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QC Check Sheets (overview)

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Using QC Inspection Checklist for As-built Verification and Mechanical Completion

A checklist is a structured form or questionnaire for collecting and analyzing data. This is a generic tool that can be adapted for a wide variety of purposes. Collecting and analyzing data is important for identifying and understanding problems and thus making appropriate changes to solve these problems.

Prospective Users
Inspection checklists are useful on construction projects that wants to improve quality and productivity, reduce defect rates, and reduce re-work.

Problem Addressed:

  • Increasing or high frequency of product faults.
  • High rates of defective products requiring repair or re-work.
  • High levels of waste materials.
  • Low productivity.
  • Verification documentation for as-building of the project for project turnover.


Process
This practice requires line managers and quality control staff to collect information about the number and sources of defects in the construction process. Information about the number, causes and frequency of the defects are recorded in the checklists and tallied to show totals. These totals can then be analyzed to see the times most defects are made, the types of defects and the most common causes of defects. This information can then be used to reduce defects.

Steps in implementation

  1. Decide what construction activity will be observed or inspected.
  2. Identify the period to be observed or inspected. This period should be relevant to the problem.
  3. Develop a standard table or form for each type of construction activity based on criticality.
  4. Name the columns and rows in the table.
  5. The checklist form is usually an A4 sheet with a table with rows indicating types of defects and columns indicating the time the mistakes are detected. The QC inspector fills in the number of defects of each type in the cell of the relevant defect and time period. This checklist helps to identify the major types of defects.
  6. Make standard format check sheets available each construction activity.
  7. Discuss the results and draw conclusions.
  8. Discuss possible actions for improvement.
  9. The inspection checklists should be stored in a safe place.
  10. The summary the inspection check sheet can be used as input for a quality improvement program. The checklist totals can be used to identify which errors are most common, and to try to prevent these errors in the future. Workers may need additional training or guidance in order to avoid making such errors.
  11. Resources Required
    • Line managers and QC quality inspectors' involvement.
    • Check sheets.
    • Document controller


Challenges and pitfalls

  • Staff may feel they have more work to do.
  • Difficulty in maintaining efforts to collect information.


Positive Impact

  • Helps to record all faults and sources of faults.
  • Saves money by helping to eliminate major sources of defects.
  • Bench mark best practices for quality improvement.
  • Transparent and honest reporting


Indicators for monitoring

  • QC Check sheets form created and made available.
  • QC Check sheets filled, summarized and discussed.


1. Application For Inspection

  • 01 APPLICATION FOR INSPECTION

2. Material Control

  • 01A MATERIAL RECEIVING REPORT
  • 01B OVER SHORTAGE DAMAGE REPORT
  • 002 MATERIAL INSPECTION REPORT
  • 003 STORAGE REPORT
  • 005 HANDLING REPORT
  • 008 MATERIAL REQUEST ISSUE SLIP
  • 009 STOCK CARD
  • 010 MATERIAL RETURN SLIP
  • 011 MATERIAL SURPLUS LIST
  • 109 MATERIAL ACCEPTED LABEL
  • 110 MATERIAL REJECTED LABEL
  • 111 MATERIAL HOLD LABEL
  • 112 CONDITIONAL RELEASE LABEL
  • 113 MATERIAL RELEASED LABEL

3. Surveys

  • 122 FINAL INSPECTION OF INTERSECTION POINTS, PIPE SUPPORT & CROSSFALLS
  • 123 SURVEY REPORT PAD AND EQUIPMENT AREA
  • 124 FINAL INSPECTION OF PIPE COLUMN
  • 125 FINAL INSPECTION OF PIPE COLUMN, HEAD, SHOE
  • 126 SURVEY REPORT
  • 127 FINAL INSPECTION OF PIPE ANCHOR
  • 128 FINAL INSPECTION OF ROAD CROSSING
  • 129 FINAL INSPECTION OF ROAD
  • 130 EQUIPMENT TEST

4. Building Installation

  • 01 ASPHALT WATER PROOFING WORK
  • 02 WATER PROOFING PROTECTION
  • 03 DAMPPROOFING/WATER REPELLENT WORK
  • 04 CAULKING AND JOINT FILLER INSTALLATION
  • 05 TILE WORK
  • 06 WOOD WORK
  • 07 ROOFING INSULATION, ROOFING AND SIDING WORK
  • 08 DOWN SPOUTS AND ROOF DRAIN WORK
  • 09 STEEL FRAMING WORK
  • 10 MISCELLANEOUS METALS INSTALLATION
  • 11 INSPECTION OF PLASTER WALL & FLOOR FINISH
  • 12 FIXTURES AND HARDWARE INSTALLATION
  • 13 GLASS AND GLAZING INSTALLATION
  • 14 VINYL FLOOR TILE WORK
  • 15 GYPSUM BOARD INSTALLATION
  • 16 ACOUSTICAL BOARD INSTALLATION
  • 17 PIPING INSTALLATION (1 of 2)
  • 18 PIPING INSTALLATION (2 of 2)
  • 19 SANITARY EQUIPMENT INSTALLATION
  • 20 MISCELLANEOUS EQUIPMENT INSTALLATION
  • 21 PRESSURE TEST
  • 22 LEAKAGE TEST
  • 23/1 FIRE PROTECTION EQUIPMENT INSTALLATION
  • 23/2 FIRE PROTECTION EQUIPMENT INSTALLATION CHECK
  • 24 TEST RECORD OF PIPING & DUCTING
  • 25 BUILDING INSPECTION RECORD
  • 26 ACCEPTANCE OF BUILDING EXTERNAL
  • 27 ACCEPTANCE OF BUILDING INTERNAL

5. H.V.A.C.

  • 01 AIR HANDLING UNIT & FANS
  • 02 HVAC SYSTEM FUNCTION CHECK
  • 03 HVAC SYSTEM NOISE MEASUREMENT
  • 04 ACCEPTANCE CERTIFICATE OF BUILDING EQUIPMENT
  • 05 HVAC INSTALLATION CHECK LIST

6. Earthwork

  • 01 SEWER PIPING WORK
  • 02 OPEN DITCH
  • 03 WATER LEAKAGE OF SEWER LINE
  • 12 NEW ROADS FINISHING WORKS
  • 13 COMPACTION OF STRUCTURAL FILL
  • 14 CLEARING OF NEW LAND
  • 15/1 COMPACTION TEST OF SAND BEDDING BY CLEGG HAMMER
  • 15/2 COMPACTION TEST OF SAND BEDDING BY CLEGG HAMMER
  • 16 INSPECTION OF LANDSCAPING
  • 17 INSPECTION OF LANDSCAPE EQUIPMENT

7. Concrete Work

  • 01 TRIAL MIX OF CONCRETE
  • 02 COMPRESSIVE STRENGTH TEST OF CONCRETE
  • 03 RECORD OF ANCHOR BOLT FOR STEEL STRUCTURE
  • 04 CONTROL MIX OF CONCRETE
  • 05 TANK FOUNDATION RECORD
  • 06 EARTH & CONCRETE WORK FOUNDATION
  • 06/1 PRE-CONCRETE INSPECTION RECORD
  • 07 PROCTOR TEST
  • 08 CONCRETE AGGREGATES
  • 09 CABLE PULL PITS PRE POURING
  • 10 CABLE PULL PITS POST POURING
  • 11 INSPECTION OF REINFORCING BAR INSTALLATION

8. Piping Work

  • 01 PIPE WORK PRETEST CHECK LIST
  • 02 HYDROSTATIC TEST REPORT
  • 02/2 HYDROSTATIC TEST REPORT
  • 03 FLUSHING, BLOWING AND CHEMICAL CLEANING ACCEPTANCE CERTIFICATE
  • 03/2 FLUSHING AND CLEANING REPORT
  • 04 PIPE WORK POST TEST CHECK LIST
  • 05 MECHANICAL COMPLETION OF PIPE WORK
  • 06 PIPING WORKS INSTALLATION
  • 07 BURIED FRP PIPE INSTALLATION

9. Structural

  • 01 STEEL WORK FABRICATION CHECK LIST
  • 02 STEEL WORK INSTALLATION CHECK LIST
  • 03 STRUCTURE INSTALLATION

10. Structural Steel For Buildings

  • 01 INSPECTION OF STRUCTURAL STEEL FABRICATION
  • 02 INSPECTION OF STRUCTURAL STEEL ERECTION

11. Welding

  • 01 WELDER QUALIFICATION TEST
  • 2/1 PROCEDURE QUALIFICATION RECORD (PQR)
  • 2/2 PROCEDURE QUALIFICATION RECORD (PQR)
  • 03 WELDING PROCEDURE SPECIFICATION
  • 04 WELDERS QUALIFICATION LOG
  • 05 WELDERS PERFORMANCE CHART
  • 06 DAILY FIELD WELD REPORT
  • 07 WELDER B31.3 RANDOM RADIOGRAPHIC CONTR. LOG
  • 8/1 WELD TRAVEL SHEET
  • 09 HEAT TREATMENT INSTRUCTION SHEET
  • 10 CONSUMEABLE CHECK LIST FOR WELDING WORK

12. New/Special Processes

  • 01 RADIOGRAPHIC EXAMINATION LOG
  • 02 MAGNETIC PARTICLE EXAMINATION LOG
  • 03 LIQUID PENETRANT EXAMINATION LOG
  • 04 ULTRASONIC EXAMINATION LOG
  • 05 RADIOGRAPHIC EXAMINATION REPORT
  • 06 LIQUID PENETRATION EXAMINATION REPORT
  • 07 HARDNESS TESTING RECORD

13. Pipe Cleaning Blow Down

  • 01 PIPEWORK PRETEST CHECK LIST
  • 02 HYDROSTATIC TEST REPORT
  • 03 FLUSHING, BLOWING AND CHEMICAL CLEANING ACCEPTANCE CERT
  • 04 POST PIPE CLEANING/BLOW DOWN CHECK LIST
  • 05 MECHANICAL COMPLETION OF PIPE WORK
  • 06 PREPARATION CHECK FOR PIPE CLEANING /BLOW DOWN

14. Pressure Testing

  • 01 PIPEWORK PRETEST CHECK LIST
  • 02 HYDROSTATIC TEST REPORT
  • 04 PIPEWORK POST TEST CHECK LIST

15. Coating

  • 01 DAILY REPORT ON PAINT OPERATIONS
  • 02 IN-PROCESS PAINT INSPECTION

16. Insulation

  • 01 INSULATION INSPECTION RECORD
  • 02 EQUIPMENT/PIPING RELEASE FOR INSULATION
  • 03 FIELD LININGS INSPECTION RECORD

17. Static Equipment

  • 01-STATIC EQUIPMENT INSTALLATION
  • 02 HEAT EXCHANGER INSTALLTION INSPECTION
  • 03 FINAL VESSEL CLOSURE
  • 04 SPECIAL EQUIPMENT INSPECTION
  • 05 AUXILIARY EQUIPMENT INDEX MISCELLANEOUS ITEMS
  • 06 FIRED HEATER INSTALLATION INSPECTION
  • 07 FIRED BOILER INSPECTION

18. Rotating Equipment

  • 01 EQUIPMENT PROTECTION, PRESERVATION & EQUIPMENT
  • 02 ALIGNMENT INSPECTION
  • 03 EQUIPMENT FLANGE ALIGNMENT
  • 04 COMPRESSOR INSPECTION
  • 05 PUMP INSPECTION
  • 06 FAN & BLOWER INSPECTION
  • 07 ELECTRICAL MOTOR INSPECTION

19. Electrical

  • 02 OIL DIELECTRIC STRENGTH TEST RECORD
  • 03 CABLE TRAY INSPECTION CHECK LIST
  • 04 CABLE PULLING INSPECTION CHECK LIST
  • 05 MEGGER RADINGS (POWER, CONTROL WIRE & CABLE)
  • 06 MEGGER READINGS (ELECTRICAL, EQUIPMENT INCLUDED MOTORS)
  • 09 INSULATING RESISTANCE TEST RECORD (ROTATION)
  • 10 GROUND WELL RESISTANCE READINGS
  • 12 MEGGER READINGS (TRANSFORMER)
  • 13/1 SWITCHGEAR, PANEL & CUBICLE INSPECTION RECORD
  • 13/2 SWITCHGEAR, PANEL & CUBICLE INSPECTION RECORD
  • 14-380V SWITCH GEAR INSPECTION RECORD
  • 15/1 MOTOR CONTROL CENTER INSPECTION RECORD
  • 15/2 MOTOR CONTROL CENTER INSPECTION RECORD
  • 16 LIQUID FILLED TR. INSPECTION CHECK LIST
  • 17/1 PRE-COMMISSIONING OF POWER TRANSFORMER
  • 17/2 PRE-COMMISSIONING OF POWER TRANSFORMER
  • 17/3 CHECK ON ARRIVAL FOR TRANSFORMER
  • 20 NEUTRAL GROUNDING RESISTOR INSPECTION RECORD
  • 21 BATTERY & BATTERY CHARGER INSPECTION RECORD
  • 22 REPLACEMENT OF FIELD CONTROL STATION TEST R
  • 23 CONNECTION OF EXISTING LOADS TO NEW MCC'S T
  • 24 LIGHTING CHECK SHEET
  • 25 SMALL POWER INSPECTION CHECK LIST
  • 26 2DISTRIBUTION BOARDS PANEL INSPECTION CHECK LIST
  • 27 TELEPHONE SYSTEM INSPECTION CHECK LIST
  • 28 UNDERGROUND CONDUIT INSPECTION CHECK LIST
  • 29 ABOVEGROUND CONDUIT INSPECTION CHECK LIST
  • 30 IPB INSTALLATION CHECK LIST
  • 31 DIESEL ENGINE GENERATOR INSTALLATION CHECK LIST
  • 32 DCS/CONSOLE DESK CHECK LIST
  • 33 CONTROL PANEL INSTALLATION CHECK LIST
  • 34 LV BUS DUCT CONNECTION CHECK LIST
  • 35 LOCAL PANEL & BOX INSTALLATION CHECK LIST
  • 36 LIGHTING PROTECTION INSTALLATION
  • 37 OA SYSTEM INSTALLATION
  • 38 FIRE ALARM SYSTEM INSTALLATION CHECKLIST
  • 01 OVERALL COMPLETION OF EARTHING GRID
  • 02 EARTHING RISER LAYOUT
  • 03 EARTHING WIRE LAYOUT
  • 04 CADWELD CONNECTION OF EARTH GRID WIRE

20. Instrumentation

  • 01 SITE INSPECTION CERTIFICATE FOR LOCAL MOUNTEDINSTT
  • 02 INSTRUMENT POWER SUPPLY INSPECTION RECORD
  • 03 ALARM ANNUNCIATOR TEST RECORD
  • 04 CONTROL SYSTEMS PUNCHLIST RECORD
  • 05 CONTROL SYSTEM TEST EQUIPMENT CALIBRATION LOG
  • 06/1 CALIBRATION FORM ONE
  • 06/2 CALIBRATION FORM TWO
  • 07 INSTALLATION AND LOOP CHECK RECORD
  • 08 MEGGER READINGS
  • 10 INSTRUMENTS INSTALLATION

21. Gas Removal System

  • 01 GAS REMOVAL SYSTEM CHECK LIST SUPPORT STRUCTURE INSTALLATION
  • 02 GAS REMOVAL SYSTEM CHECK LIST EJECTOR, CONDENSER & SEPARATOR
  • 03 GAS REMOVAL SYSTEM VACUUM PUMP INSTALLATION

22. Overhead Crane

  • 01 O/H CRANE INSTALLATION CHECK LIST

23. Generator

  • 01 GENERATOR INSTALLATION CHECK LIST
  • 01/2 GENERATOR INSTALLATION CHECK LIST
  • 01/3 GENERATOR INSTALLATION CHECK LIST

24. Hotwell Pump

  • 01 HOTWELL PUMP INSTALLATION CHECK LIST

25. Cooling Tower

  • 01/1 COOLING TOWER INSTALLATION CHECK LIST
  • 01/2 COOLING TOWER INSTALLATION CHECK LIST

26. Turbine

  • 01/1 TURBINE INSTALLATION CHECK LIST
  • 01/2 TURBINE INSTALLATION CHECK LIST
  • 01/3 TURBINE INSTALLATION CHECK LIST

27. Condenser

  • 01/1 CONDENSER INSTALLATION CHECK LIST
  • 01/2 CONDENSER INSTALLATION CHECK LIST

28. General Construction Punchlist Report

  • 01/1 GENERAL CONSTRUCTION PUNCHLIST REPORT
  • 01/2 GENERAL CONSTRUCTION PUNCHLIST REPORT