At Quality Safety Times, we believe in the power of sharing lessons learned.
We encourage our readers to contribute to improving the construction industry’s image by providing QST with stories or “Lessons Learned” from their experiences involving QUALITY CONTROL (i.e., examples of where re-work was required). We are not looking for stories regarding safety topics at this time.
Please TELL YOUR STORY. By sharing it with us, others can learn from your experience, and you will help us in our mission to reduce construction re-work.
Story Requirements
- Due to copyright laws, we can only accept stories, pictures, images, graphics, and other content that you own or have the authority to release
- An acknowledgment to release the rights to your story and pictures, etc., and acceptance that QST will be using this content for commercial use is required (see checklist below)
- We reserve the right to modify the story for formatting and coherence
- We may or may not accept stories submitted
If your story is selected, you will receive a t-shirt, or a contribution in your name will be made to Central Washington University’s Safety Program Clarke Endowment Fund with a matched donation from QST. You will be asked to select below.
Thank you.
Example Story
ELECTRICAL LOW-VOLTAGE TRADE
ELECTRICAL CABLE—MATERIAL ORDER ERROR
ELECTRICAL CABLE PROJECT BACKGROUND
An International Airport awarded an Industrial Controls company the contract for a new baggage conveyor system.
• The project included all the controls for all the baggage lines for the entire conveyor system.
• The new baggage conveyor system delivered central routing to the Explosive Detection equipment and outbound Airline
Pick Up areas.
• The baggage handling contract was a design-build contract that included the Baggage Handling Control System.
ELECTRICAL CABLE—MATERIAL ORDER ERROR ISSUE
The project was completed and commissioned.
• Months after completion, airport personnel reported baggage control system
problems.
The new system was not communicating properly with the central controllers.
• Re-inspection of the wiring connections was completed multiple times, but
intermittent problems persisted.
Eventually, an airport technician compared the new contract submittal data for the
low-voltage wiring against the new low-voltage wiring installed in the field.
• It was determined that the new low-voltage wiring installed in the field was a
different model number from the design-specified low-voltage wiring.
The design-specified model number is related to radio frequency shielding. Airports
are high radio frequency locations.
• The newly installed low-voltage cabling did not contain radio frequency shielding.
• It was determined the electrical contractor ordered the wrong cabling.
• The cabling was replaced, and the intermittent problems subsided.
Actual Loss: Approximately $500 K includes the new cable, installation time to correct the
system, penalties, and schedule delay costs.
HOW TO PREVENT THESE TYPES OF ISSUES
• All contractors should hold an internal pre-construction meeting to discuss new
contract submittals and ensure all materials are ordered according to approved
submittals.
• Approved submittals should be forwarded to suppliers. Any questions about specified equipment and materials should be
addressed to the engineer of record in writing.
• All contractors should document all variances, no matter how small, through submittals, Requests For Information (RFI),
and substitution requests.
• Never change material or equipment orders without prior and proper approval.
• Putting such concerns in writing informs the construction manager and general contractor. Such documentation goes a
long way in avoiding disputes and claims and becoming a party involved in a court case.
ELECTRICAL CABLE—MATERIAL ORDER ERROR: DISCUSSION Q & A
1. Are we using internal pre-construction meetings?
2. Does shipping and receiving compare materials received to the ordered material and the project specifications?
3. Is the RFI log updated, and is information transferred to field operations, including shipping and receiving?
4. How would the project supervision or the crew know the roll of wire was correct for the project?
ELECTRICAL CABLE - MATERIAL ORDER ERROR
ELECTRICAL CABLE PROJECT BACKGROUND
An International Airport awarded an Industrial Controls company the contract for a new baggage conveyor system.
• The project included all the controls for all the baggage lines for the entire conveyor system.
• The new baggage conveyor system delivered central routing to the Explosive Detection equipment and outbound Airline
Pick Up areas.
• The baggage handling contract was a design-build contract that included the Baggage Handling Control System.
ELECTRICAL CABLE—MATERIAL ORDER ERROR ISSUE
The project was completed and commissioned.
• Months after completion, airport personnel reported baggage control system
problems.
The new system was not communicating properly with the central controllers.
• Re-inspection of the wiring connections was completed multiple times, but
intermittent problems persisted.
Eventually, an airport technician compared the new contract submittal data for the
low-voltage wiring against the new low-voltage wiring installed in the field.
• It was determined that the new low-voltage wiring installed in the field was a
different model number from the design-specified low-voltage wiring.
The design-specified model number is related to radio frequency shielding. Airports
are high radio frequency locations.
• The newly installed low-voltage cabling did not contain radio frequency shielding.
• It was determined the electrical contractor ordered the wrong cabling.
• The cabling was replaced, and the intermittent problems subsided.
Actual Loss: Approximately $500 K includes the new cable, installation time to correct the
system, penalties, and schedule delay costs.
HOW TO PREVENT THESE TYPES OF ISSUES
• All contractors should hold an internal pre-construction meeting to discuss new
contract submittals and ensure all materials are ordered according to approved
submittals.
• Approved submittals should be forwarded to suppliers. Any questions about specified equipment and materials should be
addressed to the engineer of record in writing.
• All contractors should document all variances, no matter how small, through submittals, Requests For Information (RFI),
and substitution requests.
• Never change material or equipment orders without prior and proper approval.
• Putting such concerns in writing informs the construction manager and general contractor. Such documentation goes a
long way in avoiding disputes and claims and becoming a party involved in a court case.
ELECTRICAL CABLE—MATERIAL ORDER ERROR: DISCUSSION Q & A
1. Are we using internal pre-construction meetings?
2. Does shipping and receiving compare materials received to the ordered material and the project specifications?
3. Is the RFI log updated, and is information transferred to field operations, including shipping and receiving?
4. How would the project supervision or the crew know the roll of wire was correct for the project?