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This article provides you information about Construction Contractor Quality Control Plan. This plan must be generated based on the contractor quality control manual and also the requirements of the plant owner or End-user inspection and test plan. The sample quality control plan is also provided in this article.
This plan collects all inspections and tests requirements from construction codes and standards and summarizes them in the simple table.
The construction contractor quality control plan is generated for specific projects. Here is sample QC plan for construction of an industrial plant.
If you need to immediately review quality control sheets, skip this section and scroll down to the end of this page.
Contractor Quality Control Plan – Purpose
This quality control plan has been prepared to establish the quality control and Test to be conducted at the project work site.
Contractor Quality Control Plan – Project Description
Project shall mean XXX unit located on the XXX of XXX, at XXX approximately XXX Kilometers from XXX.
Contractor Quality Control Plan – Project Definition
COMPANY is XXX Company (Plant Owner)
EPC CONTRACTOR is XXX Company
TPI Third Party Inspection Agency is XXX Company
PROJECT is XXX Project XXX UNIT
Construction Contractor is XXX Company
SPECIFICATION collectively means all technical specifications, drawings, requisitions and other technical documents referenced in contractual documents.
QUALITY CONTROL collectively means quality control of the construction works for compliance with the project specification and all the engineering and construction procedures, specifications, codes of practices and engineering standards pertaining to the contract and would be done by construction contractors.
Inspection Survey, Test and/or Examination and would be done by a Third Party Inspection Company.
FIELD INSPECTION RECORD means the individual record of a required test or Inspection.
MILL TEST REPORT A document generated by the manufacturer of material, which completely identifies the supplied material and the specification under which it was produced and reports all required test values necessary to demonstrate compliance with that specification.
VT is Visual Inspection.
DT is Dimensional Check.
M is Monitoring which is a Random Check by direct/indirect inspection to ensure the conformance of the item or activity.
H is Hold, which is work should not be continued until Inspection has been finished successfully.
MOM is Minutes of Meeting.
OPI is Opened Package Inspection.
W is Witness, which is when a construction contractor notifies the EPC contractor and the third party inspection agency regarding the day and the corresponding activity for the inspection. In the case that an EPC contractor and inspection agency is not present, the construction contractor will continue the respective activity.
RD is Review of Documents & Certificates.
WPS is Welding Procedure Specification.
PQR is Welding Performance Qualification Record.
WPQ is Welders Performance Qualification Certificate.
NDT is Non-destructive Testing.
PWHT is Post Weld Heat Treatment.
DFT is Dry Film Thickness.
P&ID is Piping and Instrumentation Diagram.
N/A is Not Applicable.
A is Approval, which is Review and Verification of Docs with applicable Specification, and is required prior to proceeding.
I.R. is Insulation Resistance.
SHOULD Indicates recommendation but not necessary.
SHALL Indicates a mandatory requirement.
Contractor Quality Control Plan – Scope
The quality control plan covers the general field of inspection and testing of piping, equipment, pipeline and structural steel, electrical, instrumentation, insulation and painting activities during construction, installation, pre-commissioning and, commissioning at XXX Project.
Contractor Quality Control Plan – Reference Documents
This is the list of related engineering documents issued by EPC contractors
Contractor Quality Control Plan – Documentation
Documents are prepared, reviewed, approved and issued by authorized personnel. Documents requiring multi-discipline review are identified together with the key personnel holding the primary responsibility and the parties who shall carry out the review.
Changes and revisions to the project documents are checked and approved by the same discipline/group that conducted the check and approval of the original documents. Reasons for, outline of, and points of the changes and revisions are indicated in the documents or in their attachments.
The type of documents to be controlled, the elements of control and the numbering system to be used on the PROJECT are defined.
The Document Control system
- Identify the key documents, e.g., documents for progress measurement (such as P&IDs and Plot Plans), documents to be reviewed by CLIENT or requiring approval by third parties (e.g., Licensors) or regulatory authorities
- Allow access to the project personnel and CLIENT
- Record the issue dates and status
- Generate reports on the document status and warning reports for overdue documents
A document distribution matrix is prepared, which relates data and document types to interested parties. The distribution to the CLIENT and third parties is reviewed and agreed upon with such external parties. Distribution within an organization is specified by each section manger and reviewed by the Project Manager. Internal distribution is on an “as needed basis”, i.e., selective distribution and not indiscriminate distribution to a large number of project personnel. Key personnel ensure that the related disciplines/sections have been included in the distribution list.
A master copy of each document is kept in a Centre File. When updated documents are issued, the previous revision is marked “Superseded”.
Contractor Quality Control Plan – Quality Records
The quality records control (including Quality Control Records ) is the responsibility of the QC Manager. The quality records include:
- The person in charge for specific items
- The identification of regulatory and CLIENT requirements for permanent records
- Retrieval, filing and indexing of the fabrication record books
- Submission format, quality of reproductions, number of copies and archive requirements
- Final disposition at completion of the work
- Results of reviews, inspections, tests, audits and materials certificates
- Qualification of personnel, procedures and equipment
- Non-conforming and corrective action reports
- Other documentation, such as drawings, specifications
Test reports are prepared within 7 working days of test completion and are submitted on an immediate basis.
All repair procedure, specific method statements and Test Equipment Calibration Certificates, as required by the requisition, are reviewed approved prior to use.
In case of conflict, the orders of precedence are as follows:
- Contract
- AFC Drawings
- Project Specification
- Other relevant Project Specification
- Applicable Codes and Standards
Contractor Quality Control Plan – Codes and Standards
The codes and standards that the contractor will follow will be laid out. These includes codes and standards for installation, construction, fabrication, inspection and/or testing of materials, services, or equipment for the XXX Project is in accordance with those specified in the contractual documents, purchase order, requisition specification, data sheets and drawings.
The Construction contractor will refer queries regarding the referenced codes and standards to the EPC CONTRACTOR and TPI for decision.
Material Receiving Quality Control
As soon as the equipment and materials are delivered to the site, receiving quality control is performed by the material controller. After receiving quality control, the material controller prepares the Material Receiving Report.
If any loss, damage or quality faults are found, a Shortage/Damage or Non-conformity Report is made and reported to the site manager using the “Shortage/Damage or Nonconformity Report”.
Field Quality Control and Test
The quality control and test of field construction are carried out based on the inspection and test plan (ITP) issued by EPC Contractors and endorsement of the plant owner. Inspection and test that are not covered by the ITP shall be defined in conformity with issued drawings, specifications, codes and standards during the progress of the work execution stage depending upon specific WORK requirements.
Alteration is made in the form of changes as per specific WORK requirements from time to time.
The construction contractor informs in writing the EPC Contractor and TPI of the inspection points (WITNESS & HOLD), which are required to be witnessed before execution of any stage of the work.
Inspection and Test Plan
The EPC Contractor inspection and test plan has been considered in this quality control plan.
The construction contractor controls the individual inspection procedure for in-process or final quality control/testing, and records it. The records are the work instruction, checklists, and test records that give evidence that the work has passed quality control and/or testing with defined acceptance criteria.
The construction contractor holds pre-inspection meeting(s) with the EPC Contractor to resolve questions concerning compliance with the individual quality control procedure, specific quality control requirements, and related specification. The construction contractor arranges for meeting attendance by all necessary means to achieve resolution of technical questions, schedules, and quality control requirements.
Inspection Access
The construction contractor provides free entry to any part of site to the EPC Contractor and plant owner inspectors for testing /inspection, on any contracted portion of the project that is being performed.
The Construction contractor cooperates with the inspector to monitor, audit and visit plants or other inspection locations where work is undertaken as part of the scope of work for the project.
NON-CONFORMANCE CONTROL
Non-conformances are classified as follows:
- Major non-conformance: affecting the safety and operation of equipment or plant component.
- Minor non-conformance: not designated as major non-conformance.
When a non-conformance is found, the non-conforming system or materials are marked or tagged. A non-conformance report showing the cause and recommended corrective action is prepared by quality control personal. Clarification of minor non-conformance would be the responsibility of the quality control manager.
For major non-conformities, all repair procedures prepared by the construction contractor would be submitted to the EPC Contractor and would be reviewed by the EPC Contractor for approval.
Required quality control in sufficient details is done during the execution of any and all repairs.
Executive Summary & Industrial Inspection Scope
In demanding industrial environments across Oil, Gas, Petrochemical, Offshore, and Heavy Process Infrastructure, rigorous compliance with ISO 9001 / ASME / API is essential to ensure operational integrity, personnel safety, and compliance with statutory regulatory frameworks. This technical specification provides QA/QC managers, procurement engineers, welding inspectors, and third-party inspection (TPI) agencies with an authoritative, field-tested guideline for “Construction Contractor Quality Control Plan”.
Ensuring compliance regarding construction contractor quality control plan minimizes the risk of catastrophic asset failures, costly unscheduled shutdowns, and supplier non-conformances. The following technical sections delineate the scope of inspection, mandatory verification protocols, acceptance criteria, documentation deliverables, and root cause mitigation strategies.
Governing International Engineering Codes & Specifications
Verification and validation of Construction Contractor Quality Control Plan must strictly conform to the latest editions of the following international engineering codes and project specifications:
• **Primary Standard Reference:** ISO 9001 / ASME / API
• **Quality Management & Inspection Systems:** ISO 9001:2015 & ISO/IEC 17020 (Requirements for the operation of various types of bodies performing inspection)
• **Material Compliance & Traceability:** EN 10204 Type 3.1 / 3.2 Inspection Certificates for metallic and non-metallic pressure-retaining components
• **Personnel Qualification:** ASNT SNT-TC-1A / ISO 9712 for NDT personnel, CSWIP 3.1 / AWS CWI for welding inspection, and NACE / AMPP Level 2/3 for coating and corrosion personnel
• **Statutory & Health Safety Directives:** ASME Boiler & Pressure Vessel Code (BPVC), API Standards, OSHA, and regional local authority regulations.
Step-by-Step Quality Control & Inspection Procedure
The execution of quality surveillance for Construction Contractor Quality Control Plan is structured across four progressive QA/QC intervention phases:
Stage 1: Pre-Inspection & Engineering Document Review (Review Point – R)
Prior to commencement of any physical activities or manufacturing operations related to Construction Contractor Quality Control Plan, the contractor or vendor must submit all technical submittals to the Owner or TPI agency for formal review and approval.
- Verification of approved Inspection and Test Plan (ITP) identifying all Hold (H), Witness (W), Review (R), and Surveillance (S) intervention points.
- Cross-examination of Material Test Reports (MTR / Mill Certificates) against standard design specifications (ISO 9001 / ASME / API).
- Review and approval of specific Procedure Qualification Records (PQR), Welding Procedure Specifications (WPS), or calibration certificates.
- Verification that all measurement instruments, gauges, and NDT equipment hold valid calibration certificates from ISO/IEC 17025 accredited calibration laboratories (within 6 to 12 months validity).
Stage 2: In-Process Witnessing & Fabrication Control (Witness / Hold Point – W/H)
During the active execution phase, the certified inspector performs physical surveillance to ensure strict adherence to certified drawings, manufacturing procedures, and code tolerances.
- Verification of material traceability (heat number, heat treatment lot, plate number) transferred accurately onto fabricated components.
- Dimensional verification and visual inspection using calibrated gauges, micrometer depth dials, or laser alignment systems.
- Monitoring ambient environmental parameters (relative humidity, dew point, substrate temperature) when applying surface treatments, welding preheat, or pressure testing.
- Witnessing non-destructive examination (RT, UT, MT, PT, PMI) at specified percentages according to project critical rating and code requirements.
Stage 3: Final Acceptance, Pressure/Performance Testing & Marking (Hold Point – H)
The culminating milestone where the fully assembled or completed item is subjected to definitive acceptance tests in the presence of the Owner’s Third-Party Inspector (TPI).
- Execution of pressure proof tests (Hydrostatic at 1.3x to 1.5x MAWP or Pneumatic test) with dual calibrated pressure gauges and temperature recorders.
- Full visual inspection of completed surfaces, welds, protective coatings, and flange contact faces for absence of mechanical damage or code defects.
- Validation of permanent stamping, low-stress die markings, nameplate data verification, and barcoding in strict conformity with project specs.
- Clearing all open punch-list items, non-conformance reports (NCRs), and concession requests prior to issuance of the release note.
Stage 4: Packing, Preservation & Inspection Release (Inspection Release Certificate – IRC)
Ensuring the inspected equipment is adequately protected against atmospheric corrosion, mechanical shock, and marine transit degradation.
- Inspection of rust preventative coatings, desiccant bags, flange face blind protectors, and vapor corrosion inhibitor (VCI) packaging.
- Verification of heavy-lift sea fastening lugs, center-of-gravity markings, and export crating compliance (ISPM 15 wooden crating).
- Compilation and signing of the final Inspection Release Certificate (IRC / Shipping Release) and manufacturer data dossier (MDR).
Technical Acceptance Criteria & Tolerances Matrix
All measurements and physical characteristics must comply with the engineering tolerances and acceptance thresholds tabulated below:
| Inspection Parameter / Test Item | Applicable Standard & Clause | Permissible Tolerance / Acceptance Limit | Verification Method | Intervention Type |
|---|---|---|---|---|
| Material Chemical & Mechanical Verification | ISO 9001 / ASME / API / EN 10204 3.1 | 100% compliance with minimum tensile, yield, elongation, and impact values (Charpy V-Notch at design temp) | Optical Emission Spectrometry (OES) / MTR Verification | Review (R) |
| Visual & Dimensional Tolerances | ISO 9001 / ASME / API / Project Specs | Zero cracks, lack of fusion, severe pitting; dimensional tolerances within ±1.0mm to ±3.0mm per code drawings | Calibrated Vernier, Bridge Cam, Depth Micrometer | Witness (W) |
| Non-Destructive Examination (NDT) | ASME Sec V / ASNT SNT-TC-1A | 100% compliant with code acceptance criteria; zero planar defects or unpermitted volumetric indications | Radiographic (RT) / Ultrasonic (UT) / Magnetic Particle (MT) | Hold (H) |
| Pressure / Proof Testing (Hydrostatic) | ISO 9001 / ASME / API / ASME Sec VIII | Test pressure maintained for minimum 30 to 60 mins; zero pressure drop, zero leakage or visible sweating | Dual calibrated Bourdon pressure gauges + Chart Recorder | Hold (H) |
| Surface Prep & Protective Coating Quality | SSPC-SP / NACE / ISO 8501 | Surface profile 50 – 75 µm; Dry Film Thickness (DFT) within 80/20 rule of specified nominal thickness | Replica Tape (ASTM D4417) & Magnetic Gauge (SSPC-PA 2) | Witness (W) |
| Nameplate & Final Preservation Verification | API / ASME / Client Specs | 316L SS nameplate securely affixed with correct design code, MAWP, design temp, and national board stamping | Physical visual check & VCI preservation verification | Hold (H) |
Mandatory QA/QC Dossier & Inspection Deliverables
Prior to the final issuance of the Inspection Release Certificate (IRC), the contractor and vendor must compile and submit the verified manufacturer data record containing:
- Approved Inspection & Test Plan (ITP) with sign-off stamps by Contractor, Client, and TPI.
- Material Test Reports (MTR / Mill Test Certificates EN 10204 Type 3.1 or 3.2).
- Certified Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Performance Qualifications (WPQ).
- Calibration Certificates for all test instruments and measuring equipment (NABL / ISO 17025 accredited).
- Non-Destructive Examination Reports (RT, UT, MT, PT, PMI, Ferrite Content) evaluated by Level II/III inspectors.
- Heat Treatment & PWHT Time-Temperature Recorder Charts with thermocouple layout drawings.
- Hydrostatic / Pneumatic Pressure Proof Test Certificate with calibrated chart recorder logs.
- Surface Preparation and Protective Coating Inspection Reports (Daily environmental log, blast profile, DFT summary).
- Non-Conformance Report (NCR) and Concession Disposition Closeout Log.
- Official Inspection Release Certificate (IRC / Shipping Release Note) permitting packing and dispatch.
Common Non-Conformances & Field Mitigation Strategies
Based on extensive third-party inspection field records in oil & gas projects, the following deviations require heightened surveillance:
Defect / Hazard: Material Grade Substitution & Lack of Heat Traceability
Root Cause: Uncontrolled workshop storage, missing color coding, or unverified supplier sub-tier procurement without EN 10204 3.1 documentation.
Preventative Action: Enforce strict 100% Positive Material Identification (PMI) prior to cutting, and mandatory material receiving inspection with physical stamping cross-referenced to original mill test certificates.
Defect / Hazard: Out-of-Tolerance Fit-Up & Alignment Mismatch
Root Cause: Poor thermal cutting, thermal distortion from excessive preheat, or inadequate jigging and tacking arrangements.
Preventative Action: Establish a mandatory Witness/Hold point at joint fit-up before root pass deposition. Use calibrated Hi-Lo gauges to verify bevel angle, root face, and root gap according to the qualified WPS.
Defect / Hazard: Premature Coating Delamination & Blistering Under Film
Root Cause: Excessive soluble salt contamination (>20 mg/m²) left on the substrate, blast cleaning below dew point (<3°C above dew point), or oil/moisture in the blasting compressor air line.
Preventative Action: Perform Blotter Test (ASTM D4285) daily on compressed air, enforce Bresle patch chloride testing, and apply primer within 4 hours of abrasive blasting before rust blooming initiates.
Defect / Hazard: Pressure Drop During Final Hydrostatic Proof Testing
Root Cause: Micro-leakage through temporary test flange gaskets, entrapped air pockets inside vessel high points, or inadequate temperature stabilization.
Preventative Action: Ensure thorough venting at all high-point vents until bubble-free fluid emerges, allow minimum 15-minute temperature stabilization between filling medium and ambient metal, and torque all blind flanges with calibrated torque wrenches.
Frequently Asked Questions (FAQ)
Q: What are the mandatory qualifications for inspectors verifying Construction Contractor Quality Control Plan?
A: Inspectors must hold recognized international certifications applicable to the discipline. For welding and fabrication: CSWIP 3.1/3.2, AWS CWI, or API 510/570 Source Inspector. For NDT: ISO 9712 or ASNT SNT-TC-1A Level II minimum. For coatings: NACE / AMPP Level 2 or FROSIO Level III. Additionally, the inspection agency must operate under an ISO/IEC 17020 accredited quality management system.
Q: How does PtroTek resolve non-conformances (NCRs) encountered during vendor surveillance?
A: When a deviation from certified drawings or ISO 9001 / ASME / API is detected, the inspector issues a formal Non-Conformance Report (NCR) within 24 hours. The vendor must submit a Root Cause Analysis (RCA) and proposed disposition (Rework, Repair, or Concession). Work on the affected component is halted (Hold Point) until the Owner’s engineering authority approves the disposition and a re-inspection confirms full compliance.
Q: What is the difference between Witness (W) and Hold (H) points in an Inspection & Test Plan (ITP)?
A: A Hold Point (H) is a mandatory milestone where fabrication or testing CANNOT proceed without the physical presence of the designated client or third-party inspector. Written clearance or stamping is strictly required. A Witness Point (W) requires prior notification (typically 24 to 48 hours) to the inspector; however, if the inspector fails to attend at the scheduled time, fabrication or testing may proceed with subsequent review of the test records.
Q: Can international clients review inspection reports and photos in real time?
A: Yes. PtroTek provides comprehensive Flash Reports issued within 24 hours of inspection completion, followed by detailed formal inspection reports accompanied by high-resolution calibrated photographic evidence, dimension logs, and signed vendor test records for complete global transparency.
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