When construction inspections find defects, should they be handled simply as punch list items that need to be corrected (but need no special record keeping), or should they be managed as construction nonconformances that include the extra procedures and record keeping? The following guidelines will help you decide and should keep your quality record keeping as simple as possible.

Punch lists and nonconformances fill different purposes in a quality assurance system. While both deal with the control and management of defects and do complement each other, the sign-off of the completion inspection is the dividing line between the two.

Punch List Items

Defects can be managed as punch items if the remedy is clear and the repairs can be carried out in a timely fashion. For instance, an electrical contractor punch list could include outlets without power and the wrong size circuit breaker. In this case, corrective actions are usually made in a few days. 

After that, the inspector can verify the punch list is complete and sign off on the inspection. Therefore, any defects found and corrected to 100% of specifications – before the sign-off – can be considered punch items.

Nonconformances

On the other hand, there are situations when defects found cannot be corrected to 100% of specifications in a few days. One reason may be that the remedy is not clear or the decision on how to resolve the issue must be made by a higher authority.

For instance, if a foundation is half an inch over the specified tolerance, should it be left as-is or should you start chipping the concrete? This is not a decision field personnel can make. Only a higher authority, which may include the customer, can make decisions that deal with out-of-specification situations. This type of defect is always a nonconformance. 

Another situation that is a nonconformance is when a portion of work is left to be completed at a later time.  Even if the work is easy to complete, it may still be a nonconformance.

Suppose a low-E glass door is out of stock. In order for the project to continue, a standard glass door is installed temporarily. This is a nonconformance, and the item should be marked and a nonconformance report should be prepared to control the deviation until it is corrected.

So what is the difference between a punch list item and a nonconformance? If the item will be corrected later or require decisions by others it crosses the dividing line and should be upgraded to a nonconformance.

Written policies and procedures for controlling, correcting, and preventing nonconformances should be included in your construction quality control plan.

Download a Nonconformance Report Template

Click on the link and Download a Nonconformance Report Template and use it as part of your quality control process.

About the Author - Ed Caldeira is founder of First Time Quality, LLC, specializing in submittal-ready construction quality plans as well as construction quality control software.