Essentials Fabrication

Quality Plan Sample

Selected pages not a complete plan

Includes Standards and Forms for Structural Steel
Fabrication

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Fabrication
Quality Assurance/Quality Control Plan
[ProjectName]
[ProjectNumber]

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Version: 20150308

Effective Date: 20150308

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20150308

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Version

Version notes

Initial issue

Approved

_____________________________________________________
[QualityManagerName], Quality Manager

Documents provided by [CompanyName] disclose proprietary information as well as copyright information

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not share them with other organizations, even if you do not charge a fee. Submittal of documents does not
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PROJECT-SPECIFIC WELDING QUALITY PLAN

TABLE OF CONTENTS
A. [CompanyName] Quality Policy ........................................................................................................... 3
B. Key Elements of the Weld Quality Plan ................................................................................................ 4
C. Project Quality Coordination and Communication ............................................................................... 7
D. Project QC Personnel ......................................................................................................................... 11
Project QC Job Position Assignments ....................................................................................................... 11
Duties, Responsibilities, and Authority of QC Personnel .......................................................................... 11
Quality Responsibilities ............................................................................................................................ 11
Project QC Organization Chart ................................................................................................................. 14

E. Personnel Qualifications and Technical Certifications ........................................................................ 15

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Personnel Certification and Qualification Requirements ......................................................................... 16

Training ..................................................................................................................................................... 17
F. Qualification of Third Party Inspection/Testing Companies and Subcontractors and Suppliers .......... 19
Qualification of Testing Laboratories ....................................................................................................... 19
G. Weld Project Quality Specifications ................................................................................................... 21

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Compliance with Industry Welding Standards ......................................................................................... 21

Project - Specific Welding Procedure Standards ...................................................................................... 22
H. Material Traceability ......................................................................................................................... 28

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Identification of Lot Controlled Materials ................................................................................................ 28

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I. Weld Inspection and Test Plan ............................................................................................................ 31

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Welding Inspection and Testing Standards .............................................................................................. 32

Control of Inspection, Measuring, and Test Equipment ........................................................................... 33
J. Welding Work Task Quality Inspections .............................................................................................. 36
Work Tasks Series of Inspections ............................................................................................................. 36
Daily Quality Control Report..................................................................................................................... 36
K. Quality Control of Corrections, Repairs, and Nonconformances ........................................................ 48
L. Project Completion Inspections .......................................................................................................... 50
M. Quality Assurance Surveillance ......................................................................................................... 52
N. Control of Quality Records and Documents ....................................................................................... 54
O. Servicing and Warranty ..................................................................................................................... 55

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G. WELD PROJECT QUALITY SPECIFICATIONS

Fulfilling customer contract expectations is a primary objective of the [CompanyName] Quality System. To
ensure that customer expectations will be fulfilled, [CompanyName] clearly defines the requirements for
each contract before it is approved.
The Project Manager ensures that the information in customer contracts clearly defines customer
expectations and that the necessary details are provided to set requirements for fabrication.
[CompanyName] personnel and subcontractors and suppliers are accountable for compliance to
standards-based written specifications.
To achieve expectations reliably and consistently, specifications are clearly spelled out, not only for results
but also for processes. Specifications apply to materials, work steps, qualified personnel and
subcontractors and suppliers, safe work rules, and environmental work conditions.

Standards ensure that results are specified rather than left to discretionary practices.

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All [CompanyName] fabrication activities comply with generally accepted good workmanship practices
and industry standards.

COMPLIANCE WITH INDUSTRY WELDING STANDARDS

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Codes that may apply to this project include those listed below.

Regulatory Codes and Industry Standards

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Reference Standard
No.

Description

Minimum spacings and edge

distances for screws

AISI SG02-KIT

North American Specification for the Design of Cold-Formed Steel

Structural Members

Installation of bracing and

permanent bracing and bridging

CFSEI

Field Installation Guide for Cold-Formed Steel Roof Trusses

Installation of chimneys, vents, and

smokestacks

NFPA 211

Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning

Appliances

Framing and reinforcing openings

through a steel deck

SDI DDP

Deck Damage and Penetrations

Install high-strength bolts

Welding standards

AWS B2.1/B2.1M

Specification for Welding Procedure and Performance Qualification

Standard practices for structural

steel fabrication bound series of
standadards

AISC Code of Standard

Practice for Steel Buildings
and Bridges

AISC Code of Standard Practice for Steel Buildings and Bridges

Specification for steel fabrication for

structural steel buildings

AISC Specification for

Structural Steel Buildings

AISC Specification for Structural Steel Buildings

Structural steel joints

RCSC Specification for

Structural Joints Using
ASTM A325 or A490 Bolts

RCSC Specification for Structural Joints Using ASTM A325 or A490

Bolts

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Reference Standard Title

RCSC's "Specification for Structural Joints Using ASTM A 325 or A

490 Bolts"

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Standar design symbols

ANSI/AWS A2.4

Symbols

Standard terms

ANSI/AWS A3.0

Terms and Definitions

QA recommended practices

AWS Welding Quality

Assurance Guideline for
Fabricators (WQAG)

Welding Quality Assurance Guideline for Fabricators (WQAG)

Coating of steel

SSPC Steel Structures

Painting Manual, Volume I,
Good Painting Practice

Steel Structures Painting Manual, Volume I, Good Painting

Practice

Coating of steel

SSPC Steel Structures

Painting Manual, Volume II,
Systems and Specifications

Steel Structures Painting Manual, Volume II, Systems and

Specifications

Special provisions for seismic

applications

AISC Seismic Provisions for

Structural Steel Buildings

Seismic Provisions for Structural Steel Buildings

Detailing standards for the design of

structural steel details

AISC Detailing for Steel

Construction

Detailing for Steel Construction

Workmanship and techniques for

welded construction

AWS D1.1/D1.1M

Structural Welding Code Steel

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PROJECT - SPECIFIC WELDING PROCEDURE STANDARDS

The Quality Manager approves welding procedures before they can be used to fabricate metal.

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Welding procedures shall be qualified and approved, in accordance with the applicable AWS Welding
Code(s) or Specification(s) (i.e., D1.1., D1.5) or AWS B2.1, Specification for Welding Procedure and
Performance Qualification.
The welding procedure must identify the filler material.

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When the governing AWS Welding Code(s) mandates that welding procedures be qualified by test, the
Welding Fabricator shall have PQRs that support the applicable WPSs. When prequalified WPSs or
Standard Welding Procedure Specifications (SWPSs) published by the AWS are permitted, PQRs are not
required.
The Quality Manager or Certified Welding Inspector (CWI) reviews and approves the welding procedure
before being used in production welding operations.
The WPSs and PQRs are controlled by the Quality Manager according by the document and record control
procedures specified in the relevant section of this Quality Manual.
The applicable WPSs shall be available to welders or welding operators during testing and production
welding.

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Form N-1 Welding Procedure Specification Prequalification

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http://www.aws.org/technical/forms/N-1.pdf

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Form N-3 WPS QUALIFICATION TEST RECORD_ELECTROSLAG

and ELECTROGAS WELDING

http://www.aws.org/technical/forms/N-3.pdf

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Form N-4 WELDER, WELDING OPERATOR, OR TACK WELDER

QUALIFICATION TEST RECORD

http://www.aws.org/technical/forms/N-4.pdf

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Form N-9 STUD WELDING APPLICATION QUALIFICATION TEST

DATA

http://www.aws.org/technical/forms/N-9.pdf

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H. MATERIAL TRACEABILITY
Products and materials are controlled to assure the use of only correct and acceptable items. Controls
include identification of the inspection status. Materials that require lot control traceability and the
method of traceability are listed on the Controlled Materials form included as an exhibit in this
subsection.

IDENTIFICATION OF LOT CONTROLLED MATERIALS

The Quality Manager determines types of project materials that require quality controls.
For each type of quality controlled material, the Quality Manager determines lot control traceability
requirements, if any, and specifies the means of lot identification. Identification methods may include
physical labels, tags, markings and/or attached certification documents.

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When lot controlled materials are received, the Superintendent verifies that materials have the specified
lot identifications.
The Superintendent maintains lot identification at all production phases from receipt, through production,
installation, or assembly, to final completion. Acceptable methods for preserving lot identification include
physically preserving observable lot identifications, recording the lot identification on a work task quality
inspection form or other work record, or collecting the physical lot identifier as a record along with
supplemented with location.

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If lot controlled materials are without lot identification, the Superintendent deems the materials as
nonconforming and segregates them and/or clearly marks them to prevent inadvertent use. The
Superintendent treats the material according to the company policy for nonconformances. Only the
Quality Manager can re-identify or re-certify the materials.

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[CompanyName]
Controlled Materials Form
Version 20150308

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Lot Traceability
Requirements

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Intended Use
(if description is necessary)

[ProjectName]

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Material

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Contract Section/ Activity

ID

Preparer

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[ProjectNumber]

Contract Name

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Contract ID

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Method for identification of

Approved Inspection Status

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[CompanyName]
Material Inspection and Receiving Report
Version 20150308

[ProjectNumber]

[ProjectName]
Stock/Part
No.

Supplier
Quantity
Received

Description

Bill of Lading No.

Condition

Marking

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Item No.

Purchase Order No.

Contract Name

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Contract ID

Listed items have been accepted by me or under my supervision

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ACCEPTANCE

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Receiving Quality Control

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

Received in apparent good condition EXCEPT as noted

Signature of authorized person and date: _________________________________________________________________

EXCEPTIONS:

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Accept

Conditional
Use

Date

Reject

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For More Information:

Contact: FirstTimeQuality

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410-451-8006

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www.FirstTimeQuality.com

[email protected]

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

4104518006 www.firsttimequality.com [email protected]