1.6. Exceptions.......................................................................................................................................... 14

2. Project Quality Assurance/Quality Control Plan ................................................................................. 15

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2.1. Overview ............................................................................................................................................ 15
2.2. [CompanyName] Project License and Qualification Requirements .................................................. 15

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2.3. Project Personnel and Qualifications ................................................................................................ 16
2.4. Project Quality Assurance/Quality Control Plan ................................................................................ 17
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2.5. Identification of Quality Controlled Features of Work ...................................................................... 17
2.6. Project Quality Inspection and Test Plan ........................................................................................... 17
2.7. Project Quality Communications Plan ............................................................................................... 17
2.8. Project Quality Training Plan ............................................................................................................. 17
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2.9. Customer Training On Operation And Maintenance ......................................................................... 18

2.10. Project Records and Documentation Plan ....................................................................................... 18
2.11. Project Audit Plan ............................................................................................................................ 18
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3. Contract Specifications ....................................................................................................................... 19

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3.1. Overview ............................................................................................................................................ 19

3.2. Contract Technical Specifications ...................................................................................................... 19
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3.3. Contract Drawings ............................................................................................................................. 19

3.4. Contract Submittals ........................................................................................................................... 19
3.5. Customer Submittal Approval ........................................................................................................... 21
3.6. Contract Warranty ............................................................................................................................. 21
3.7. Contract Review and Approval .......................................................................................................... 22
4. Design Control.................................................................................................................................... 23

4.1. Overview ............................................................................................................................................ 23

4.2. Design Input Review .......................................................................................................................... 23
4.3. Project Design Quality Assurance/Quality Control Plan .................................................................... 23
4.4. Design Progress Reviews ................................................................................................................... 24
4.5. Design Output Verification and Approval .......................................................................................... 24

5. Project-Specific Quality Standards ..................................................................................................... 25

5.1. Overview ............................................................................................................................................ 25

5.2. Regulatory Codes ............................................................................................................................... 25

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5.3. Industry Quality Standards ................................................................................................................ 25

5.4. Material and Equipment Specifications ............................................................................................. 25
5.5. Work Process Specifications .............................................................................................................. 26
5.6. Controlled Material Identification and Traceability .......................................................................... 26
5.7. Measuring Device Control and Calibration ........................................................................................ 27
5.8. [CompanyName] Quality Standards .................................................................................................. 27
5.9. Application of Multiple Sources of Specifications ............................................................................. 27

6. Project Purchasing ............................................................................................................................. 28

6.1. Overview ............................................................................................................................................ 28

6.2. Qualification of Suppliers, Subcontractors, and Departments .......................................................... 28
6.3. Quality Responsibilities of Key Subcontractor Personnel .................................................................. 29
6.4. Requirements for Subcontractor QC Plan ......................................................................................... 30
6.5. Subcontractor Quality Policy ............................................................................................................. 30
6.6. Project Subcontractor and Supplier List ............................................................................................ 31

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6.7. Purchase Order Requirements .......................................................................................................... 31
6.8. Project Purchase Order Approvals..................................................................................................... 31

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7. Process Controls ................................................................................................................................. 33

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7.1. Overview ............................................................................................................................................ 33
7.2. Project Startup and Quality Control Coordination Meeting .............................................................. 33
7.3. Preparatory Project Quality Assurance/Quality Control Plan Planning ............................................. 33
7.4. Weekly Quality Planning and Coordination Meetings ....................................................................... 34
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7.5. Process Control Standards ................................................................................................................. 34

7.6. Daily Quality Control Report .............................................................................................................. 36
7.7. Monthly Quality Control Report ........................................................................................................ 36
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8. Inspections and Tests ......................................................................................................................... 37

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8.1. Overview ............................................................................................................................................ 37

8.2. Required Feature of Work Quality Inspections and Tests ................................................................. 37
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8.3. Additional Inspection Requirements for Process Tasks ..................................................................... 38

8.4. Inspection of Special Processes ......................................................................................................... 39
8.5. Independent Measurement and Tests .............................................................................................. 39
8.6. Commissioning Functional Acceptance Tests .................................................................................... 39
8.7. Hold Points for Customer Inspection ................................................................................................. 39
8.8. Quality Inspection and Test Specifications ........................................................................................ 39
8.9. Inspection And Test Acceptance Criteria ........................................................................................... 39
8.10. Inspection and Test Status............................................................................................................... 40
8.11. Independent Quality Assurance Inspections ................................................................................... 40
8.12. Inspection and Test Records ............................................................................................................ 40
8.13. Project Completion and Closeout Inspection .................................................................................. 41

9. Nonconformances and Corrective Actions ......................................................................................... 43

9.1. Overview ............................................................................................................................................ 43

9.2. Nonconformances ............................................................................................................................. 43
9.3. Corrective Actions ............................................................................................................................. 44

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10. Preventive Actions ........................................................................................................................... 45

10.1. Overview .......................................................................................................................................... 45

10.2. Identify Preventive Actions for Improvement ................................................................................. 45
10.3. Train Preventive Actions for Improvement ..................................................................................... 45

11. Quality System Audits ...................................................................................................................... 47

11.1. Overview .......................................................................................................................................... 47

11.2. Project Quality System Audit ........................................................................................................... 47
11.3. Company-wide Quality System Audit .............................................................................................. 47

12. Record and Document Controls ........................................................................................................ 48

12.1. Overview .......................................................................................................................................... 48

12.2. Quality System Documents ............................................................................................................. 48
12.3. Document Controls .......................................................................................................................... 48
12.4. Record Controls ............................................................................................................................... 49

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13. Appendix .......................................................................................................................................... 51

13.1. Definitions of Terms ........................................................................................................................ 51

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Please keep in mind that quality materials provided by [CompanyName] are copyright registered. Please
do not share them with other organizations, even if you do not charge a fee.
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CROSS REFERENCES
The [CompanyName] Quality System complies with US Army Corps of Engineers Quality Control
Requirements “USACE/NAVFAC/AFCESA/NASA Quality Control Requirements UFGS-01 45 00.00 20
(November 2011)”.

USACE Requirements Section Quality Manual Section

1.5 QC Organization 2.3.1 Project Organization Chart

1.6 Quality Control Plan 2 Project Quality Assurance/Quality Control Plan

1.7 QC Plan Meetings 2 Project Quality Assurance/Quality Control Plan

1.8 Coordination and Mutual Understanding Meeting 7.2 Project Startup and Quality Control Coordination Meeting

1.9 QC Meetings 7.4 Weekly Quality Planning and Coordination Meetings

1.10 Design Review and Documentation 3.7 Contract Review and Approval

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4.2 Design Input Review
1.11 Three Phases of Control 7.3 Preparatory Project Quality Assurance/Quality Control Plan
8.2.2.2Initial Work in process Inspection
8.2.2.3Follow-up Work in Process Inspections

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1.12 Submittal Review and Approval 3.4

1.13 Testing
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6.2.1.1.1 Independent Laboratory Credential Requirements
8.12 Inspection and Test Records
1.14 QC Certifications Daily Quality Control Report7.6 Daily Quality Control Report
8.13 Project Completion and Closeout Inspection
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1.15 Completion Inspections 8.13 Project Completion and Closeout Inspection

1.16 Training 2.9 Customer Training On Operation And Maintenance

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1.17 Documentation 12 Record and Document Controls

1.18 Notification of Noncompliance 9 Nonconformances and Corrective Actions

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7. PROCESS CONTROLS
HOW WORK IS CARRIED OUT

7.1. OVERVIEW
The construction process plan defines how project work is to be done and approved for the overall
project. The construction process plan is communicated to all key personnel, subcontractors and suppliers
in a startup meeting. As the project proceeds, feature of work plans provide additional details of how
each individual feature of work is carried out. Features of work planning meetings are used to
communicate expectations of the feature of work plan to key personnel responsible for carrying out the
feature of work.

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7.2. PROJECT STARTUP AND QUALITY CONTROL COORDINATION MEETING
Prior to the commencement of work, the Project Manager holds a meeting to discuss and coordinate how
project work will be performed and controlled. Key personnel from [CompanyName], subcontractors, and

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suppliers meet to review expectations for project quality results as well as quality assurance and quality
control policies and procedures including:

 Key requirements of the project

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 The Project Quality Assurance/Quality Control Plan
 Required quality inspections and tests
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 The project submittal schedule

 Quality policies and heightened awareness of critical quality requirements
 Project organization chart and job responsibilities
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 Methods of communication and contact information

 Location of project documents and records
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7.3. PREPARATORY PROJECT QUALITY ASSURANCE/QUALITY CONTROL PLAN PLANNING

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7.3.1. FEATURE OF WORK REQUIREMENTS REVIEW

In preparation for the start of an upcoming feature of work, the Superintendent reviews an integrated
and coordinated set of documents that collectively define quality requirements for the feature of work
including:

 Objectives and acceptance criteria of the feature of work

 Quality standards that apply to the feature of work
 Work instructions, process steps, and product installation instructions that apply to the feature
of work
 Shop drawings
 Submittals
 Tools and equipment necessary to perform the work
 License, certification, or other qualification requirements of personnel assigned to work
 Required records of the process and resulting product
 The subcontractor contracted to perform the work, if applicable
 Customer contract requirements
 Required quality inspections and tests

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 Method for clearly marking nonconformances to prevent inadvertent use

 Location of quality system records and documents
 Personnel training

7.3.2. PREPARATORY SITE INSPECTION

The Superintendent also performs a quality inspection of the work area and:

 Assesses completion of required prior work

 Verifies field measurements
 Assures availability and receiving quality inspection status of required materials
 Identifies any nonconformances to the requirements for the feature of work to begin
 Identifies potential problems

7.3.3. FEATURE OF WORK PREPARATORY QUALITY PLANNING MEETINGS

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List of Included Forms

Standard Forms:

 Point Of Contact List

 Project Organization Chart
 Project Quality Communications Plan
 Quality Manager Appointment Letter
 Project Manager Appointment Letter
 Superintendent Appointment Letter
 Personnel Certifications and Licenses
 Project Personnel Resumes
 Project Subcontractor and Supplier List
 Training Plan
 Training Log
 Regulatory Codes and Industry Standards
 Project Regulatory Building Codes
 Controlled Materials Form
 Metals Material Receiving Inspection Report
 Material Inspection and Receiving Report
 Inspection and Testing Standards
 Quality Inspection and Test Plan
 Test Equipment Calibration Plan and Log
 Quality Controlled Work Task List
 Daily Production Report
 Work Task Inspection Form
 Nonconformance Report
 Punch List
 Project Completion Inspection Form
 System Document Control Form
 Project Records Control Form
 Project Quality System Audit Form
 Questions? Call First Time Quality 410-451-8006

[CompanyName]
Laboratory Qualification Form
Version April 7, 2012
Company Name: Scope of Work (specification sections):

Project ID Project Name Approval Approved By

Yes
Conditional
[ProjectNumber] [ProjectName] No
Review Topics Project-Related Job Credentials

Licenses required: License and expiration dates:

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Certification required: Certifications and expiration dates:
NRTL: A nationally recognized testing laboratory
according to 29 CFR 1910.7.

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NVLAP: A testing agency accredited according to
NIST's National Voluntary Laboratory Accreditation
Program. Pa
The American Association of State Highway and
Transportation Officials (AASHTO)
International Accreditation Services, Inc. (IAS)
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U. S. Army Corps of Engineers Materials Testing

Center (MTC)
American Association for Laboratory Accreditation
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(A2LA) program
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Training required: Training completed and expiration date:

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Type and length of experience required: Certifications and expiration dates:

Personnel license, certification, and training required: List each person’s credentials on the Subcontractor and
Supplier Certifications and Licenses form.

Qualifications

Senior person designated as QC Manager Production capacity

Demonstrated skills and knowledge Staffing availability
Demonstrated experience

QUALIFICATION NOTES:

Provisional Approval: Action plan for improvement

Follow-up results and date

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[CompanyName]
Material Inspection and Receiving Report
Version April 7, 2012
Contract ID Contract Name Purchase Order No. Supplier Bill of Lading No. Date

[ProjectNumber] [ProjectName]
Stock/Part Quantity Conditional

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Item No. No. Description Received Condition Marking Accept Use Reject

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Receiving Quality Control
ACCEPTANCE ct
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Listed items have been accepted by me or under my supervision

Conform to contract specifications EXCEPT as noted herein or on supporting documents.

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Received in apparent good condition EXCEPT as noted

Signature of authorized person and date: _________________________________________________________________

EXCEPTIONS:

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 For More Information:
Contact: FirstTimeQuality

410-451-8006

www.FirstTimeQuality.com

[email protected]

For More Information, contact: CaldeiraQuality, LLC • First TimeQuality℠.

410‐451‐8006 • www.firsttimequality.com • [email protected]