Forge Ops QA/QC plan

Forge Ops is the field quality control system our crews run on every building, in every state. Six phases, each with a hold point, a checklist, and a signed sign-off before the next phase starts.

  • 6 field phases
  • 117 checklist items
  • 6 signed hold points

Phase 1: Pre-erection

PLAN = Pre-Layout & Assessment Now

Before a single anchor bolt is set, before the crane arrives, before the crew is on the ground — the PLAN system must be executed completely. The most expensive steel erection mistakes happen because of issues that existed before erection began: anchor bolts in the wrong location, concrete that has not cured, drawings that do not match the stamped permit set, or materials that were not fully received.

  1. Permit & Drawings Verified

    Approved permit set on-site and accessible. Erection drawings match the permit set in all key dimensions. Any RFIs or addenda documented and crew briefed.

  2. Layout & Anchor Bolt Check

    Every anchor bolt location, diameter, projection, and plumb verified from a confirmed baseline — not bolt-to-bolt. Out-of-tolerance bolts flagged and reported to EOR before erection begins.

  3. Assembly Inventory & Staging

    All steel packages received and counted against the BOM. Missing or damaged members documented and back-ordered immediately. Materials staged in erection sequence.

  4. Notify & Safety Brief

    Pre-job safety meeting conducted and signed by all crew. Fall protection, crane capacity, and emergency plan reviewed. AHJ inspector notified of erection start date.

P — Permit & Drawings Verified

The approved permit set must be physically present on-site and accessible. Erection drawings must be cross-referenced against the approved permit drawings — any discrepancies must be resolved with the Engineer of Record before erection begins.

  • Stamped, approved permit drawings are on-site in a weatherproof sleeve or job box
  • Erection drawings match the permit set in span, bay spacing, eave height, and load conditions
  • Anchor bolt layout on erection drawings matches the approved foundation drawings
  • Any RFIs, addenda, or design changes are documented and crew has been briefed
  • Special inspection requirements are identified and inspector contact is confirmed
L — Layout & Anchor Bolt Check

Anchor bolt verification is the single most critical pre-erection task. An anchor bolt in the wrong location, at the wrong elevation, or not plumb can halt an entire erection sequence.

  • Each anchor bolt location measured from a confirmed baseline — not bolt-to-bolt
  • Bolt diameter and thread length match erection drawings
  • Bolt projection above concrete matches base plate and nut engagement requirements
  • All bolts are plumb — check with a bubble level or plumb bob on each bolt
  • Pier and slab elevations checked at all column locations with a level instrument
  • Concrete compressive strength confirmed (typically minimum 75% of design strength for erection)
  • Any out-of-position bolts flagged and reported to the EOR before proceeding
A — Assembly Inventory & Staging

It is common for pieces to be missing, damaged, or mislabeled. Discovering a missing piece during erection is one of the most expensive delays in the trade. Inventory everything before you need it.

  • All steel packages received and counted against the Bill of Materials
  • Primary framing members counted and labeled by mark number
  • Secondary framing verified by count and size
  • Fastener packages inventoried — anchor hardware, high-strength bolts, self-drilling screws
  • Panel packages counted and color verified against contract color schedule
  • Any damaged or missing members documented and back-ordered immediately
  • Materials staged in erection sequence — what goes up first is most accessible
N — Notify & Safety Brief

No crew sets foot on a jobsite without a documented pre-job safety meeting. This is non-negotiable — legally, morally, and practically.

  • Site-specific hazard identification: overhead utilities, underground utilities, traffic, ground conditions
  • Fall protection plan reviewed — anchor points, harness inspection, lanyard requirements above 6 feet
  • Crane and rigging plan: lift capacities, swing radius, pick points, exclusion zones
  • Communication system: hand signals, radio channels, stop-work authority for all crew
  • Emergency action plan: first aid location, nearest hospital, site emergency contact
  • AHJ inspector notified of erection start date with required notice — typically 24–48 hours
  • Crew roles and responsibilities assigned — lead erector, rigger, connectors identified

PLAN checklist

0 / 18

  • Foreman
  • Foreman
  • Lead
  • Lead
  • Lead
  • Lead
  • Foreman
  • Foreman
  • Lead
  • Lead
  • Lead
  • Foreman
  • Crew
  • Foreman
  • Foreman
  • Rigger
  • Foreman
  • Foreman

Hold point: PLAN is signed off by the DD Construction superintendent and the GC or owner representative before the next phase begins.

Phase 2: Steel erection

LIFT = Level, Install, Fasten, True

Steel erection is the backbone of the entire building. Everything that follows — panels, trim, doors, and mechanical — is only as good as the steel frame it hangs from. The LIFT system governs safe, accurate, and properly sequenced erection of all primary and secondary structural steel. Plumb, level, and brace each bay before releasing the crane and before advancing to the next.

  1. Level Base Plates & Set Columns

    Shim base plates to correct elevation before column placement. Bearing must be uniform — no rocking or high-point bearing. Do not release the crane until the temporary column brace is engaged.

  2. Install Primary Frames

    Install temporary bracing immediately — never release the crane hook until the frame is secured. A single unsupported frame in wind conditions can collapse in seconds. No exception, no shortcut.

  3. Fasten Secondary Framing

    Girts, purlins, flange braces, and eave struts per drawings. Verify spacing and lap dimensions before fastening. Do not over-drive self-drilling fasteners — neoprene washers must be flat, not dished.

  4. True & Tension Final

    Plumb all columns with instrument. Install and tension all rod bracing. Torque all high-strength bolts to specification using a calibrated torque wrench. Remove temporary bracing only after permanent bracing is complete.

L — Level Base Plates & Set Columns
  • Set leveling nuts or shims to bring base plate to correct elevation — confirm with level instrument
  • Bearing must be uniform — no rocking or high-point bearing
  • Confirm anchor bolt projection is sufficient for nut engagement and leveling nut clearance
  • Set columns with crane per erection sequence — typically from one end toward the other
  • Do not release crane until temporary column brace is engaged
I — Install Primary Frames
  • Erect frames in the sequence specified in erection drawings — do not deviate
  • Install temporary cable or pipe bracing at each bay before releasing the crane
  • Install ridge and knee brace or haunch connection hardware before releasing frames independently
  • Plumb each column immediately with temporary guy wires — do not leave frames free-standing without bracing
F — Fasten Secondary Framing
  • Install eave struts at all eave conditions per drawings — confirm connection detail at each rafter
  • Install roof purlins at spacing shown on drawings — verify from eave up, not from ridge down
  • Install wall girts at spacing shown on drawings — verify from grade up
  • Install flange braces at all locations shown — these brace the weak-axis of the rafter and are not optional
  • Do not over-drive self-drilling fasteners — neoprene washers should be compressed flat, not dished
  • Verify all purlin and girt laps are oriented per manufacturer direction
  • Install bridging and anti-roll clips at all required locations
T — True & Tension Final
  • Plumb all columns with optical level or digital plumb device — document readings
  • Check diagonal dimension of each bay corner-to-corner to confirm square
  • Install all diagonal rod bracing per erection drawings — confirm size and location
  • Tension rod bracing using turnbuckles — hand-tight plus wrench-snug, not over-tensioned
  • Torque all high-strength bolts to specification using a calibrated torque wrench — document per inspection requirements
  • Remove all temporary bracing only after permanent bracing is fully installed and tensioned
  • Request structural inspection from AHJ prior to covering steel with panels

LIFT checklist

0 / 18

  • Lead
  • Lead
  • Rigger
  • Foreman
  • Connectors
  • Lead
  • Crew
  • Lead
  • Lead
  • Crew
  • Crew
  • Lead
  • Lead
  • Crew
  • Lead
  • Lead
  • Lead
  • Foreman

Hold point: LIFT is signed off by the DD Construction superintendent and the GC or owner representative before the next phase begins.

Phase 3: Wall sheeting

WRAP = Weather, Reference, Align, Pin

Wall panels are the building's first line of defense against weather. They must be installed plumb, correctly lapped, properly fastened, and fully sealed. A wall that looks complete from a distance can be leaking, buckling, or losing thermal efficiency if any one of those elements was missed.

  1. Weather Barrier & Insulation Set

    Install vapor retarder and insulation before panel installation. Confirm thickness and facing direction. Band at girt line. Pre-cut all penetration locations — do not tear insulation around openings.

  2. Reference Line Established

    Snap a plumb reference line at the starting corner before any panel is lifted. Confirm base condition is level along its full length. One bad start panel cascades the entire wall.

  3. Align Panels & Check Plumb

    Engage side-lap rib fully before driving any fasteners. Check plumb on every panel. Verify drift every 5 panels. Do not force panels — find and correct the cause.

  4. Pin & Seal Fasteners

    Drive fasteners in the flat of the panel — never in the rib. Neoprene washer must be flat and slightly compressed — not dished. Apply sealant at all penetrations, base conditions, and trim interfaces.

W — Weather Barrier & Insulation Set
  • Confirm insulation thickness and R-value specified for wall condition on drawings
  • Install vapor retarder facing toward the warm-in-winter side unless drawings specify otherwise
  • Cut insulation cleanly — compressed or torn insulation loses R-value and creates condensation pathways
  • Band or tape insulation at girt line to hold position before panel installation
  • Mark and pre-cut all penetration locations — do not tear insulation around openings
R — Reference Line Established
  • Snap a plumb chalk line at the starting corner — verify with a spirit level and plumb bob
  • Confirm the base condition is level along its full length before panels begin
  • Confirm panel color, profile, and orientation before the first panel is lifted
  • Mark door and window rough opening dimensions on the girt line before panels begin
A — Align Panels & Check Plumb
  • Set first panel to reference line — confirm plumb before fastening
  • Engage side-lap rib fully before driving any fasteners — never drive a fastener into a partially engaged lap
  • Check plumb with a level on every panel — verify drift every 5 panels with a plumb bob or laser
  • If drift is detected, correct over the next 2–3 panels — do not try to correct in one panel
  • Do not force panels — find the cause and correct it before fastening
P — Pin & Seal Fasteners
  • Drive fasteners in the flat of the panel — never in the rib
  • Fastener spacing at side laps: typically 12 inches O.C. — confirm per drawings
  • Fastener spacing at intermediate girts: typically 24 inches O.C. — confirm per drawings
  • Neoprene washer must be seated flat and slightly compressed — a dished washer is over-driven
  • Apply butyl sealant tape or caulk at all penetrations, base conditions, and panel-to-trim interfaces
  • Flash all door and window rough openings before frames are set

WRAP checklist

0 / 19

  • Lead
  • Lead
  • Crew
  • Lead
  • Lead
  • Lead
  • Foreman
  • Lead
  • Crew
  • Crew
  • Lead
  • Lead
  • Crew
  • Lead
  • Lead
  • Lead
  • Crew
  • Crew
  • Foreman

Hold point: WRAP is signed off by the DD Construction superintendent and the GC or owner representative before the next phase begins.

Phase 4: Roof paneling

RIDGE = Run, Insulate, Drive, Guard, End

The roof is the most critical weather management system of any building. A roof that leaks is a failed building, regardless of how well everything else was built. Every step in the RIDGE system is a water management decision — from panel alignment to ridge cap to end lap dimensions.

  1. Run Eave-to-Ridge Reference

    Confirm eave strut is level end-to-end with an instrument before any panel is set. Snap a chalk line from eave to ridge at the first bay. Start square — stay square.

  2. Insulate: Lap & Seal

    Install insulation continuously ahead of panels — no bare purlins covered. Lap ends at purlin lines — minimum 2 inch overlap. Do not compress below design thickness.

  3. Drive Panels & Engage Clips

    Standing seam: seat clips at every purlin — seams must be fully engaged. Through-fastened: fasteners in panel FLATS only. Driving in ribs creates stress concentrations and destroys weathering.

  4. Guard Against Water Intrusion

    Foam closures at eave and ridge — fully seated and compressed. Butyl tape at all end laps before upper panel is set. Ridge cap installed in one direction only — never from both ends.

  5. End Laps & Edge Terminations

    Confirm minimum end lap per manufacturer spec — panels lapped less than minimum will leak during driven rain. De-burr all cut edges. Clear all metal filings from panels before overnight.

R — Run Eave-to-Ridge Reference
  • Confirm eave strut is level end-to-end with a level instrument — correct if needed before panels begin
  • Snap a chalk line from eave to ridge on the first purlin line at the starting bay
  • Verify panels will run perpendicular to the eave strut — confirm with a square from the endwall
  • Identify and mark all roof penetrations before panels start
  • Confirm panel color, profile, and thickness match contract documents
I — Insulate: Lap & Seal
  • Install insulation blanket across purlins ahead of panel installation — do not panel over bare purlins
  • Lap insulation ends at purlin lines — minimum 2 inch overlap
  • Do not compress insulation below design thickness — compressed insulation loses R-value proportionally
  • Band or tape insulation at purlin lines before panels are set to prevent bunching
  • Confirm vapor retarder facing direction — typically facing down on roof assemblies
D — Drive Panels & Engage Clips

Standing seam and through-fastened roofs have fundamentally different installation requirements:

  • Standing seam: set clips at each purlin line per manufacturer specification — confirm clip type: fixed vs. floating
  • Standing seam: seam must be snapped or seamed per manufacturer — do not leave seams open or partially closed
  • Through-fastened: fasteners must be driven in the panel FLATS — never in the ribs
  • Driving fasteners in ribs creates stress concentrations and destroys the panel's weathering ability
  • Confirm fastener spacing at laps and field per drawings
G — Guard Against Water Intrusion
  • Install foam closure strips at all eave and ridge conditions — confirm foam is fully seated and compressed
  • Apply butyl tape at all end laps before panels are stacked — tape below, panel above
  • Install ridge cap in one direction from one end to the other — do not work from both ends to the middle
  • Flash all roof penetrations with manufacturer-approved curbs or pipe flashings
  • Apply sealant at all trim-to-panel interfaces along the ridge and endwall conditions
E — End Laps & Edge Terminations
  • Confirm minimum end lap per manufacturer specification — typically 6 inches for low-slope and 12 inches for steeper panels
  • Apply butyl sealant tape at all end laps before the upper panel is set
  • Flash all endwall panel-to-endwall-trim conditions
  • De-burr all field-cut panel edges — a sharp edge cuts sealant and gaskets over time
  • Inspect entire roof surface for debris, dropped fasteners, and panel damage before completing the phase

RIDGE checklist

0 / 21

  • Lead
  • Lead
  • Lead
  • Foreman
  • Foreman
  • Crew
  • Lead
  • Lead
  • Lead
  • Lead
  • Crew
  • Crew
  • Lead
  • Crew
  • Crew
  • Crew
  • Lead
  • Lead
  • Crew
  • Crew
  • Foreman

Hold point: RIDGE is signed off by the DD Construction superintendent and the GC or owner representative before the next phase begins.

Phase 5: Trim out

EDGE = Execute, Detail, Gap-Seal, Examine

Trim is both the finished appearance and the weather management system of a metal building. Every piece of trim is doing a job: shedding water, sealing a gap, covering a cut edge, or bridging a transition. Trim installed in the wrong sequence, without proper laps, or without sealant is not cosmetic trim — it is a water infiltration pathway waiting to be activated by the first rain.

  1. Execute Trim Installation Sequence

    Install trim in the correct order: base, corners, jamb, head, gutter, rake. Out-of-sequence trim creates reverse-lapped conditions where water runs behind instead of off.

  2. Detail All Transitions & Laps

    Upper piece ALWAYS laps over lower piece. Minimum 2 inch overlap at all trim joints. Miter or notch corners cleanly. No raw cut ends exposed to weather.

  3. Gap-Seal All Penetrations

    Every door, window, louver, and pipe penetration must be flashed and sealant-finished. Walk every elevation systematically. Every gap is a leak path — no exceptions.

  4. Examine Final Appearance

    Walk every elevation from at least 20 feet back. Check color, trim alignment, fastener pattern. Clear all metal filings immediately — they rust and stain panels within days.

E — Execute Trim Installation Sequence
  • Step 1: Base trim and base angle at all wall bottoms
  • Step 2: Corner trim at all wall corners
  • Step 3: Jamb trim at door and window rough openings
  • Step 4: Head trim at door and window tops
  • Step 5: Gutter and downspout installation
  • Step 6: Rake and fascia trim at roof edges
  • Step 7: Any specialty trim — parapet caps, louver frames, canopy trim
D — Detail All Transitions & Laps
  • All trim laps: upper piece ALWAYS laps over lower piece — water flows off, not behind
  • Minimum 2 inch overlap at all trim-to-trim lap joints
  • Miter or notch corners cleanly — no raw overlapping cuts at visible corners
  • Do not leave raw cut ends of trim exposed to weather — terminate with end cap or sealant
  • Align trim fasteners consistently — a consistent fastener pattern is a quality signal
G — Gap-Seal All Penetrations
  • Apply sealant at all door frame perimeters — between jamb trim and wall panel
  • Apply sealant at all window frame perimeters — top, sides, and sill
  • Flash and seal all louver frames — high-risk infiltration points
  • Seal all conduit, pipe, and mechanical penetrations with approved pipe flashings
  • Inspect gutter and downspout connections — confirm end caps are sealed and all joints lapped
  • Confirm all base trim-to-concrete or base trim-to-slab interfaces are sealed
E — Examine Final Appearance
  • Color consistency: confirm all panels and trim match the specified color
  • Trim alignment: confirm all horizontal and vertical trim runs are straight and consistent
  • Fastener pattern: confirm fasteners are aligned and consistently spaced on trim faces
  • Finish condition: no scratches, dents, or paint damage on visible surfaces
  • Metal filings: clear all metal shavings from all panel surfaces immediately — they will oxidize and stain within days

EDGE checklist

0 / 19

  • Crew
  • Crew
  • Crew
  • Crew
  • Lead
  • Crew
  • Crew
  • Lead
  • Lead
  • Lead
  • Lead
  • Crew
  • Crew
  • Crew
  • Crew
  • Crew
  • Crew
  • Crew
  • Foreman

Hold point: EDGE is signed off by the DD Construction superintendent and the GC or owner representative before the next phase begins.

Phase 6: Completion

CLOSE = Confirm, Log, Owner Walk, Submit, Exit

The CLOSE system is where the building is formally handed over to the owner. It is the phase most often rushed and the one that causes the most warranty disputes, so we run every item, on every job.

  1. Confirm All Inspections Passed

    All AHJ inspections completed and signed. Special inspection reports submitted. Certificate of Occupancy obtained and filed. A building without a final inspection is not a completed project.

  2. Log All As-Built Documentation

    Red-line as-built drawings completed and retained permanently. All material substitutions and change orders documented with authorization. Warranties organized for delivery.

  3. Owner Walk & Punch List

    Bring your own punch list to the walk — show you already identified issues. Complete every punch list item before requesting final payment. Obtain written, signed acceptance.

  4. Submit Warranties & Manuals

    Deliver building manufacturer warranty, panel warranty, door manuals, touch-up paint, and manufacturer service contacts. Educate the owner on maintenance requirements to keep warranties valid.

  5. Exit Site Clean

    Remove all equipment and debris. Photograph all four elevations plus interior as the permanent quality record for the project.

C — Confirm All Inspections Passed
  • All AHJ inspections completed and signed — structural, framing, energy, and final
  • Special inspection reports (bolt torque, weld inspection if applicable) completed and submitted to the AHJ
  • Certificate of Occupancy or final inspection record obtained and filed
  • Any inspection correction notices have been addressed and re-inspected
L — Log All As-Built Documentation
  • Mark up a set of erection drawings with all field deviations — retain this red-line set permanently
  • Document all material substitutions: what was specified, what was installed, and engineer approval if required
  • Document all change orders — scope, cost, owner authorization, and final disposition
  • Retain all special inspection reports, bolt torque records, and any third-party testing results
O — Owner Walk & Punch List
  • Prepare your own punch list of known items before the walk — show the owner you already identified them
  • Walk systematically: exterior perimeter first, then roof access if safe, then interior
  • Document every punch list item with a written description and photo
  • Agree on completion timeline for each item — do not agree to open-ended punch items
  • Complete all punch list items before requesting final payment
  • Obtain written, signed owner acceptance of the completed work
S — Submit Warranties & Manuals
  • Building manufacturer's structural warranty — confirm term and conditions with the owner
  • Wall and roof panel coating and weathertightness warranty — review exclusions with owner
  • Door and hardware manuals and warranties
  • Touch-up paint — at least one can of matching color for each panel color used
  • List of manufacturer service contacts and authorized repair contractors
  • Owner education: what maintenance is required to keep warranties valid
E — Exit Site Clean
  • Remove all equipment, scaffolding, lifts, and temporary structures from the site
  • Remove all construction debris — no panel scraps, packaging, or waste left on site
  • Clean all panel surfaces — remove any remaining metal filings, sealant smears, or dirt
  • Photograph all four elevations of the completed building plus interior — retain permanently

CLOSE checklist

0 / 22

  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Lead
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Foreman
  • Crew
  • Crew
  • Crew
  • Foreman

Hold point: CLOSE is signed off by the DD Construction superintendent and the GC or owner representative before the next phase begins.

The DD Construction standard

TRUST earns the work. SELECT prices it right. BUILD sets it up to win. PLAN verifies the foundation. LIFT raises the steel. WRAP seals the walls. RIDGE locks the roof. EDGE finishes the details. CLOSE protects the project. Nine systems, in sequence, on every project.

Request a bid
Skip to content