NAVFAC PACIFIC 2010 NAVFAC PACIFIC DESIGNER & BUILDER SYMPOSIUM HIGHLIGHTS OF THE QUALITY CONTROL (QC) SPECIFICATIONS & CONSTRUCTION QUALITY MANAGEMENT (CQM) LESSONS LEARNED AND CHALLENGES 1 December 2010 Steven Agena, P.E. Dennis Tanaka, P.E. Agenda •NAVFAC QC Specifications –Current NAVFAC QC Specs/Requirements –Where to Find Specs –CQM Fundamentals –Comparison of QC Specs •CQM Lessons Learned and Challenges 2 NAVFAC Pacific Construction Division NAVFAC PACIFIC 2010 NAVFAC PACIFIC DESIGNER & BUILDER SYMPOSIUM HIGHLIGHTS OF THE QUALITY CONTROL SPECIFICATIONS 1 December 2010 Steven Agena, P.E. Current NAVFAC Quality Control Specifications/Requirements NAVFAC uses the Unified Facilities Guide Specifications (UFGS) from the Department of Defense (DOD) and military services Unified Facilities Criteria (UFC) program. The objective of the UFC program is to streamline the military criteria system by eliminating duplication of information, increasing reliance on private-sector standards, and creating a more efficient criteria development and publishing process. 4 NAVFAC Pacific Construction Division Current NAVFAC Quality Control Specifications/Requirements Design Bid Build (DBB): •UFGS-01 45 00.00 20 NAVFAC Quality Control –Normally used for large projects, small complex projects •UFGS-01 45 00.10 20 NAVFAC Quality Control for Minor Construction –Small projects, repair & maintenance work –Low risk/complexity Design Build (DB): •UFGS-01 45 00.05.20 Design and Construction Quality Control –Normally used for large projects, small complex projects –Used in Standard Template, 9 Model Request for Proposal (RFP) Templates •Small Project Design-Build template - Part 2 General Requirements –$750K - $3.5M: Depends – low complexity/routine construction (ex. warehouse additions, utility enclosure, recreation facilities, etc.) –<$750K: Yes – non-complex NAVFAC makes final decision which spec to use 5 NAVFAC Pacific Construction Division Where To Find Specifications •Whole Building Design Guide (WBDG) Web Site www.wbdg.org/ - website was revised Department of Defense 6 NAVFAC Pacific Construction Division Where To Find Specifications •WBDG Department of Defense –Unified Facilities Guide Specifications (UFGS) 7 NAVFAC Pacific Construction Division Where To Find Specifications Unified Facilities Guide Specifications (UFGS) 8 NAVFAC Pacific Construction Division Where To Find Specifications Unified Facilities Guide Specifications (UFGS) (USACE) (NAVFAC) (NASA) 9 NAVFAC Pacific Construction Division Where To Find Specifications •WBDG Department of Defense –NAVFAC Design Build Master 10 NAVFAC Pacific Construction Division Where To Find Specifications NAVFAC Design-Build Request For Proposal –Standard Template 11 NAVFAC Pacific Construction Division Where To Find Specifications NAVFAC Design-Build Request For Proposal –Model Request for Proposal: 9 Templates 12 NAVFAC Pacific Construction Division Construction Quality Management Fundamentals From the CQM for Contractors Training: •CQM is the performance of tasks, which ensure that construction is performed according to plans and specifications, on time, within a defined budget, and a safe work environment •Quality is conformance to properly developed requirements – The designer establishes the quality standards – The contractor controls the quality of the work – The purpose of CQM is the Government’s efforts, separate from, but in coordination and cooperation with the contractor, to assure that the quality set by the plans and specifications is achieved 13 NAVFAC Pacific Construction Division Construction Quality Management Fundamentals From the CQM for Contractors Training (cont.): •Contractor Quality Control: The primary function of CQC is to ensure that the completed project meets all quality requirements of the contract •Government Quality Assurance: The means by which the Government protects its interest through reviews, inspections, and tests to assure that CQC is working effectively, and that the end product complies with the quality established by the contract 14 NAVFAC Pacific Construction Division Construction Quality Management Fundamentals •Underlying principals –Contractor is responsible for Quality Control •Contractor required to have a QC Manager on the job site during construction work or testing. •QC Manager requires current CQM for Contractors Certificate –Government is responsible for Quality Assurance •We do Construction Quality Management (CQM) –Want Contractor and Government to be proactive instead of reactive –Prevent mishaps and deficiencies from occurring –Not rely on inspection to achieve required quality CQM = QC + QA 15 NAVFAC Pacific Construction Division What Has Changed Since Last Year DBB: •UFGS-01 45 02 NAVFAC Quality Control (Nov 2009) –Superseded by UFGS-01 45 00.00 20 (Feb 2010) –No changes to content •UFGS-01 45 02.10 NAVFAC Quality Control for Minor Construction (Nov 2008) –Superseded by UFGS-01 45 00.10 20 (Feb 2010) –No changes to content DB: •UFGS-01 45 00.05 20 Design and Construction Quality Control (Nov 2010 – Nov 2007? date shown) –No changes to content •Small Project Design-Build Template - Part 2 General Requirements (2009) –No changes for QC 16 NAVFAC Pacific Construction Division Quality Control Plan Important points •DBB: –Acceptance of the QC Plan is required prior to the start of construction –Only on-site work authorized prior to acceptance is mobilization of trailers, temporary utilities, and surveying •DB: –The Contractor shall perform no design until the Design Quality Control (DQC) Plan is approved and no construction until the CQC Plan is approved. –DQC Plan: Submit prior to Post Award Kickoff (PAK) meeting •All Plans shall be unique to the contract, not a corporate quality control plan •Treat as “living documents” 17 NAVFAC Pacific Construction Division Comparison of Quality Control Specifications All DBB and DB project require three stage inspection process: 1) Punch-out Inspection 2) Pre-Final Inspection 3) Final Inspection DBB: Inspections are listed and defined in the specifications DB: Inspections are listed but NOT defined in the specifications Suggestion: •For DB contracts, follow definitions used in DBB specs. Definitions provides goal of inspections, when, who leads and who attends. 18 NAVFAC Pacific Construction Division Completion Inspections Completion Inspections •Punch-Out Inspections •Contractor responsibility [QC Mgr & Commishing Authority (CA)] •Non-conforming work noted on Rework Items List (one list), including when deficiencies will be completed •Contractor informs Government when all deficiencies corrected •Pre-Final Inspection •Facilities Engineering and Acquisition Division (FEAD)/Resident Officer in Charge of Construction (ROICC) staff and contractor (QC Mgr & CA) participates •Non-conforming work noted on Rework Items List •Deficiencies corrected before request for Final Inspection 19 NAVFAC Pacific Construction Division Completion Inspections Completion Inspections (cont.) •Final Inspection •Contractor notifies Contracting Officer at least 14 calendar days prior to final acceptance inspection date •Contractor states within notice that all items previously identified will be corrected by Final Inspection •FEAD/ROICC staff, Support Command, contractor (QC Mgr, CA & Project Superintendent) participates •No Surprises!! •“Failure of the contractor to have all contract work acceptably complete for this inspection will be cause for the Contracting Officer to bill the Contractor for the Government’s additional inspection cost in accordance with the Contract Clause entitled “Inspection of Construction”.” 20 NAVFAC Pacific Construction Division Inspection •By contract clause, Contractor should be inspecting their work –In Follow-Up Phase: • Ensure the work is in compliance with Contract requirements • Maintain the quality of workmanship required • Ensure that rework items are being corrected • Assure manufacturers reps have performed necessary inspections… •QC does not replace inspections, but should minimize inspection efforts and potential rework –Old adage “measure twice, cut once” •Government does not currently use construction inspectors –We still inspect •It’s the Government’s right •To ensure that the Contractor’s QC Program is working •That the end product complies with the quality established by the contract 21 NAVFAC Pacific Construction Division Bottom line: Construction Quality Management (CQM) is our foundation! 22 NAVFAC Pacific Construction Division Any Questions? 23 NAVFAC Pacific Construction Division NAVFAC PACIFIC 2010 NAVFAC PACIFIC DESIGNER & BUILDER SYMPOSIUM CONSTRUCTION QUALITY MANAGEMENT (CQM) LESSONS LEARNED AND CHALLENGES Dennis Tanaka, P.E. 1 December 2010 Construction Quality Management Lessons Learned & Challenges Discussion Topics •Contractor’s Proposal •Quality Control (QC) Manager •Alternate QC Manager •QC Plan Changes •Environmental Protection Plan •Design Quality Control (DQC) Plan •3-Week Look Ahead Schedule •Buy American Act •Fire Protection System •Completion Inspections •As-Built Drawings •Too Much Oversight !! •Performance Improvements •QC + QA = CQM 25 LEED – separate session NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •Contractor’s Proposal Requirement: Contractor’s proposal becomes part of contract requirements •Used in selection process/Govn’t paying for these items Example: QC Manager qualifications (experience/ education) Lesson learned: •QC Plan/QC staff does not reflect Contractor’s proposal •Change of personnel going back to original contract requirement 26 NAVFAC Pacific Construction Division Specification Proposal QC Plan 1 Dec 2010 Lessons Learned •Quality Control (QC) Manager Corporate Officer Requirement: QC Manager reports to Superintendent •NF PAC requirement •Both held accountable Lesson learned: Reporting chain not consistent, often QC Manager reports to corporate official Superintendent NAVFAC Quality Control Specifications: • 01 45 00.00 20 Quality Control • 01 45 00.10 20 Quality Control for Minor Construction • 01 45 00.05 20 Design and Construction Quality Control QC Manager 27 NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •Alternate QC Manager Requirement: The Alternate QC Manager will serve in the absence of the QC Manager or oversee shift work Lesson learned: •Not available when needed •Does not meet contract requirements Ref: Quality Control Specifications QC Manager 28 Alternate QC Manager NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •Quality Control Plan Changes Requirement: Changes to plan must be submitted and approved by the Contracting Officer Lesson learned: •Updates and changes not incorporated in plan •Plan not updated Ref: Quality Control Specifications QC Manager Working at Jobsite Approved 29 NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •Environmental Protection Plan Requirement: Changes to plan must be submitted and approved by the Contracting Officer Lesson learned: Actual project controls differs from approved plan. Contract modifications not incorporated in plan. Ref: Spec Section 01 57 19.00 20 Temporary Environmental Controls 30 NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •Design Quality Control (DQC) Plan Requirement: Design & construction must be completed in the contract period Lesson Learned: •DQC Plans must be approved prior to start of design. •Delays in approval of DQC Plan impacting construction period. Note: Contractors includes liquidated damages in contract w/ AEs Construction Phase LDs Design phase DQC Plan approval 31 Late approvals NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •3-Week Look Ahead Schedule Requirement: Submit a 3-Week Look Ahead Schedule Lesson learned: •Contractors fail to submit in required format –Should provide detailed information (1 to 5 day duration). Include prep & initial meetings, test, outages, critical safety events. –Should not be a slice out of the project schedule –Prepare in MS Excel •Important for short duration contracts Info: Used by Govn’t staff as a time management tool Ref: UFGS 01 32 17.00 20 Network Analysis Schedule 32 NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •Buy American Act Requirement: Usage of domestic construction materials in contracts performed in the United States. Lesson learned: •Many contractors not aware of requirement •Many contractors don’t read requirements •Believe in compliance … if you purchase from an American supplier •Costly error -> no compensation for $ and time Ref: FAR Subpart 25.2 Buy American Act – Construction Materials 33 NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •Fire Protection System Requirement: A Registered Fire Protection Engineer (QC FPE) shall witness all preliminary inspections. When complete QC FPE will submit a signed certification to QC Manager. Lesson learned: •Systems are not ready when Government FPE arrives at the jobsite to witness formal testing/acceptance. •What about certification by QC FPE? Ref: UFGS 01 45 00.05 20 Design and Quality Control 34 NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •Completion Inspections Requirement: Punch Out Inspection. Contractor Pre-Final Inspection. Contractor + NAVFAC Final Acceptance Inspection. Contactor + NAVFAC + Client Lesson learned: •Contractors not aware of their responsibility •Only one punch list Ref: Quality Control Specifications 35 NAVFAC Pacific Construction Division 1 Dec 2010 Lessons Learned •As-Built Drawings Requirement: As-Build drawings updated by QC Manager on a daily basis Lessons learned: •Not being maintained •Misplaced or lost (walks away…) •Drawings marked “As-Build Drawings” •Drawings should be bound Ref: Quality Control Specifications 36 NAVFAC Pacific Construction Division 1 Dec 2010 Challenge •Too Much Oversight Requirement: Example: QC Specialist/Inspector Qualifications/Exper Area of Responsibility Third Party Inspector Application of EFIS (Exterior Design Institute) material Frequency Full time during Construction Challenge: •Govn’t/AE sometimes over specifies QC requirements •Govn’t/AE sometimes over specifies inspection – techn spec Additional contract cost Notify Contracting Officer during RFP period/prior to award 37 NAVFAC Pacific Construction Division 1 Dec 2010 Challenge •Performance Improvements Requirement: Complete contract within contract completion period (NAVFAC Pacific AOR) Challenge: •NAVFAC not meeting internal goals. Within 5% cost & 10% schedule of original contract amount. Road Ahead: •Paradigm change for NAVFAC, AEs & contractors •Focus on pre-award, as well as post-award contract construction management actions •Incentivize contractors – evals & performance awards •Continue increase use of performance-based DB contracts 38 NAVFAC Pacific Construction Division 1 Dec 2010 Guiding Principle •QC + QA = CQM Requirement: •Quality Control (QC) – contractor system to ensure that completed project meets quality requirements of the contract •Quality Assurance (QA) – through reviews and inspections the Government assures that the contractors QC system is working effectively and end product complies with quality established by the contract •Construction Quality Management (CQM) - combined efforts of the contractor and Government Contractor and Government staff not aware of their role. 39 NAVFAC Pacific Construction Division 1 Dec 2010 Any Questions? 40 NAVFAC Pacific Construction Division 1 Dec 2010
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