# APPENDIX A. FORMS, AND THE WRITTEN PROCEDURE FOR THE USE OF EACH Compliance Assurance Program, In-Plant Quality Assurance Manual [KEN TO CONFIRM: legal entity name] | MT-QAM Rev. 0 (draft, not submitted) This appendix answers **ICC/MBI 1205 §501.17‡**, which requires the forms used as part of the program to appear in the manual together with a written procedure for how each form is used, and **Montana bureau list item MT-6**, sample of inspection control form used. It also answers the Montana list item MT-7, record-keeping procedures for quality control forms, in combination with §14 of the manual. The ‡ mark carries the same meaning as in the manual: the ICC/MBI section number came from the posted approved ballot draft of the standard and must be verified against the purchased 2021 edition before submission. [KEN TO CONFIRM: ...] marks a fact about the plant that does not exist yet. [PE TO SET: ...] marks a numeric criterion the engineer of record must set. --- ## A.0 Rules that apply to every form 1. **Every form carries a footer** reading `QF-nn Rev. __ | MT-QAM Rev. __ | page __ of __`. Forms are controlled documents registered on QF-29. A superseded blank is withdrawn from the floor when a revision is issued. 2. **Entries are made in ink at the time the work is done**, by the person who did it. No form is completed in advance and no form is reconstructed afterwards. 3. **A correction is a single line through the error, with the correct value written beside it, initialled and dated.** Entries are not erased, whited out or overwritten. 4. **A blank field is not an accepted field.** Where a characteristic does not apply, `N/A` is written and initialled. Where an inspection was not performed, the item does not advance. 5. **A signature is a signature**, written by the person's own hand, with the date. Initials are acceptable only where the form's signature block also carries that person's full signature and printed name once. 6. Every form that concerns a specific product carries the **serial number** assigned under manual §10.1, so that the record can be found from the product and the product from the record. 7. Where a form records a measured characteristic against a criterion, the **measured value is written**, not a tick. A tick records that somebody looked; a value records what they found. 8. Filing, access and retention are per manual §14. **A note on media.** [KEN TO CONFIRM: whether these forms are run on paper, in a spreadsheet, or in a production system. This appendix is written as paper forms because a paper form can be signed at the bed and because ICC/MBI 1200 §503.2‡ requires a printed copy of the approved plan in the plant. If any form is run electronically, the manual must state how the electronic record is protected from alteration, how a signature is attributed to a person, and how a record is produced to an inspector who arrives without notice.] --- # PART 1. MATERIALS AND PURCHASING ## QF-01 Approved vendor and testing agency list | | | |---|---| | Governed by | Manual §5.2 | | Purpose | Names every supplier and every testing laboratory the plant is permitted to use, and states what each is approved for | | Completed by | Quality manager | | Signed by | Quality manager; reviewed at least annually and at each management review | | Filed | Quality manager's program file; a current copy at purchasing and at receiving | | Retention | Current issue plus 5 years of superseded issues | **Form layout** Header: `Issue no. ____ Issue date ____ Supersedes issue ____ Approved by ____` | # | Vendor or laboratory | Address | Contact and phone | Approved to supply or perform | Certification the vendor must furnish | Date approved | Approved by | Last review | Status | |---|---|---|---|---|---|---|---|---|---| | 1 | | | | Portland cement, type ____ | Cement mill report per lot | | | | Active / Suspended / Removed | | 2 | | | | Foam concentrate | Certificate of compliance, ASTM C869/C869M | | | | | | 3 | | | | Cold-formed studs, track, channel | Mill cert or cert of compliance, ASTM A1003/A1003M, ASTM C955 | | | | | | 4 | | | | Screws | ICC-ES evaluation report number | | | | | | 5 | | | | Basalt mesh | Manufacturer's certificate with tensile data | | | | | | 6 | | | | Lifting inserts | Published capacity data, evaluation report where one exists | | | | | | 7 | | | | HSS and plate for the skid | Mill test report, ASTM A500 / A36 / A572 | | | | | | 8 | | | | Testing laboratory: ASTM C495/C495M, C567/C567M, C157/C157M, E488/E488M | Accreditation certificate and scope | | | | | | 9 | | | | Calibration service | Traceability statement to nationally recognized standards | | | | | | 10 | | | | Fixtures, appliances, wiring devices, pipe and fittings | Listing and labeling | | | | | [KEN TO CONFIRM: every row. No vendor has been approved and no laboratory has been selected.] **Procedure of use** 1. A vendor is added only by the quality manager, and only after form QF-02 records the evidence of approval. 2. Purchasing issues an order for a quality-affecting material only to a vendor shown **Active** on the current issue of this list. 3. Receiving checks the vendor on this list at every delivery and rejects a delivery from a vendor not on it, under manual §5.6. 4. A vendor whose material has caused a nonconformance is either moved to **Suspended**, which blocks new orders, or is left Active with increased receiving inspection recorded on QF-02. 5. The quality manager reviews the whole list at least annually and at each management review, and reissues it with a new issue number whenever any row changes. 6. A change of cement source or of foaming agent supplier on this list triggers mix requalification under manual §6.3 before the material is used. --- ## QF-02 Vendor evaluation record | | | |---|---| | Governed by | Manual §5.2 | | Purpose | Records why a vendor was approved and how the vendor has performed | | Completed by | Quality manager | | Signed by | Quality manager | | Filed | One sheet per vendor, in the vendor file | | Retention | 5 years after the vendor is removed from QF-01 | **Form layout** | Field | Entry | |---|---| | Vendor | | | Material or service | | | Basis of initial approval | Certification reviewed / sample tested / qualification testing per QF-08 / prior performance / other: | | Evidence held | | | Date approved | Approved by | | Date | Order or delivery | Event: on-time / certification correct / nonconformance no. / complaint | Detail | Action taken | By | |---|---|---|---|---|---| | | | | | | | | Annual review date | Findings | Decision: retain / increase inspection / suspend / remove | Signed | |---|---|---|---| | | | | | **Procedure of use** 1. Open a sheet before a vendor is added to QF-01, and record the evidence relied on. 2. Record every delivery event that matters: a late delivery that forced a substitution request, a missing or wrong certification, a receiving rejection, a nonconformance traced to the vendor's material. 3. Cross-reference every nonconformance report number so that the vendor's record and the product's record point at each other. 4. Review annually, record the decision, and update QF-01 to match. --- ## QF-03 Incoming material receiving and inspection log | | | |---|---| | Governed by | Manual §5.3; ICC/MBI 1205 §502.1‡; MT-2 | | Purpose | Records the inspection of every delivery at the point of receipt, and the accept or reject decision | | Completed by | Receiver, then QC inspector | | Signed by | QC inspector; **countersigned by the quality manager on any reject** | | Filed | Receiving log book, chronological, cross-referenced to the certification index QF-04 | | Retention | 5 years from the release of the last product the lot was used in | **Form layout** Header: `Page ____ Month ____ Plant ____` | Date | Supplier | PO no. | Material and designation | Lot / heat / batch no. | Qty | Certification received (type and no.) | Checks performed (identity, marking, condition, damage, count) | Accept / Reject | Quarantine released to stock (date, initials) | Inspector | Quality manager (rejects only) | |---|---|---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | | | | | | | | | | | | | | | Standing check list printed on the reverse of the form, taken from manual §5.3: | Material | Checked at receipt | |---|---| | Cement | Type, supplier, date, no lumping or moisture damage; mill report present | | Foam concentrate | Product, batch, manufacture date, use-by date, container integrity; ASTM C869/C869M certificate present | | Studs, track, channel | Designation read off the member: web, flange, mil, grade; coating; straightness; count | | Basalt mesh | Product, grid, roll width, no damage or contamination; certificate present | | Screws | Type, size, point, coating; evaluation report number on the carton | | Lifting inserts | Type, size, rated capacity, manufacturer marking | | HSS and plate | Grade marking or heat number, size, straightness; mill test report present | | Fixtures and devices | Model against the bill of material, listing mark, damage, completeness | **Procedure of use** 1. Every delivery goes to the quarantine area and is entered on this log on the day it arrives. Nothing goes to stock before the inspection line is signed. 2. The receiver enters the delivery data and the certification received. The QC inspector performs the checks on the reverse, writes what was checked, and signs accept or reject. 3. On **accept**, the material is moved to stock, the release column is initialled and dated, and the certification is filed and indexed on QF-04. 4. On **reject**, the material is red-tagged and moved to the rejected material area, the quality manager countersigns, and QF-05 is opened. 5. Where the certification has not arrived with the delivery, the material stays in quarantine. It is **not** released to stock against a promise of a certificate. 6. Where a material with a shelf life is accepted, the lot is also entered on QF-06 the same day. --- ## QF-04 Material certification file index | | | |---|---| | Governed by | Manual §5.4 | | Purpose | Points to every mill report, certificate of compliance and evaluation report on file, and links each to the lots and the production orders it covers, so that traceability under §10.2 works in both directions | | Completed by | Quality manager | | Signed by | Quality manager | | Filed | Certification file | | Retention | 5 years from the release of the last product the lot was used in | **Form layout** | Index no. | Certificate type | Material | Supplier | Certificate or report no. | Date | Lot / heat covered | Received log ref. (QF-03 line) | Production orders the lot was used on | Filed location | |---|---|---|---|---|---|---|---|---|---| | | Mill report / cert of compliance / evaluation report / listing | | | | | | | | | **Procedure of use** 1. Index every certificate on the day it is filed. 2. Add the production order to the "orders used on" column each time the lot is drawn for an order, so that a recall or an investigation can go from a certificate to every panel it touched. 3. Screw and insert evaluation reports, and appliance listings, are indexed once and carried forward; the index row records the revision or issue date of the report so that a superseded report is detectable. 4. The index is checked at every internal audit by selecting a released serial number and tracing it back to every certificate. --- ## QF-05 Rejected material tag and disposition log | | | |---|---| | Governed by | Manual §5.6; ICC/MBI 1205 §502.3‡ | | Purpose | Segregates rejected material and tracks it to return, scrap or a non-product use, so that it cannot re-enter production | | Completed by | QC inspector | | Signed by | **Quality manager signs every disposition** | | Filed | Rejected material log | | Retention | 5 years | **Tag layout** (red card, wired to the material) ``` REJECTED - DO NOT USE - DO NOT RETURN TO STOCK Tag no. ______ Date ______ Material ______________________ Lot / heat ______________ Quantity ______________ QF-03 line ref. ______ Reason __________________________________________ Rejected by ______________ Location: rejected material area Removal from this area requires the quality manager's signature on QF-05. ``` **Log layout** | Tag no. | Date | Material and lot | Qty | Reason (failed receipt / failed at point of use / damaged in storage / past use-by) | Disposition: return to supplier / scrap / non-product use | Disposition date | Carrier or destination | Quality manager signature | NCR no. if product was affected | Vendor record QF-02 updated | |---|---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | **Procedure of use** 1. Tag the material at the moment of rejection, before it is moved. 2. Move it to the segregated rejected material area. Where it is too large to move, barricade and tag it in place and record the location on the log. 3. Enter the tag on the log the same day. 4. Material leaves the rejected area only on a signed disposition line. A verbal release is not a release. 5. Where rejected material had already been placed in product, open a nonconformance report QF-22 against that product and enter its number on this log. 6. Where the rejection reflects on a vendor, update QF-02. --- ## QF-06 Shelf life and stock rotation log | | | |---|---| | Governed by | Manual §5.5 item 8; MT-3 | | Purpose | Ensures material with a shelf life is used oldest first and is quarantined when it expires | | Completed by | Stores or yard lead | | Signed by | Quality manager at the monthly review | | Filed | At the material store, with the current page; completed pages to the program file | | Retention | 5 years | **Form layout** Header table, filled once from the manufacturers' data: | Material | Manufacturer's stated shelf life | Storage conditions required | Source of the figure | |---|---|---|---| | Portland cement | [KEN TO CONFIRM] | Dry, off the ground, covered | Manufacturer's data | | Foam concentrate | [KEN TO CONFIRM] | [KEN TO CONFIRM: temperature range, protect from freezing and sun] | Manufacturer's data | | Admixture, if used | [KEN TO CONFIRM] | | | | Sealants and adhesives | [KEN TO CONFIRM] | | | | Curing compound, if used | [KEN TO CONFIRM] | | | | Paint | [KEN TO CONFIRM] | | | Body: | Date received | Material | Supplier | Lot / batch | Qty | Manufacture date | Use-by date | Location in store | Date first drawn | Date exhausted | Quarantined as expired (date, initials) | |---|---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | Monthly review block: `Reviewed by ____ Date ____ Items within 30 days of expiry: ____ Action: ____` **Procedure of use** 1. Enter every shelf-life material on this log the day it is received, at the same time as the QF-03 entry. 2. Mark the container with the use-by date in a way that is readable at the mixer. 3. Draw stock oldest first. Record the date a container is first drawn. 4. The batch operator checks the use-by date at the mixer before charging foam concentrate or admixture, and writes the container batch number on the batch log QF-09. 5. The quality manager reviews this log monthly, quarantines anything expired under manual §5.6, and lists anything within 30 days of expiry so production can plan around it. --- # PART 2. CONCRETE ## QF-07 Mix design record | | | |---|---| | Governed by | Manual §6.1 | | Purpose | The approved proportions and controls for each mix. It is the document the batch operator batches to | | Completed by | Quality manager | | Signed by | Quality manager, **countersigned by the engineer of record** | | Filed | Appendix E of the manual; a laminated copy at the batch station | | Retention | While approved, and 5 years after it is superseded | **Form layout** | Field | Entry | |---|---| | Mix designation | M-35 / M-30 | | Used for | M-35: skin pour, cladding sheets, roof strip ground pour and top pour, floor panel. M-30: cavity fill | | Target fresh density | 35 pcf / 30 pcf | | **Acceptance band on fresh density** | **[PE TO SET: plus and minus, in pcf]** | | **Design compressive strength at 28 days** | **[PE TO SET: no C495 data exists]** | | Cement: type, source, proportion | [KEN TO CONFIRM] | | Water: source, proportion, temperature limits | [KEN TO CONFIRM] | | Foam concentrate: product, dilution, generator setting, foam density | [KEN TO CONFIRM] | | Admixture, if any: product and dose | [KEN TO CONFIRM] | | Batching sequence | [KEN TO CONFIRM] | | Mixing method and mixing time | [KEN TO CONFIRM; ACI 523.1R-06 §5.3 warns that excessive mixing may change density and consistency, so a maximum as well as a minimum is stated] | | Placing method and consolidation | [KEN TO CONFIRM: depends on the pump and mixer selected] | | Product curing method | [KEN TO CONFIRM; see §6.8] | | Specimen curing method, stated separately | **[PE TO SET]** | | Cold weather provision | Type III cement, or Type I with heated mixing water, when below 32 F is predicted within 8 hours of placement; no mixing or placing in freezing weather, rain or snow, or over standing water, snow or ice (ACI 523.1R-06 §5.7) | | Hot weather provision | [KEN TO CONFIRM; ACI 523.1R-06 §5.8 applies above 100 F] | | Qualification evidence | QF-08 reference no. | | Approval | Quality manager ____ date ____ ; Engineer of record ____ P.E. no. ____ date ____ | | Revision | Rev. ____ , supersedes Rev. ____ , document register QF-29 line ____ | **Procedure of use** 1. A mix is not used in production until this record is complete, the qualification on QF-08 is attached and both signatures are present. 2. The batch operator batches only to the current revision at the batch station. The operator has no authority to adjust proportions, and water is not added to improve workability. 3. Any change to any row is a new revision, requires requalification under manual §6.3 where the change is one of the triggers listed there, and goes through document control on QF-29. 4. The record is reissued to the batch station and the superseded copy withdrawn on the same day. --- ## QF-08 Mix qualification and requalification record | | | |---|---| | Governed by | Manual §6.2, §6.3 | | Purpose | Holds the evidence that a mix produces the target density and the required strength with the materials, equipment, methods and curing the plant actually uses, before it is used in production | | Completed by | Quality manager | | Signed by | Quality manager, and the engineer of record where the qualification supports a design value | | Filed | With the mix design QF-07 | | Retention | While the mix is approved, and 5 years after | **Form layout** | Field | Entry | |---|---| | Qualification no. | | | Mix | M-35 / M-30, revision | | Reason | Initial qualification / requalification, trigger: cement source / foaming agent / admixture / water source / mixing or foam equipment / proportions / test results (manual §6.3) | | Materials used: cement source and mill report no., foam concentrate product and lot, water source, admixture | | | Equipment used: mixer, foam generator, pump | | | Batching, mixing, placing and curing representative of production? | Yes / No, and how | | Test | Standard | Specimens | Date | Result | Criterion | Pass / Fail | |---|---|---|---|---|---|---| | Foaming agent compliance | ASTM C869/C869M | certificate | | | Compliant | | | Foaming agent with this cement and water | ASTM C796/C796M | | | | [PE TO SET] | | | Fresh density of the trial batch | ASTM C138/C138M | | | | Target ± [PE TO SET] | | | Compressive strength, 7 day | ASTM C495/C495M | 3 x 6 in, min. 3 | | | [PE TO SET] | | | Compressive strength, 28 day | ASTM C495/C495M | 3 x 6 in, min. 3 | | | [PE TO SET] | | | Hardened density | ASTM C567/C567M | | | | [PE TO SET] | | | Drying shrinkage | ASTM C157/C157M | 3 prisms | | | [PE TO SET] | | Conclusion block: `Mix qualified for production: Yes / No. Quality manager ____ date ____ Engineer of record ____ date ____` Laboratory reports attached: `list ____` **Procedure of use** 1. Open a record before the mix is first used, and again on every trigger listed in manual §6.3. 2. Run the qualification with the plant's own equipment, methods and curing environment, not with laboratory convenience batching. A qualification run under conditions the plant does not use proves nothing about the plant. 3. Attach every laboratory report. A result quoted without its report is not evidence. 4. Do not release the mix to production until the conclusion block is signed. 5. On a requalification, state plainly what changed and compare the new results to the previous qualification on the same form. --- ## QF-09 Daily batch and density log | | | |---|---| | Governed by | Manual §6.4, §6.6; ICC/MBI 1205 §501.7‡ | | Purpose | The record of every batch made, what went into it, where it was placed, and every density and temperature reading taken while it was placed | | Completed by | Batch and mixing operator; density and temperature columns by the QC technician | | Signed by | Batch operator and QC technician; reviewed and signed daily by the quality manager | | Filed | With the production order, by date | | Retention | 5 years from the release of the last product the batch was placed in | **Form layout** Header: `Date ____ Shift ____ Ambient temp. start ____ F Weather ____ Mix ____ Rev ____` Pre-run batching device check, manual §6.4 item 2: | Device | Check performed | Result | OK / Not OK | Initials | |---|---|---|---|---| | Scale E-1 | | | | | | Water meter E-2 | | | | | | Foam generator and nozzle E-3 | | | | | Batch body: | Batch no. | Time | Cement wt. | Water vol. | Foam vol. or generator setting | Foam concentrate lot | Admix. | Mixing time | Placed in (bed/slot or unit, and panel serial nos.) | Pour: skin / cladding / ground / top / fill | |---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | Density and temperature body, at the point of placement: | Time | Batch no. | Fresh density pcf (ASTM C138/C138M) | Acceptance band [PE TO SET] | In band? | Concrete temp. F | Ambient temp. F | Cylinders cast? (QF-10 set no.) | Technician | |---|---|---|---|---|---|---|---|---| | | | | | | | | | | Out-of-band block: | Time | Reading | Action taken | Placement stopped? | Panels affected (serial nos.) | NCR no. | Notified | |---|---|---|---|---|---|---| | | | | | | | | Footer: `Batch operator ____ QC technician ____ Quality manager review ____ date ____` **Procedure of use** 1. Complete the pre-run device check before the first batch of each production run. A device that fails is tagged out of service and no batching occurs on it. 2. Record every batch as it is made. The batch number is assigned sequentially within the day and is the link between the concrete and the panel: it is written on the traveler QF-13 of every panel the batch reaches. 3. Take a fresh density reading at the point of placement on the first placement of each batch and at intervals **not exceeding 30 minutes** while placing continues, following ACI 523.1R-06 §4.3 and §5.3. Record the reading, not a tick. 4. Record the concrete temperature and the ambient temperature at the same times, and record the weather whenever it is near the cold or hot weather limits at manual §6.9. 5. A reading outside the acceptance band **stops placement**. Complete the out-of-band block, check the batching devices, identify every panel the batch reached by serial number, and raise a nonconformance under manual §6.10 and §9. 6. Cast cylinders at the frequency the mix design and manual §6.6 require, at the same time as a density test, and cross-reference the QF-10 set number here. 7. The quality manager reviews and signs the log daily and files it with the order. --- ## QF-10 Cylinder cast and break log | | | |---|---| | Governed by | Manual §6.6; ASTM C495/C495M | | Purpose | Tracks every strength specimen from casting to result, and ties the result back to the concrete and to the panels it represents | | Completed by | QC technician; results entered by the quality manager | | Signed by | QC technician at casting; quality manager on the result | | Filed | Concrete records file, with the laboratory reports attached | | Retention | 5 years from the release of the last product the batch was placed in | **Form layout** | Set no. | Date cast | Time | Batch no. (QF-09) | Mix | Bed / slot or unit | Panel serial nos. represented | Cyls cast (no.) | Specimen mark | Fresh density at the time of casting (pcf) | Filling and consolidation method | Initial cure: covered, protected, ≥24 h (time in / out) | Transported to lab (date, by) | Technician | |---|---|---|---|---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | | | | Results: | Set no. | Test age | Date tested | Laboratory | Report no. | Result 1 | Result 2 | Result 3 | Average | Design strength [PE TO SET] | Pass / Fail | Action if fail (NCR no.) | Quality manager | |---|---|---|---|---|---|---|---|---|---|---|---|---| | | 7 day | | | | | | | | | | | | | | 28 day | | | | | | | | | | | | **Procedure of use** 1. Cast specimens at the same time as a density test, at the point of placement, and by the filling and consolidation method stated on the mix design, so that the specimen represents the product. This is not a formality with foam concrete: a specimen consolidated differently from the panel does not represent the panel. 2. Mark each cylinder with the set number, the date and the mix **before the concrete sets**. 3. Record the fresh density of the concrete the specimens were taken from, on this form as well as on QF-09, so that a low break can be read against the density it came from. 4. Cover and store the specimens in a protected area for at least 24 hours before transport, per ACI 523.1R-06 §4.3. 5. Record the transport and the laboratory. Attach every laboratory report to this log. 6. Enter each result on the day it is received. A **7 day result below expectation is acted on immediately** and is not left to be confirmed at 28 days. 7. A result below the design strength is a nonconformance against **every panel the batch was placed in**, identified from QF-09, and is handled under manual §6.10. 8. Overdue results are reviewed at each internal audit. A pending 28 day result on released product must be traceable to the engineer of record's written acceptance of early release recorded on QF-20. --- ## QF-11 Cure log | | | |---|---| | Governed by | Manual §6.8 | | Purpose | Proves the cure of the specific bed and slot a panel came out of, and controls the 7 day release rule | | Completed by | Production lead, daily | | Signed by | **QC inspector signs the release before any panel is stripped** | | Filed | With the production order | | Retention | 5 years | **Form layout** Header: `Bed ____ Cycle no. ____ Pour date ____ Pour complete time ____ Mix ____ Curing method ____` | Slot | Panel serial no. | Batch nos. placed | |---|---|---| | 1 | | | | 2 | | | | 3 | | | | 4 | | | | Day | Date | Time | Temp. at the bed F | Curing method maintained? (Y/N, note) | Enclosure or heat on? | Recorded by | |---|---|---|---|---|---|---| | 0 (pour) | | | | | | | | 1 | | | | | | | | 2 | | | | | | | | 3 | | | | | | | | 4 | | | | | | | | 5 | | | | | | | | 6 | | | | | | | | 7 | | | | | | | Release block: | Check | Entry | |---|---| | Seven days elapsed from pour completion | Yes / No, date and time of the 7 day point | | Every daily temperature within the accepted range | Yes / No; exceptions listed | | Alternative release on cylinder strength, if the engineer of record has set one | [PE TO SET: not available today; the 7 day rule governs] | | Released for stripping | QC inspector ____ date ____ time ____ | **Procedure of use** 1. Open a cure log for every bed cycle at the moment the pour is complete. 2. Record the temperature at the bed at least once each day, from a calibrated instrument on the calibration register. 3. **No panel is stripped until the release block is signed.** Stripping without that signature is a nonconformance against the panel. 4. Where a day's temperature falls outside the accepted range, note it, notify the quality manager, and hold the panels pending the disposition at manual §9. Do not sign the release. 5. File the cure log with the production order and cross-reference it from each panel's traveler. --- # PART 3. PRODUCTION ## QF-12 Daily production log | | | |---|---| | Governed by | Manual §4.3 | | Purpose | The plant's day book: what was made, in which bed and slot, and every problem or deficiency found and what was done about it | | Completed by | Plant manager or production lead | | Signed by | Production lead, reviewed and signed by the quality manager | | Filed | Production log book, chronological | | Retention | 5 years | **Form layout** Header: `Date ____ Shift ____ Crew present ____ Weather ____` | Time | Station | Activity | Order / model | Serial nos. worked | Qty | Notes | |---|---|---|---|---|---|---| | | | | | | | | Problems and deficiencies found today: | Time | What was found | Where / serial nos. | Action taken | NCR raised? no. | By | |---|---|---|---|---|---| | | | | | | | Downtime, equipment and visitors: | Item | Detail | |---|---| | Equipment out of service | | | Third-party inspection agency visit | Inspector, times, areas seen, report no. | | Bureau visit | | | Other visitors with plant access | | Footer: `Production lead ____ Quality manager review ____ date ____` **Procedure of use** 1. One log per production day, opened at the start of the shift. 2. The "problems and deficiencies" block is completed **even when the problem was fixed on the spot**. A problem that is only fixed and never recorded is a problem that will recur and that no audit can see. 3. Record every visit by the third-party inspection agency or the bureau, with the report number if one is issued. 4. The quality manager reviews and signs each day's log and follows up any entry that should have produced a nonconformance report but did not. --- ## QF-13 Panel and unit traveler, in-process station sign-off sheet | | | |---|---| | Governed by | Manual §7.1; ICC/MBI 1205 §501.8‡ | | Purpose | The single sheet that travels with each panel, strip, floor panel, cladding sheet or unit and carries every station sign-off, including every hold point. It is the primary record of conformance for that item | | Completed by | Each station's crew and inspector, on their own line | | Signed by | Each named signer on their own line; closed by the quality manager at release | | Filed | With the production order, filed by serial number | | Retention | 5 years from release | **Form layout** Header block: | Field | Entry | |---|---| | Serial number | | | Item type | Wall panel / cladding sheet / roof strip / floor panel / shower house unit | | Model and model number | | | Order no. | Customer | | Drawing set and revision built to | (from QF-29) | | Bed and slot | Cycle no. | | Pour date and time | Batch nos. placed | | Cure log ref. | QF-11 cycle | | Panel height and width, as designed | | Station lines: | # | Station | Work performed | Inspection | Form | Result | HOLD | Name (print) | Signature | Date | |---|---|---|---|---|---|---|---|---|---| | 1 | Bed preparation | | Bed and form check | QF-14 | Pass / Fail | | | | | | 2 | Steel placement | | Steel, mesh, embedment | QF-15 | Pass / Fail | | | | | | 3 | Lifting inserts | | Insert placement | QF-16 | Pass / Fail | **HOLD** | | | | | 4 | Pre-pour | | Completeness, drawing revision, weather | this form | Pass / Fail | **HOLD** | | | | | 5 | Pour | | Placement, density, specimens | QF-09, QF-10 | | | | | | | 6 | Cure | | Cure complete, 7 days | QF-11 | Released | **HOLD** | | | | | 7 | Strip | | Handling, damage | QF-17 | | | | | | | 8 | Dimensional and surface | | Measured values recorded | QF-17 | Pass / Fail | | | | | | 9 | Assembly (unit only) | | Skid, floor, walls, roof | QF-18 | Pass / Fail | | | | | | 10 | MEP rough-in (unit only) | | Before cavity fill | QF-18 | Pass / Fail | **HOLD** | | | | | 11 | Cavity fill and close (unit only) | | Fill density | QF-09 | | | | | | | 12 | Systems tests (unit only) | | Electrical, water, DWV, fixtures | QF-19 | Pass / Fail | | | | | | 13 | Final inspection and release | | §11.1 checklist | QF-20 | Released | **HOLD** | Quality manager | | | Nonconformance block: | NCR no. | Raised at station | Characteristic | Disposition | Re-inspected (station, date, by) | Closed | |---|---|---|---|---|---| | | | | | | | Label block: | Item | Number | Date applied | Applied by | |---|---|---|---| | Third-party agency certification label (components) | | | | | Montana insignia (units) | | | | | Permanent serial number marking | n/a | | | **Procedure of use** 1. The quality manager opens a traveler for every item when the order is released, with the serial number already assigned from QF-28. 2. The traveler stays with the item, or at the item's station in a controlled holder. It is not kept in the office. 3. Each station's signer signs **their own line, by their own hand, after the work and the inspection are done.** Signing another person's line, or signing in advance, is falsification of a quality record. 4. **At a HOLD line the item does not advance until that line is signed.** Any person may stop an item; only the named signer may release it. 5. Where a nonconformance is raised, enter it in the nonconformance block, and record the disposition and the re-inspection when they happen. The traveler carries the item's whole history, including its failures. 6. The quality manager closes the traveler at release, records the labels applied, and files it with the order. 7. A traveler with an unsigned line cannot be closed and the item cannot be released. --- ## QF-14 Bed and form check | | | |---|---| | Governed by | Manual §7.2 | | Purpose | Verifies the slot, the forms, the end board and the liner before any steel is placed, because none of it can be checked after the pour | | Completed by | QC inspector | | Signed by | QC inspector | | Filed | With the production order, attached to the travelers of the panels cast in the cycle | | Retention | 5 years | **Form layout** Header: `Bed ____ Cycle no. ____ Date ____ Panels to be cast: slot 1 ____ slot 2 ____ slot 3 ____ slot 4 ____ (serial nos.)` | Characteristic | How measured | Criterion | Slot 1 | Slot 2 | Slot 3 | Slot 4 | |---|---|---|---|---|---|---| | Slot length, end A | Tape | [PE TO SET] | | | | | | Slot length, end B | Tape | [PE TO SET] | | | | | | Slot width, end A / mid / end B | Tape | [PE TO SET] | | | | | | Movable end board position (cut panels) | Tape from the fixed end | [PE TO SET] | | | | | | Edge form straightness | Straightedge | [PE TO SET] | | | | | | Edge form plumb and height | Level and rule | [PE TO SET] | | | | | | Bed and liner flatness | Straightedge over [PE TO SET] length | [PE TO SET] | | | | | | Liner condition | Visual: tears, wrinkles, debris, cured residue | Free of any defect that prints through to the finish face | | | | | | Release agent | Visual: correct product, even, not on mesh or steel bearing positions | Per the manufacturer's instructions | | | | | | Slot clean and dry | Visual | Free of debris, water, ice and snow | | | | | Footer: `All slots accepted for steel placement: Yes / No. Exceptions and action: ____ QC inspector ____ date ____ time ____` **Procedure of use** 1. Perform the check after the bed is set up and **before any steel, mesh or embedment is placed**. A check made after the steel is in cannot see the liner. 2. Write the measured value in each cell. A tick is not a measurement. 3. Where a slot fails, it is not used until it is corrected and re-checked on a new line of this form. 4. Attach the completed form to the cycle's travelers, so that each panel's record shows the bed it was cast in. 5. Until the [PE TO SET] criteria exist, the inspector records the measured values and refers any doubt to the quality manager; no slot is accepted against a criterion that has not been set. --- ## QF-15 Mesh and embedment placement check | | | |---|---| | Governed by | Manual §7.3, §7.4, §7.5 | | Purpose | Verifies the steel, the mesh and every embedded item before the pour | | Completed by | QC inspector | | Signed by | QC inspector | | Filed | With the panel's traveler | | Retention | 5 years | **Form layout** Header: `Serial no. ____ Bed / slot ____ Drawing and revision ____ Date ____` Steel: | Characteristic | Method | Criterion | Measured / observed | OK | |---|---|---|---|---| | Stud designation, read off the member | Read marking | Matches bill of material | | | | Stud count | Count | Per drawing | | | | Stud spacing, cumulative from one end | Tape | 16 in o.c., tolerance [PE TO SET] | | | | Stud straightness and flange orientation | Visual, straightedge | No permanent deformation; per drawing | | | | Track at top and bottom: designation and engagement | Read marking, visual | Per drawing | | | | Jambs, headers, sills, cripples at each opening | Count and position | Per panel schedule | | | | Opening size and position, each opening | Tape, both dimensions and both offsets | [PE TO SET] | | | | Channel rows: position from panel end | Tape | 48 in o.c. from 12 in, or per drawing | | | | Spacer blocks at each channel-to-stud crossing | Count | One at every crossing | | | | Screws channel-to-stud, stud-to-track: type and count | Read carton, count | Per detail; counts [PE TO SET] | | | | Steel clean | Visual | Free of oil, mud, ice, release agent where bond is required | | | Mesh: | Characteristic | Method | Criterion | Measured / observed | OK | |---|---|---|---|---| | Mesh product against the bill of material | Label | Match | | | | Position through the thickness | Measured from the liner face | [PE TO SET] | | | | Coverage over the panel and at openings | Visual | Continuous, trimmed to the opening | | | | Lap length at every mesh joint | Tape | [PE TO SET] | | | | Support and restraint against floating | Visual | Held | | | | Contamination | Visual | Clean | | | Embedments: | Item | Position from datum 1 | Position from datum 2 | Criterion [PE TO SET] | Sealed and restrained | OK | |---|---|---|---|---|---| | Sleeve 1 | | | | | | | Sleeve 2 | | | | | | | Floor drain 1 (floor panel) | | | | | | | Blockout 1 | | | | | | | Cast-in electrical box 1 | | | | | | Footer: `Accepted for insert check and pre-pour: Yes / No. Exceptions: ____ QC inspector ____ date ____` **Procedure of use** 1. Perform after the steel, mesh and embedments are placed and before the lifting insert check. 2. Read every steel designation **off the member**, not off the bundle label and not from memory. 3. Write measured positions for every embedment. For the shower house floor panel the drains, slopes and sleeves are the items that can never be corrected and can never be inspected at the site, so they get a measured value each, not a tick. 4. Where any line fails, the item does not advance; the failure goes to the quality manager and, if the condition cannot be corrected before the pour, a nonconformance is raised. 5. Attach to the panel's traveler. --- ## QF-16 Lifting insert placement check. HOLD POINT. | | | |---|---| | Governed by | Manual §7.6 | | Purpose | The highest consequence placement check in the plant. A misplaced or wrong insert is a dropped pick | | Completed by | QC inspector | | Signed by | QC inspector, as a hold point on the traveler | | Filed | With the item's traveler | | Retention | 5 years | **Form layout** Header: `Serial no. ____ Item: roof strip / floor panel / other ____ Drawing and revision ____ Insert schedule ref. ____ Date ____` `Design pick weight ____ lb Number of inserts ____ Per-insert share ____ lb Required capacity [PE TO SET] ____` | Insert ID | Type and size marked on the insert | Matches schedule | Position from datum 1 | Position from datum 2 | Tolerance [PE TO SET] | Embedment depth | Required embedment [PE TO SET] | Perpendicular | Positively restrained | OK | |---|---|---|---|---|---|---|---|---|---|---| | 1 | | | | | | | | | | | | 2 | | | | | | | | | | | | 3 | | | | | | | | | | | | 4 | | | | | | | | | | | | 5 | | | | | | | | | | | | 6 | | | | | | | | | | | | 7 | | | | | | | | | | | | 8 | | | | | | | | | | | Pre-pick block, completed later, before the item is lifted: | Check | Entry | |---|---| | Concrete condition required before the insert is loaded | [PE TO SET] | | Cure log released (QF-11) | Yes / No, date | | Cylinder result relied on, if any | QF-10 set no., result | | Rigging inspected | By ____ date ____ | | Pick authorised | Quality manager ____ date ____ | Footer: `HOLD POINT SIGNED: insert placement accepted. QC inspector ____ date ____ time ____` **Procedure of use** 1. Perform after QF-15 and **before the pre-pour hold point**. Nothing is poured over an unsigned insert check. 2. Write the measured position of **every** insert. Inserts are not sampled. 3. No substitution of insert type is permitted at the bed. A different insert is a design change under manual §3.2. 4. The pre-pick block is completed before the item is lifted for the first time, and the quality manager authorises the pick. 5. Until the engineer of record has set the insert type, its capacity in 35 pcf cellular concrete established by ASTM E488/E488M pull-out testing in this plant's concrete, the required embedment and the safety factor, **no item may be picked on cast-in inserts.** This form records that the values are not yet set. --- ## QF-17 Panel dimensional and surface inspection | | | |---|---| | Governed by | Manual §7.9, §7.10 | | Purpose | Records the as-built dimensions and the surface condition of each panel after stripping, against the acceptance criteria | | Completed by | QC inspector | | Signed by | QC inspector | | Filed | With the panel's traveler | | Retention | 5 years | **Form layout** Header: `Serial no. ____ Type ____ Design length ____ Design width ____ Design thickness ____ Date stripped ____ Date inspected ____` Dimensional: | Characteristic | Measurement points | Measured | Criterion [PE TO SET] | OK | |---|---|---|---|---| | Length | Edge A / centreline / edge B | | | | | Width | End 1 / mid / end 2 | | | | | Overall thickness | Four corners and centre | | | | | Skin thickness at the edge | Four edges | | | | | Squareness | Diagonal 1 / diagonal 2 / difference | | | | | Bow, out of plane | Straightedge full length | | | | | Bow, in plane | Straightedge full length | | | | | Twist | Four corner method | | | | | Face flatness of the finish face | Straightedge over [PE TO SET] length, worst gap | | | | | Opening 1 size and position | Both dimensions, both offsets | | | | | Opening 2 size and position | | | | | | Insert position as built | From two datums | | | | Surface, finish face and cavity face: | Defect class | Found? | Location and extent (sketch on the reverse) | Criterion [PE TO SET] | Accept / Repair / Nonconforming | |---|---|---|---|---| | Cracks: width, length, through-thickness | | | | | | Voids and bugholes on the finish face | | | | | | Edge and corner damage | | | | | | Honeycomb or segregation | | | | | | Exposed mesh | | | | | | Insert or embedment displacement | | | | | | Finish face texture against the reference panel | | | | | Repair block: | Repair no. | Defect | Repair procedure ref. | Material | Date | By | Re-inspected (date, by) | Accepted | |---|---|---|---|---|---|---|---| | | | | | | | | | Footer: `Result: Accept / Repair and re-inspect / Nonconforming (NCR no. ____). QC inspector ____ date ____` **Procedure of use** 1. Inspect every panel after stripping. The frequency is each panel, not a sample, until the engineer of record and the third-party inspection agency agree in writing to a sampling plan. 2. **Write the measured value in every dimensional cell.** The cumulative run tolerance across a wall of panels can only be managed if individual widths are recorded as numbers. 3. Compare the finish face against the accepted reference sample panel kept in the plant. Where no reference panel exists, the inspection is recorded and the panel is held, because there is nothing to compare it to. 4. A defect within the repairable class is repaired only by the written repair procedure, and is re-inspected against the same criterion. 5. A defect outside the repairable class, or any insert or embedment displaced beyond tolerance, is a nonconformance under manual §9 and the disposition is the quality manager's, with the engineer of record's written concurrence where the characteristic is structural. 6. Sketch defect locations on the reverse and, where the defect will inform the acceptance criteria that do not yet exist, photograph it and file the photograph with this form. --- ## QF-18 Shower house assembly and MEP rough-in inspection | | | |---|---| | Governed by | Manual §7.11, §7.12 | | Purpose | Records the assembly of the unit and the rough-in inspection that must happen before the cavity fill conceals it permanently | | Completed by | QC inspector | | Signed by | QC inspector; the rough-in section is a hold point | | Filed | With the unit's traveler | | Retention | 5 years | **Form layout** Header: `Unit serial no. ____ Model and model number ____ Order ____ Drawing set and revision ____` Section 1, skid: | Characteristic | Criterion | Measured / observed | OK | |---|---|---|---| | Member sizes and grades against the drawing | [PE TO SET: the sizes are placeholders today] | | | | Weld visual inspection to AWS D1.1/D1.1M | [PE TO SET: acceptance level and any NDE required] | | | | Lug plate size, position, weld | [PE TO SET] | | | | Lug proof load performed and recorded | [PE TO SET: value] | | | | Fork pocket position, spacing and reinforcement | [PE TO SET] | | | | Tie-down points | Per drawing | | | | Surface preparation and paint or galvanizing | Per specification | | | Section 2, floor panel on the skid: | Characteristic | Criterion | Measured / observed | OK | |---|---|---|---| | Floor panel serial number | Matches the order | | | | Bearing on runners and cross members | Per drawing | | | | Position and squareness on the skid | [PE TO SET] | | | | Drain and sleeve positions verified before anything covers them | QF-15 values re-verified | | | Section 3, walls, partitions and roof: | Characteristic | Criterion | Measured / observed | OK | |---|---|---|---| | Panel serial numbers against the key plan | Exact match | | | | Panel plumb, each panel | [PE TO SET] | | | | Joint gap, each joint | [PE TO SET] | | | | Joint screws: type, count, pattern, each joint | [PE TO SET] | | | | Bottom track anchorage to the floor panel or skid | [PE TO SET] | | | | Demising panel and partitions | Per drawing | | | | Roof strips set, bearing, connection to the top track | Per drawing | | | | Roof top pour and membrane | Per specification | | | | Outside width over cladding and over the roof edge | Not more than 168 in | | | | Overall length and height | Per drawing and §12.5 | | | Section 4, MEP rough-in. **HOLD POINT, before any cavity fill:** | Characteristic | Code basis | Observed | OK | |---|---|---|---| | DWV pipe and fittings against the approved plumbing plan | UPC 2021, ARM 24.301.301 | | | | Water supply pipe and fittings against the approved plan | UPC 2021 | | | | Pipe supports and protection where pipe passes through cast sleeves | UPC 2021 | | | | Trap primers and cleanouts | UPC 2021 | | | | Water heater and heater connections roughed | UPC 2021, NEC 2020 | | | | Conduit, boxes and conductors against the approved electrical plan | NEC 2020, ARM 24.301.401, Montana amendments to 210.8(A), 210.8(B), 210.12 | | | | Bonding and grounding, including the metal skid where required | NEC 2020 | | | | Sleeve penetrations sealed | Approved detail | | | | Water supply pressure test complete and passed (QF-19) | §8.3 | | | | DWV test complete and passed (QF-19) | §8.4 | | | | Electrical continuity and grounding checks complete (QF-19) | §8.1 | | | | Third-party inspection agency notified of the hold point | Agency agreement | | | Hold point signature: `MEP rough-in accepted, cavity fill authorised. QC inspector ____ date ____ time ____` Section 5, cavity fill: `Fill date ____ Batch nos. ____ Density readings: see QF-09 Fill complete and verified by ____` **Procedure of use** 1. Complete sections 1 to 3 as the assembly proceeds, not retrospectively. 2. **Section 4 is a hold point. No cavity fill is pumped until it is signed.** The fill is irreversible and it permanently conceals work that a site inspector will never see. 3. The pressure and continuity tests named in section 4 are performed and recorded on QF-19 **before** the hold point is signed, not after. 4. Notify the third-party inspection agency of the hold point in accordance with the agency agreement and record the notification. 5. Where any line fails, the item does not advance and a nonconformance is raised. --- ## QF-19 In-plant systems test record | | | |---|---| | Governed by | Manual §8.1 to §8.5; Montana bureau list item MT-10 | | Purpose | The record of the electrical, gas, water supply, drain-waste-vent and fixture tests Montana names explicitly. Applies to the shower house; not to house wall panels, which leave the plant with no plumbing and no wiring | | Completed by | QC inspector, with the licensed electrician and plumber where the work is licensed work | | Signed by | QC inspector and the licensed tradesperson who performed the work | | Filed | With the unit's traveler | | Retention | 5 years | **Form layout** Header: `Unit serial no. ____ Model ____ Date(s) of test ____ Codes: NEC 2020 (ARM 24.301.401, MT amendments 210.8(A), 210.8(B), 210.12); UPC 2021 (ARM 24.301.301); IFGC 2021 (ARM 24.301.173) if gas is present` **1. Electrical** | Test | Equipment used (from QF-21) | Stage: rough-in / final | Result | Criterion | Pass | |---|---|---|---|---|---| | Branch circuit continuity and identification, each circuit | | | | All circuits correct | | | Equipment grounding conductor continuity to every device, box and appliance | | | | Continuous | | | Bonding of water piping and of the metal skid where required | | | | Bonded | | | Receptacle polarity and ground, every receptacle | | | | Correct | | | GFCI operation, every device and protected outlet, tested with an instrument | | | | Trips | | | AFCI operation where required by the amended 210.12 | | | | Trips | | | Insulation resistance, if adopted | | | | [KEN TO CONFIRM: applied voltage and minimum value] | | | Operational test: every luminaire, fan, heater, water heater, receptacle | | | | Operates | | Circuit schedule (one line per circuit): `Ckt no. | Description | OCPD | Conductor | GFCI/AFCI | Continuity | Polarity | Operated | Initials` **2. Gas line** `No fuel gas piping or fuel gas appliance is installed in this unit: Yes / No` If **No**, complete: | Test | Equipment | Test pressure | Duration | Start reading | End reading | Criterion | Pass | |---|---|---|---|---|---|---|---| | Fuel gas piping pressure test per the adopted IFGC 2021 | | [KEN TO CONFIRM: read from the adopted code] | [KEN TO CONFIRM] | | | No pressure drop | | **3. Water supply** | Test | Equipment | Test pressure | Duration | Start | End | Criterion | Pass | |---|---|---|---|---|---|---|---| | Rough-in pressure test, before concealment | | [KEN TO CONFIRM: from the adopted UPC 2021] | [KEN TO CONFIRM] | | | No loss | | | Final pressure test after fixtures | | | | | | No loss | | | Item | Observed | Pass | |---|---|---| | Every joint inspected visually before concealment | | | | Pipe supports and protection at cast sleeves | | | | Water heater connections | | | | Tempering or mixing device installed and set | [KEN TO CONFIRM: maximum delivered temperature and the device] | | | Delivered water temperature measured at the furthest fixture | ____ F | | **4. Drain, waste and vent** | Test | Equipment | Test head or pressure | Duration | Start | End | Criterion | Pass | |---|---|---|---|---|---|---|---| | DWV test per the adopted UPC 2021, before concealment | | [KEN TO CONFIRM: from the adopted code] | [KEN TO CONFIRM] | | | No loss | | | Item | Observed | Pass | |---|---|---| | Every joint inspected | | | | Grade of drainage piping | | | | Trap arm lengths | | | | Vent sizing and termination | | | | Sleeves through the cast floor panel, and their seals | | | | Floor drain bodies, clamping rings, and the floor slope to each drain | | | **5. Fixtures** | Fixture | Model against bill of material | Filled and drained | Trap seal proved | Operated through a full cycle | Stops and valves operated | No leaks under running conditions | Mounting and sealing | Accessible heights, clearances and grab bars (accessible rooms) | Initials | |---|---|---|---|---|---|---|---|---|---| | Shower, room 1 | | | | | | | | | | | Water closet, room 1 | | | | | | | | | | | Lavatory, room 1 | | | | | | | | | | | Shower, room 2 | | | | | | | | | | | Water closet, room 2 | | | | | | | | | | | Lavatory, room 2 | | | | | | | | | | | Floor drains | | | | | | | | | | | Hose bib | | | | | | | | | | | Water heater | | | | | | | | | | Footer: `All systems tests passed: Yes / No. Failures: NCR no. ____ QC inspector ____ date ____ Licensed electrician ____ licence no. ____ Licensed plumber ____ licence no. ____` **Procedure of use** 1. Perform the rough-in tests **before any concealment**, including before the cavity fill, and record them here before the QF-18 hold point is signed. 2. Perform the final tests after fixtures and devices are installed, before the final inspection at QF-20. 3. Record the actual test pressure, the duration and the start and end readings. "Passed" without readings is not a test record. 4. Record the identification of every instrument used, from the calibration register QF-21, so that a test can be re-examined if the instrument is later found out of calibration. 5. Any failure is a nonconformance under manual §9. The re-test after correction is recorded on a new line, not by altering the failed line. 6. The gas section is completed as "no gas piping installed" on every current model. It is not deleted, so that the record shows the question was asked. --- ## QF-20 Final unit inspection and release record | | | |---|---| | Governed by | Manual §11; ICC/MBI 1205 §503.2‡ | | Purpose | The single record that a unit or a lot of components met every requirement and was released. It is also the record Montana's published list requires, substantiating that each unit was inspected and complies with the reviewed plans | | Completed by | Quality manager | | Signed by | **Quality manager only** | | Filed | With the order, with the traveler attached | | Retention | 5 years | **Form layout** Header: `Serial no(s). ____ Item type ____ Model and model number ____ Order and customer ____ Drawing set and revision ____ Date ____` | # | Check | Evidence | Yes / No | Note | |---|---|---|---|---| | 1 | Traveler QF-13 complete, every station line signed, every hold point signed by the named signer | QF-13 | | | | 2 | Every nonconformance closed, disposition signed, re-inspection recorded | QF-22 | | | | 3 | Batch log entries present for all concrete in the item | QF-09 | | | | 4 | All density readings within the acceptance band, or out-of-band dispositioned | QF-09 | | | | 5 | Cylinder results available and acceptable, or 28 day result pending with the engineer of record's written acceptance of release attached | QF-10 | | | | 6 | Cure log complete and released | QF-11 | | | | 7 | Dimensional and surface inspection complete and within criteria | QF-17 | | | | 8 | Systems tests complete and passed (units) | QF-19 | | | | 9 | Fixtures, appliances and finishes match the bill of material and the approved plans (units) | Bill of material | | | | 10 | Overall dimensions and weight within the transport limits | §12.5 | | | | 11 | Third-party inspection agency inspection occurred at the required frequency; every deficiency in the agency report closed | Agency report no. | | | | 12 | Serial number correct and recorded in the register | QF-28 | | | | 13 | Insignia or certification label available and assigned | QF-27 | | | | 14 | Documents to be issued with the product are prepared | §11.4 | | | Release block: | Item | Entry | |---|---| | Insignia number applied (unit) | Date applied, by | | Certification label number applied (component) | Date applied, by | | Permanent serial marking applied | Date, by | | Data plate applied (unit) | Date, by | | Documents issued: installation instructions, transport and lifting instructions, key plan and panel schedule, manifest, owner information | Listed | | **RELEASED FOR SHIPMENT** | Quality manager signature ____ printed ____ date ____ time ____ | **Procedure of use** 1. No item is loaded, shipped, offered for sale or delivered before this form is signed. 2. Every "No" stops the release. A "No" is not overridden by a note; it is resolved, or the item stays. 3. Item 5 is the only place early release is possible, and only on the engineer of record's **written** acceptance attached to this form. A verbal acceptance is not acceptance. 4. The release signature is the quality manager's alone. If the quality manager performed production work on the item, manual §2.3 independence rule 2 applies and the item is held until a qualified independent signer is available. 5. File this form with the traveler attached. Together they are the item's complete conformance record. --- # PART 4. EQUIPMENT AND PROGRAM ADMINISTRATION ## QF-21 Calibration register | | | |---|---| | Governed by | Manual §8.8; ICC/MBI 1205 §501.14‡ | | Purpose | Every instrument whose reading is used to accept product, its interval, its status and the traceability of its calibration | | Completed by | Quality manager | | Signed by | Quality manager | | Filed | Program file; a status board at the test station | | Retention | 5 years, and the full history of any instrument still in service | **Form layout** | ID | Instrument | Make, model, serial | Range and resolution | Used for (manual §) | Interval | Last calibration date | Calibrated by | Certificate no. | Traceability statement on file | Next due | Status: In service / DO NOT USE | |---|---|---|---|---|---|---|---|---|---|---|---| | E-1 | Batching scale | | | §6.4 | Annual **and before the first run of each project** | | | | | | | | E-2 | Water meter | | | §6.4 | Annual and before each project | | | | | | | | E-3 | Foam metering nozzle | | | §6.4 | Annual and before each project | | | | | | | | T-1 | Density measure and balance | | | §6.6 | [KEN TO CONFIRM] | | | | | | | | T-3 | Thermometers | | | §6.6, §6.9 | [KEN TO CONFIRM] | | | | | | | | T-4 | Cure temperature recorder | | | §6.8 | [KEN TO CONFIRM] | | | | | | | | T-5 | Steel tapes used for acceptance | | | §7.2, §7.9 | [KEN TO CONFIRM] | | | | | | | | T-6 | Straightedge and feelers | | | §7.9 | [KEN TO CONFIRM] | | | | | | | | T-8 | Depth gauge or caliper | | | §7.9 | [KEN TO CONFIRM] | | | | | | | | T-12 | Receptacle tester, GFCI and AFCI | | | §8.1 | [KEN TO CONFIRM] | | | | | | | | T-13 | Digital multimeter | | | §8.1 | [KEN TO CONFIRM] | | | | | | | | T-15 | Plumbing test gauge | | | §8.3, §8.4 | [KEN TO CONFIRM] | | | | | | | Out-of-calibration finding block, required by manual §8.8 item 4: | Date found | Instrument | How found | Last good calibration | Product accepted using this instrument since that date (serial nos.) | Evaluation of that product | NCR no. | Disposition | Quality manager | |---|---|---|---|---|---|---|---|---| | | | | | | | | | | **Procedure of use** 1. Every instrument used to accept product is on this register before it is used. An instrument not on the register may not be used for an acceptance measurement. 2. Calibration is performed by an outside service or the manufacturer, traceable to nationally recognized standards, and the certificate is filed and referenced here. 3. The batching devices are additionally checked before the first batch of each production run, per ACI 523.1R-06 §5.2, and that check is recorded on QF-09, not here. 4. An instrument past its due date is tagged **DO NOT USE** and removed from service that day. 5. **When an instrument is found out of calibration, the out-of-calibration block is mandatory.** The quality manager identifies every product accepted with that instrument since its last good calibration, evaluates it, and dispositions it under §9. Recalibrating the instrument does not close the finding. 6. The register is reviewed at every internal audit against the instruments actually on the floor. --- ## QF-22 Nonconformance report | | | |---|---| | Governed by | Manual §9 | | Purpose | Identifies nonconforming product, holds it, and records the disposition and the re-inspection | | Completed by | QC inspector opens it; quality manager dispositions it | | Signed by | Quality manager; engineer of record where §9.2 requires | | Filed | NCR file, numbered sequentially; number entered on the item's traveler | | Retention | 5 years from closure | **Form layout** | Field | Entry | |---|---| | NCR no. | Date raised | | Raised by | Station | | Item: serial number(s) | Model, order | | Quantity affected | | | Characteristic | | | Requirement (drawing, specification, manual section, criterion) | | | **Actual condition, as measured** | | | How found | Routine inspection / audit / agency report / customer / other | | Related records | QF-09 batch no., QF-10 set no., QF-11 cycle, QF-15, QF-16, QF-17, material lot, QF-21 instrument | | Item held: location and tag no. | | Disposition: | Disposition | Detail | Signature | |---|---|---| | Use as is | Justification. **Engineer of record's written concurrence required where the characteristic is structural, dimensional beyond tolerance, or affects density, strength, insert capacity or anchorage** | QM ____ EOR ____ | | Rework | What is to be done | QM ____ | | Repair | Repair procedure reference and material. EOR concurrence where structural or beyond the repairable class | QM ____ EOR ____ | | Scrap | Method of destruction; serial number voided on QF-28 | QM ____ | Re-inspection: | Re-inspection performed | Against which criterion and form | Result | By | Date | |---|---|---|---|---| | | | | | | Closure: | Field | Entry | |---|---| | Corrective action required? | Yes, CAR no. ____ / No, reason ____ | | Product already released affected? | Yes: serial nos., customer notified (date), agency notified (date) / No | | Closed | Quality manager ____ date ____ | **Procedure of use** 1. Anyone who finds or suspects a nonconformance stops the item and notifies the QC inspector. The QC inspector opens this report and tags and moves the item to the hold area. 2. Record the **measured actual condition**, not "out of tolerance". The measured value is what lets the engineer of record disposition it. 3. The quality manager signs the disposition, and does not disposition work they performed themselves. 4. Rework and repair are re-inspected against the original criterion by the original inspection, and the result is recorded here and on the traveler. 5. Scrapped items are destroyed or defaced so they cannot re-enter production, and the serial number is voided on QF-28 so it can never appear on a label or an insignia application. 6. Where released product is affected, the customer and the third-party inspection agency are notified immediately and the notification dates are recorded here. 7. Review every open NCR at each internal audit; review the set of them for pattern. --- ## QF-23 Corrective action report (POCA) | | | |---|---| | Governed by | Manual §2.9; ICC/MBI 1205 §501.10‡ | | Purpose | The plan of corrective action: investigation, cause, correction, corrective action, verification and closure | | Completed by | Quality manager | | Signed by | Quality manager on the action; **owner on the closure** | | Filed | CAR file, numbered sequentially | | Retention | 5 years from closure | **Form layout** | Field | Entry | |---|---| | CAR no. | Date opened | | Source | Repeated NCR / NCR on released product / internal audit finding / agency deficiency / bureau finding / customer complaint / quality manager judgment | | Reference | NCR nos., audit report no., agency report no., complaint no. | | Statement of the problem | | | Product affected, serial nos. | | | **Investigation** | What was examined, what the evidence showed | | **Cause found** | Not the symptom. Materials / method / equipment / measurement / training / documentation / other | | **Correction to the affected product** | What was done, and to which serial numbers | | **Corrective action to the process** | What changed so it does not recur | | Does the corrective action require a change to this manual? | Yes: revision no. under §3.5 / No | | Does it require training? | Yes: QF-26 entries / No | | **Verification of effectiveness**: what evidence, measured how, by when | | | Verification evidence attached | | | Closure | Quality manager ____ date ____ ; **Owner ____ date ____** | **Procedure of use** 1. Open a report whenever any trigger at manual §2.9 item 1 is met. 2. The investigation is written before the cause. A cause stated without an investigation is a guess and produces a corrective action that does not work. 3. A corrective action that changes how the plant works requires a revision of this manual under §3.5 **before** the change is made, and the revision number is recorded here. 4. The owner does not sign the closure until the verification evidence is attached. An unverified corrective action is an open corrective action. 5. Open reports are reviewed at every internal audit and at the annual management review. --- ## QF-24 Internal audit report | | | |---|---| | Governed by | Manual §2.7 | | Purpose | Records the quarterly audit of the program against this manual | | Completed by | The auditor | | Signed by | Auditor and quality manager; where the quality manager's own area was audited, by the independent auditor named at §2.7 item 4 | | Filed | Audit file | | Retention | 5 years | **Form layout** Header: `Audit no. ____ Date(s) ____ Auditor ____ Areas audited ____ Period covered ____` | # | Area | Manual § | Sample examined (serial nos., dates, records) | Conforms? | Finding | Objective evidence | CAR raised | |---|---|---|---|---|---|---|---| | 1 | Document control: only current documents on the floor | §3.1, §3.2 | | | | | | | 2 | Traveler completeness on product released since the last audit | §7.1 | | | | | | | 3 | Batch, density, cylinder and cure records | §6 | | | | | | | 4 | Calibration register against the instruments on the floor | §8.8 | | | | | | | 5 | Material receiving and certification files | §5.3, §5.4 | | | | | | | 6 | Stock rotation and storage | §5.5 | | | | | | | 7 | Rejected material area and log | §5.6 | | | | | | | 8 | Insignia and label register reconciled to the serial number register and to the agency's issued list | §10.3, §10.4 | | | | | | | 9 | Open nonconformances and corrective actions | §9, §2.9 | | | | | | | 10 | Training records against the people on the floor | §2.6 | | | | | | | 11 | **Traceability test**: one released serial number traced back to every material certificate | §10.2 | | | | | | | 12 | Independence rule 2 observed: no person signed for their own work | §2.3 | | | | | | Footer: `Findings raised: ____ CARs opened: ____ Auditor ____ date ____ Quality manager ____ date ____` **Procedure of use** 1. Audit quarterly, and additionally whenever a corrective action, an agency deficiency or a bureau finding suggests a system failure. 2. Examine records, not opinions. Every finding carries objective evidence: a record, a serial number, an observation with a date. 3. Item 11 is performed at every audit. It is the single best test of whether the record system works. 4. An auditor does not audit their own work. Where the quality manager's own area is the subject, the independent auditor named in manual §2.7 item 4 performs that part. 5. Findings are closed through corrective action QF-23, not by a note on this report. --- ## QF-25 Management review minutes | | | |---|---| | Governed by | Manual §2.8 | | Purpose | The annual review of the quality system by management | | Completed by | Quality manager | | Signed by | **Owner** | | Filed | Program file | | Retention | 5 years | **Form layout** Header: `Review date ____ Present: owner ____ quality manager ____ plant manager ____ others ____ Period reviewed ____` | # | Input | Summary | Decision or action | Owner | Due | |---|---|---|---|---|---| | 1 | Internal audit results | | | | | | 2 | Third-party inspection agency reports and deficiencies | | | | | | 3 | Bureau correspondence, inspections, notices of violation | | | | | | 4 | Nonconformance and corrective action trends | | | | | | 5 | Concrete test trends: density, cylinder breaks, out-of-band events | | | | | | 6 | Calibration history and out-of-calibration findings | | | | | | 7 | Customer complaints and field service | | | | | | 8 | Training and qualification status; certifications due to expire | | | | | | 9 | Whether this manual still describes what the plant actually does | | | | | | 10 | Resources the program needs | | | | | | 11 | Whether audit frequency, inspection frequency or retention should change | | | | | Footer: `Manual revision required: Yes, rev. ____ / No. Owner signature ____ date ____` **Procedure of use** 1. Hold the review once each calendar year and minute it on this form. 2. Item 9 is the point of the review. If the plant is working differently from this manual, the manual is revised under §3.5 and the practice does not continue in the meantime. 3. Any decision to change how the plant works produces a manual revision **before** the change is made. 4. The owner signs the minutes. Unsigned minutes are not a management review. --- ## QF-26 Training record | | | |---|---| | Governed by | Manual §2.6; ICC/MBI 1205 §501.9‡ | | Purpose | One sheet per person: what they are qualified for, what training they have had, including training to the approved documents, and what certifications they hold and when those expire | | Completed by | Quality manager | | Signed by | Trainer and the person trained, on each line | | Filed | Personnel qualification file, indexed in Appendix F | | Retention | Duration of employment and 5 years after | **Form layout** Header: `Name ____ Role(s) ____ Date engaged ____ Stations authorised to work ____ Forms authorised to sign ____` Qualifications held: | Certification or qualification | Issuing body | Number | Date issued | Expires | Copy on file | |---|---|---|---|---|---| | | | | | | | Training delivered: | Date | Subject | Type: this manual / approved construction documents (drawing and revision) / form use / hold points / station task / code / equipment / retraining after CAR no. | Delivered by | Duration | Assessed how | Trainee signature | Trainer signature | |---|---|---|---|---|---|---|---| | | | | | | | | | Authorisation block: `Authorised to perform and sign: ____ Authorised by quality manager ____ date ____ Withdrawn ____ date ____ reason ____` **Procedure of use** 1. Open a sheet before a person performs any task that affects product quality. 2. Record training to a **specific drawing revision** when a revised document is issued, because manual §2.6 item 2 requires that training before the revision is worked to. 3. Record retraining triggered by a corrective action with the CAR number. 4. Track certification expiry and renew before expiry; the annual management review checks this. 5. A person signs a quality record only for tasks the authorisation block lists. Withdraw the authorisation in writing when a person moves off a station. --- ## QF-27 Insignia and certification label control register | | | |---|---| | Governed by | Manual §10.3, §10.4; ICC/MBI 1205 §503.1‡; ARM 24.301.1243, .1247 | | Purpose | Controls every Montana insignia and every third-party agency certification label from receipt to application, supports the month-end report, and tracks the 12 month insignia expiry | | Completed by | Quality manager | | Signed by | Quality manager. **Access restricted** | | Filed | Locked with the insignia and labels; the register itself in the program file | | Retention | Permanent | **Form layout** Part 1, Montana insignia (units): | Insignia no. | Date received from the bureau | Application ref. and fee paid | **Voids 12 months after issuance: date** | Model and model number | Unit serial no. assigned | Date applied | Applied by | Unit released (QF-20 date) | Montana destination | Status: on hand / applied / void / damaged / returned | Returned or destroyed: date and method | |---|---|---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | | Part 2, third-party agency certification labels (components): | Label no. | Agency | Date received | Component serial no. assigned | Date applied | Applied by | Agency inspection report no. and all deficiencies closed | Status | Reconciled to agency issued list (date) | |---|---|---|---|---|---|---|---|---| | | | | | | | | | | Part 3, month-end report: | Month | Insignia on hand at start | Received | Applied (serial nos.) | Voided / damaged / returned | On hand at end | Labels on hand at start | Received | Applied | On hand at end | Report sent to (recipient, date) | Prepared by | |---|---|---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | | Expiry watch: `Insignia within 3 months of the 12 month void date: ____ Reported to the owner on ____` **Procedure of use** 1. Enter every insignia and every label on the day it is received. 2. Store insignia and labels **locked**. Access is limited to the quality manager and the designated officer. [KEN TO CONFIRM: the locked location and who holds the key.] 3. An insignia is applied only after QF-20 is signed, and only by the manufacturer, per ARM 24.301.1243(2). 4. A certification label is applied only after the plant's release **and** after every deficiency in the agency's inspection report is corrected, per ICC/MBI 1205 §401.1(15)‡. Labels are obtained only from the agency. 5. Review the register monthly. Report to the owner any insignia within three months of its 12 month void date, because a void insignia is not refunded, not credited and not replaced. 6. Prepare the month-end report from Part 3 and submit it as ICC/MBI 1205 §503.1‡ requires. [KEN TO CONFIRM: recipient, format and due date, agreed in writing with the bureau and the agency.] 7. Report lost or damaged insignia to the bureau in writing. Return or destroy damaged, void and later-found insignia as directed, record the disposal here, and make no duplicates. 8. Reconcile Part 2 against the agency's own issued list at each month end and at each internal audit. --- ## QF-28 Serial number register | | | |---|---| | Governed by | Manual §10.1; ICC/MBI 1205 §501.13‡ | | Purpose | Every serial number issued, what it was issued to, and where it ended up. A serial number is never reused | | Completed by | Quality manager | | Signed by | Quality manager | | Filed | Program file | | Retention | Permanent | **Form layout** | Serial no. | Type: unit / wall panel / roof strip / floor panel / cladding sheet | Model and model number | Order and customer | Date assigned | Bed and slot | Pour date | Cure cycle (QF-11) | Label or insignia no. (QF-27) | Date released (QF-20) | Ship date | Destination | Status: in production / released / shipped / **VOID (scrapped, NCR no.)** | |---|---|---|---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | | | **Procedure of use** 1. Assign serial numbers when the order is released to the floor, in the format at manual §10.1, and print them on the travelers before work starts. 2. Fill in the production columns as the item moves, so the register is a live index into the records. 3. **A scrapped item's serial number is marked VOID with the NCR number and is never reissued.** A void number must never appear on a certification label or an insignia application. 4. Reconcile against the insignia and label register QF-27 at each month end and at each internal audit. 5. The register is the starting point for any traceability enquiry from the bureau, the agency or a customer. --- ## QF-29 Document and drawing control register | | | |---|---| | Governed by | Manual §3.1, §3.2, §3.3 | | Purpose | Every approved construction document, mix design, form and controlled procedure by revision, where each copy is, and what was withdrawn | | Completed by | Quality manager | | Signed by | Quality manager | | Filed | Program file; a copy at the controlled document station | | Retention | 5 years; the register itself while the plant operates | **Form layout** Part 1, controlled documents: | Doc no. | Title | Type: drawing / specification / mix design / form / procedure / installation instruction | Revision | Date | Approved by | Bureau approval ref. | Copies issued to (location, date, by) | Superseded revision withdrawn (date, by, destroyed or marked VOID) | |---|---|---|---|---|---|---|---|---| | | | | | | | | | | Part 2, order release check, manual §3.3: | Order no. | Model and revision | Model plan approval not expired (expiry date) | Materials on QF-01 and matching the design basis | Panel schedule, openings and key plan agree with the drawings | No process required that is not in this manual | Released by | Date | |---|---|---|---|---|---|---|---| | | | | | | | | | **Procedure of use** 1. Register a document before it is issued to the floor. An unregistered document is not a construction document. 2. Stamp each issued copy **CONTROLLED COPY** with its location and issue date, and record the issue here. 3. On a revision, issue the new revision to every location listed, **physically retrieve every superseded copy**, destroy it or mark it VOID REFERENCE ONLY, and record the retrieval. An uncontrolled printout or a photograph of a drawing is not a construction document and may not be built from. 4. Complete Part 2 before every order is released to the floor. If any check fails, do not release the order, and raise the discrepancy with the engineer of record in writing. 5. The register is checked at every internal audit against the documents actually on the floor. --- ## QF-30 Manual revision record | | | |---|---| | Governed by | Manual §3.5; ICC/MBI 1205 §501.2‡; ARM 24.301.1223(3) | | Purpose | Every proposed and issued revision of this manual, the submission to the bureau, the fee and the approval | | Completed by | Quality manager | | Signed by | Quality manager and owner | | Filed | Program file, at the front of the manual master | | Retention | Permanent | **Form layout** | Rev. | Proposed by | Date proposed | Sections affected | Reason | Change summary | Approved by owner (date) | Submitted to bureau (date) | Fee paid | Bureau response (date) | Approved / rejected | Issued to floor (date) | Superseded copies retrieved (date, by) | |---|---|---|---|---|---|---|---|---|---|---|---|---| | 0 | | | Original issue | First submission under ARM 24.301.1223(1) | | | | $20 | | | | | **Procedure of use** 1. Anyone may propose a change; only the quality manager may issue a revision. 2. Mark the changed text in the revision, update the manual's revision history at §0.7 and the cross-reference tables at §0.4 and §0.5 if section numbering moved. 3. **Submit one copy of the revised manual to the bureau with the review fee required by ARM 24.301.1261, and do not work to the revision until the bureau approves it.** 4. On approval, issue to every location on QF-29, retrieve and destroy or void every superseded copy including the printed plant copy, and record the retrieval. 5. A change made on the floor before the revision is approved is a violation of this manual and of ARM 24.301.1223(3), and it is the classic way an approved plant drifts out of compliance. --- ## QF-31 Customer complaint and field service record | | | |---|---| | Governed by | Manual §15.3 | | Purpose | Records a complaint of noncompliance, the investigation, the response and any field repair, and feeds it back into the item's history | | Completed by | Quality manager | | Signed by | Quality manager | | Filed | Complaint file, and cross-referenced against the item's serial number | | Retention | 5 years from closure | **Form layout** | Field | Entry | |---|---| | Complaint no. | Date received | Received by | | Complainant and contact | | | Serial number(s) and model concerned | | | Site address | | | Complaint as stated | | | Initial acknowledgement sent (date) | | | Investigation: what was examined, records reviewed, site visit date | | | Finding: substantiated / not substantiated / partly | | | Cause | | | Field work performed | What, by whom, date | | Materials used | | | Re-inspection and result | | | Alteration of a unit bearing an insignia? | Yes: ARM 24.301.1249 application made (date), bureau inspection requested (date), fee paid / No | | Corrective action opened? | CAR no. ____ / No, reason | | Third-party inspection agency notified? | Date | | Response to complainant (date, method) | | | Closed | Quality manager ____ date ____ | **Procedure of use** 1. Record a complaint on the day it is received, whatever channel it came through. 2. Investigate promptly and respond in writing. A substantiated complaint opens a corrective action. 3. File the record back against the item's serial number so that the unit's history is complete. 4. **Where the remedy would alter or revise a unit bearing an insignia, ARM 24.301.1249 applies**: an application goes to the bureau before the work, and a bureau inspection is requested on completion. An alteration made without that application can void the insignia and the plan review. 5. Review complaints at the internal audit and at the management review. --- # PART 5. STORAGE, SHIPPING AND SITE ## QF-32 Storage and stacking record | | | |---|---| | Governed by | Manual §12.1, §12.2; ICC/MBI 1205 §501.15‡ | | Purpose | Records where finished product is stored, that the stack limit and the support points were observed, and that weather protection is in place | | Completed by | Yard lead | | Signed by | Yard lead; checked by the QC inspector before loading | | Filed | Yard file | | Retention | 5 years | **Form layout** Header: `Location ____ Date ____ Stack limit [PE TO SET] ____ Support points per approved handling instruction ____` | Serial no. | Item type | Date stored | Storage position (row, bay, stack, level) | Orientation: flat / vertical [KEN TO CONFIRM: plant decision not made] | Dunnage positions correct | Stack level within limit | Weather protection in place | Stored by | Date removed | Condition on removal | Damage found (NCR no.) | |---|---|---|---|---|---|---|---|---|---|---|---| | | | | | | | | | | | | | **Procedure of use** 1. Record every item into storage on the day it is stored, so that any panel can be found from its serial number. 2. Observe the stack limit and the support points from the approved handling instruction. Until the engineer of record sets a stack limit, product is not stacked. 3. Inspect every item for damage before it is loaded, and record the condition. Damage found is a nonconformance. 4. Apply the same rules to storage at any point other than the plant, and state them in the installation instructions so that the erector is bound by them on site. --- ## QF-33 Loading and unloading manifest | | | |---|---| | Governed by | Manual §12.3, §12.4; ICC/MBI 1200 §704.1‡ | | Purpose | Protects the product from stress and mechanical damage in loading, transport and unloading, and tells the erector exactly how to take it off the truck | | Completed by | Production lead, jointly with the erector where §704.1‡ requires | | Signed by | Production lead and carrier at loading; receiver at unloading (QF-34) | | Filed | With the order; a copy travels with the load | | Retention | 5 years | **Form layout** Header: `Manifest no. ____ Order ____ Customer and site ____ Date ____ Carrier and driver ____ Vehicle ____ Permit no. (oversize) ____` Load list: | Position on vehicle | Serial no. | Item | Weight lb | Blocking and support positions | Protection applied | Loaded by | Checked | |---|---|---|---|---|---|---|---| | | | | | | | | | Transport data: | Item | Entry | |---|---| | Total load weight | | | Overall width, length, height on the deck | | | Permit class | | | Securement method and tie-down points | Per 49 CFR 393 Subpart I | | Handling restrictions | | Unloading instructions to the erector: | Item | Entry | |---|---| | Lifting points on each item | | | Insert or lug capacity and required sling angle | [PE TO SET] | | Spreader bar required? | [PE TO SET] | | Crane class or handling equipment the erector must provide | | | Unloading sequence | | | Temporary support, bracing and storage on site | Per the installation instructions | Footer: `Production lead ____ date ____ Carrier ____ date ____` **Procedure of use** 1. Prepare a manifest for every shipment, before loading. 2. Prepare the unloading section jointly with the erector where ICC/MBI 1200 §704.1‡ requires, so that the crane and the rigging on site match the picks the product needs. 3. Check every item for damage before loading and record it on QF-32. 4. The driver signs the manifest at loading. A copy travels with the load and is handed to the receiver. 5. Securement complies with 49 CFR 393 Subpart I; a load that cannot be secured as the manifest states does not leave. --- ## QF-34 Delivery and receipt record | | | |---|---| | Governed by | Manual §12.4 | | Purpose | Records the condition of the product on arrival and any damage in transit | | Completed by | Driver and receiver at the site | | Signed by | Driver and receiver | | Filed | Returned to the plant and filed with the order | | Retention | 5 years | **Form layout** Header: `Manifest no. ____ Order ____ Site ____ Date and time of arrival ____` | Serial no. | Item | Received | Condition on arrival: OK / damage described | Photograph taken | Receiver initials | |---|---|---|---|---|---| | | | | | | | | Field | Entry | |---|---| | Damage found in transit | Description, serial nos. | | Photographs attached | Yes / No | | Reported to the plant (date, to whom) | | | NCR raised | No. | | Unloaded in accordance with the manifest | Yes / No, exceptions | | Receiver name, company and signature | | | Driver signature | | **Procedure of use** 1. The receiver inspects every item before signing and describes any damage rather than writing "damaged". 2. Photograph any damage at the site, before unloading if the damage is on the load. 3. Report damage to the plant the same day; the quality manager raises a nonconformance and decides whether the item can be used, repaired on site or must be replaced. 4. Return the signed record to the plant and file it with the order, so that the item's history is complete from the bed to the site. --- ## END OF APPENDIX A Forms QF-01 through QF-34 are the complete set of forms used in this program. No form is used in the plant that is not in this appendix, and no form in this appendix is used in a way other than the procedure stated with it.