Quality Assurance

Caldwell Tanks, Inc. has established company wide controls, processes and procedures to ensure product quality and continual improvement of quality, and to guarantee that products conform to the AWWA Standards, API Standards and the standard procedures established by Caldwell. We are committed to providing our customers with products that meet or exceed the customer's expectations with regard to specification compliance, safety and quality of workmanship. To accomplish this, Caldwell utilizes quality control procedures and maintains an independent Quality Assurance department.

Typical staffing reporting to the manager of QA would include a welding engineer, two CWI welding inspectors, one NACE coatings inspector and one field specialist. Each employee that performs an activity that impacts product quality is trained to make the necessary checks to confirm the process and the product being produced are within specification.

The primary responsibility of the QA department is to monitor the product throughout shop fabrication, field construction and coating application to ensure required quality levels are met in all operations. This is accomplished by a combination of monitoring the quality control procedures established throughout the different operations and by random inspections by in- house inspectors or independent third party inspection firms. The QA department continually evaluates all operations to identify areas of potential improvement which would result in an increase in quality, efficiency or both.

Caldwell maintains current welder qualification records for all active welders. Procedures, processes and welders are qualified in accordance with ASME B&PVC Section IX Articles II and III and AWWA D-100 Section 8.3. Caldwell's welding engineers work to improve quality and efficiency through process improvements and the monitoring of performance to ensure our objectives are met. Welds are subject to pre-weld, in-process and post weld inspection. Prior to welding, fit-up, joint bevel angles, surface condition, tack welds and root openings are inspected to ensure they are within specification.

Proper surface preparation is critical to the application of a coating system. All materials that are to be shop prime coated will be thoroughly cleaned by a wheel-A-brator centrifugal blast cleaning process. Our current standard is SSPC-SP10 which means the removal of all foreign matter and allows for 5 percent random staining. In cases where the steel did not clean to the specified level, it will receive additional cleaning. The profile of the surface will be checked to ASTM D-4417 by the operator and/or the area supervisor to ensure that it meets the specified requirement.

Shop primer shall be applied in accordance to the specifications and in accordance with the coating manufacturer's product data sheet. A shop paint log is used to record relevant data collected during the priming operation, including ambient conditions and paint batch numbers. These logs are collected and maintained by the QA department.

The project site foreman has the day to day responsibility to complete the work in accordance with the "issued for construction" drawings from the engineering department and to monitor the quality of the work being performed by his crew. When field construction is ready for inspection, the superintendent requests inspection from QA. The QA department determines which inspection firm to use and the results are reported directly back to the QA department.

Field applied coatings may be done by one of Caldwell's in-house paint crews or a Caldwell approved paint subcontractor. Daily field paint reports are required on all Caldwell coating projects, whether done internally or by subcontractor. The log is used to record ambient conditions and paint batch numbers as well as a description of work performed on that day.

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