OOFFFFIICCEE OOFF TTHHEE SSPPEECCIIAALL IINNSSPPEECCTTOORR GGEENNEERRAALL FFOORR IIRRAAQQ RREECCOONNSSTTRRUUCCTTIIOONN AAALLL KKKAAASSSIIIKKK WWWAAATTTEEERRR SSSTTTOOORRRAAAGGGEEE TTTAAANNNKKKSSS AAALLL KKKAAASSSIIIKKK MMMIIILLLIIITTTAAARRRYYY TTTRRRAAAIIINNNIIINNNGGG BBBAAASSSEEE AAALLL KKKAAASSSIIIKKK,,, IIIRRRAAAQQQ SSSIIIGGGIIIRRR PPPAAA---000666---000777111 JJJAAANNNUUUAAARRRYYY 000888,,, 222000000777 Report Documentation Page Form Approved OMB No. 0704-0188 Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. 1. REPORT DATE 3. DATES COVERED 08 JAN 2007 2. REPORT TYPE 00-00-2007 to 00-00-2007 4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER Al Kasik Water Storage Tanks Al Kasik Military Training Base. Al 5b. GRANT NUMBER Kasik, Iraq 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) 5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION Office of the Special Inspector General for Iraq Reconstruction,400 Army REPORT NUMBER Navy Drive,Arlington,VA,22202 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S) 11. SPONSOR/MONITOR’S REPORT NUMBER(S) 12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited 13. SUPPLEMENTARY NOTES 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF 18. NUMBER 19a. NAME OF ABSTRACT OF PAGES RESPONSIBLE PERSON a. REPORT b. ABSTRACT c. THIS PAGE Same as 29 unclassified unclassified unclassified Report (SAR) Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18 SPECIAL INSPECTOR GENERAL FOR IRAQ RECONSTRUCTION January 08, 2007 MEMORANDUM FOR DIRECTOR, IRAQ RECONSTRUCTION MANAGEMENT OFFICE COMMANDING GENERAL, MULTI-NATIONAL SECURITY TRANSITION COMMAND - IRAQ COMMANDING GENERAL, GULF REGION DIVISION, U.S. ARMY CORPS OF ENGINEERS DIRECTOR, AIR FORCE CENTER FOR ENVIRONMENTAL EXCELLENCE SUBJECT: Report on Project Assessment of the Al Kasik Water Storage Tanks, Al Kasik Military Training Base, Al Kasik, Iraq (Report Number SIGIR-PA-06-071) We are providing this project assessment report for your information and use. We assessed the design and construction work being performed at the Al Kasik Water Storage Tanks, Al Kasik Military Training Base, Al Kasik, Iraq to determine its status and whether objectives intended will be achieved. This assessment was made to provide you and other interested parties with real-time information on a relief and reconstruction project underway and in order to enable appropriate action to be taken, if warranted. The assessment team included an engineer/inspector and an auditor/inspector. This report does not contain any negative findings. As a result, no recommendations for corrective action were made and further management comments are not requested. We appreciate the courtesies extended to our staff. If you have any questions please contact Mr. Brian Flynn at [email protected] or at 914-360-0607. For public or congressional queries concerning this report, please contact SIGIR Congressional and Public Affairs at [email protected] or at (703) 428-1100. Stuart W. Bowen, Jr. Inspector General i Special Inspector General for Iraq Reconstruction SIGIR PA-06-071 January 08, 2007 Al Kasik Water Storage Tanks Al Kasik Military Training Base, Iraq Synopsis Introduction. This project assessment was initiated as part of our continuing assessments of selected Multi-National Security Transition Command - Iraq reconstruction activities. The overall objectives were to determine whether selected sector reconstruction contractors were complying with the terms of their contracts or task orders, and to evaluate the effectiveness of the monitoring and controls exercised by administrative quality assurance and contract officers. We conducted this project assessment in accordance with the Quality Standards for Inspections issued by the President’s Council on Integrity and Efficiency. The assessment team included an engineer/inspector and an auditor/inspector. The objective of the project was to construct a potable water storage tank system with a capacity of no less than 7.7 million liters. In addition, all connecting piping valves, meters, pumps, and controls required to incorporate the Water Storage Tank (WST) system into the existing base potable water distribution and treatment system were included in the project’s requirements. Project Assessment Objectives. The objective of this project assessment was to provide real-time relief and reconstruction project information to interested parties in order to enable appropriate action, when warranted. Specifically, we determined whether: 1. Project components were adequately designed prior to construction or installation; 2. Construction or rehabilitation met the standards of the design; 3. The Contractor’s Quality Control and the United States Government’s Quality Assurance programs were adequate; 4. Project sustainability was addressed; and 5. Project results were consistent with original objectives. Conclusions. The assessment determined that: 1. The contract’s design and specifications were specific enough to construct the facility because extensive and complex design work was not required to construct the project consisting of eight similar water tanks. At the time of the assessment team’s site visit, construction of eight 1 million liter water tanks was in various stages, all with successful results. As a result, there is a strong likelihood that the project, if completed, will be completed without major issues related to inadequate design. 2. At the time of the site visit, construction work completed complied with the design standards for the Al Kasik Water Storage Tanks project. Based on the assessment team’s review of relevant documentation, discussions conducted with informed contractor and government personnel, and an on-site visit, the contractor’s procedures to manage construction activity appeared effective. Quality Control, Quality Assurance, and numerous test reports confirmed that the ii project has been effectively monitored. As a result, the likelihood is high that project construction, if completed, will comply with design standards. 3. The contractor's Quality Control and the U.S. Government's Quality Assurance programs were adequate because the quality control and quality assurance systems employed by the contractor and government ensured effective Quality Management during construction. In accordance with Task Order requirements, the contractor submitted a timely Quality Control Program plan that included a sufficiently detailed Construction Quality plan and a Health and Safety plan before construction started in September 2005. In addition, the government’s Quality Assurance representative provided sufficient and effective oversight of the Quality Control function. Quality Assurance reports were well written and descriptive of meaningful events and the project’s overall status. If the project is completed and current procedures are followed, the construction will very likely meet contract requirements. 4. Project sustainability was adequately addressed in the Task Order. The construction of the Water Storage Tanks consisted of a system of eight tanks of the same design and size. By their design, covered non-pressurized water holding tanks offer a high degree of sustainability when properly constructed. Once the system of tanks is filled with water, it is designed to remain in place and supply clean water to the water distribution system. If completed as designed, the project will likely be sustainable for years to come. 5. When completed, the system of eight water storage tanks should meet its intended objective to store and supply ample water for the water distribution system. The desirable outcome will result because of effective project oversight of construction activities by contractor Quality Control and government Quality Assurance personnel. In addition, the project was adequately planned and designed before construction started. If built to the current standards of construction, the water storage tanks should operate efficiently and improve overall water distribution within the service area. Recommendations and Management Comments. This report does not contain any negative findings or recommendations for corrective action. Accordingly, management comments were not required and none were offered by management. The results of this assessment were discussed with the Air Force Center for Environmental Excellence Program Manager and a Multi-National Security Transition Command - Iraq Engineering Staff Section (J-7) representative at the conclusion of fieldwork. In addition, the Assessment Team discussed the positive conditions reported with Coalition Military Assistance Training Team / Regional Support Unit personnel before departing Al Kasik. We appreciated the courtesies extended by Coalition Military Assistance Training Team / Regional Support Unit and contractor personnel. In addition, their help with billeting and travel to the site made for an effective and efficient site visit. iii Table of Contents Synopsis i Introduction Objective of the Project Assessment 1 Pre-Site Assessment Background 1 Contract, Task Order and Costs 1 Project Objective 1 Description of Facility (pre-construction) 1 Scope of Work of the Task Order 1 Site Assessment Work Completed 2 Work in Progress 3 Work Pending 16 Project Quality Management Contractor’s Quality Control Program 16 Government’s Quality Assurance Program 17 Quality Management 17 Project Sustainability 18 Conclusions 18 Recommendations and Management Comments 19 Appendixes A. Scope and Methodology 20 B. Acronyms 21 C. Report Distribution 22 D. Project Assessment Team Members 24 Introduction Objective of the Project Assessment The objective of this project assessment was to provide real-time relief and reconstruction project information to interested parties in order to enable appropriate action, when warranted. Specifically, we determined whether: 1. Project components were adequately designed prior to construction or installation; 2. Construction or rehabilitation met the standards of the design; 3. The Contractor’s Quality Control (QC) and the United States Government’s Quality Assurance (QA) programs were adequate; 4. Sustainability was addressed; and 5. Project results were consistent with original objectives. Pre-Site Assessment Background Contract, Task Order and Costs Basic Contract FA8903-04-D-8669 / Task Order 0025 / Modification 004, effective 22 July 2005, authorized AMEC Earth and Environmental, Inc. to perform work in accordance with the Statement of Work (SOW), dated 30 June 2005. Task Order (TO) 0025 was a cost-plus-fixed-fee (CPFF) contract and work on the Water Storage Tanks (WST) was estimated to cost and be funded in the approximate amount of $4.9 million. The basic contract, task order, and modification were issued by the Air Force Material Command (AFMC) and administrated by the Defense Contract Management Agency (DCMA). Project Objective The 30 June 2005 SOW required the contractor to construct a potable water storage tank system with a capacity of no less than 7.7 million liters. In addition, all connecting piping valves, meters, pumps, and controls required to incorporate the WST system into the existing base potable water distribution and treatment system were included in the SOW. The final design of the Al Kasik Water Storage Tank system consisted of eight separate tanks, with an individual tank capacity of approximately 1 million liters. Description of the Facility (pre-construction) The contractor’s construction manager advised that pre-construction water storage facilities at the Al Kasik Army base were inadequate in terms of capacity and in poor condition. Scope of Work of the Task Order The SOW laid out the contractor’s specific roles and responsibilities for the WST project. The SOW detailed the work, specifications, and testing requirements. The majority of the physical construction of the project was devoted to building a system of eight equally configured tanks to yield a minimum system capacity of approximately 7.7 million liters. In addition, piping, valves, meters, pumps, and control equipment required to incorporate the system of storage tanks with the water distribution and treatment systems were included in the SOW. 1 Site Assessment Work Completed At the time of the assessment team’s site visit, the project was reported as 57% complete by the AFCEE/VIAP1 Quality Assurance Representative (QAR). Although the TO’s Field Period of Performance (POP) had been extended to 19 September 2006, the contractor’s construction manager stated that the WST project would likely not be completed by then. QA reports confirmed that substantial rain in January, February, and March 2006 contributed to delayed WST project progress (Site Photo 1). In addition, the contractor’s construction manager stated that there had been unspecified delays attributable to equipment and material unavailability. At the time of the assessment team’s site visit, the sub-contractor was waiting for a sand blaster needed to clean all steel before a protective/finish coating (epoxy paint) could be applied. In addition, the contractor’s construction manager stated that a shortage of welders skilled enough to pass a welding test administered by the contractor’s QC manager had been a persistent problem. Site Photo 1. WST site conditions following overnight rain. (Photo from QA Report dated 3 Feb. 2006) 1 Under a separate contract, AFCEE onsite quality assurance services were provided by Versar International Assistance Projects Iraq (VIAP). 2 Site Photo 2. Workers have to re-dig footings after heavy rains. (Photo from QA Report dated 17 Mar 2006) Work in Progress Based on the Statement of Work, the contractor was required to construct a potable water storage tank system with a capacity of no less than 7.7 million liters. In addition, requirements to provide all connecting piping valves, meters, pumps, and controls required to incorporate the WST system with existing base potable water distribution and treatment system were included in the SOW. The contractor’s final design consisted of a system of eight separate, but comparable, tanks with an individual tank capacity of approximately 1 million liters. In addition, the tanks were designed to be fabricated on site by the contractor. Tank construction was divided into four major stages: concrete foundation, welded steel floor, welded steel walls, and welded steel roof. At the time of the assessment team’s site visit, foundation, floor, and wall work was in progress. Accordingly, our observations are described in the following sections: Tank Foundations, Tank Floors, and Tank Walls. Tank Foundation Tank foundation construction started with a concrete foundation, shown in Site Photos 3 and 4. Crushed course aggregate shown in Site Photo 5 was used for on- site production of foundation concrete. To conform to design standards, on-site concrete mixing included the aggregate in a prescribed combination with cement and water. The course aggregate used varied in size from small stone to larger stone, up to approximately 30 mm in diameter. In addition, the crushing process created aggregate with rough asymmetrical surfaces to facilitate effective binding in the concrete when combined with proper amounts of cement and water. We reviewed laboratory tests and confirmed that the concrete met or exceeded strength standards. 3 Site Photo 3. Steel floor placed on concrete foundation. Site Photo 4. Steel floor placed on concrete foundation 4