At Kaizen Inspection, we specialize in mechanical verification, quality assurance, and regulatory compliance for process piping, HVAC, and industrial mechanical systems.
This case study highlights the risks hidden in the gray areas of fast-tracked projects — and the importance of rigorous verification.
A Major Project — and a Critical Oversight
It was proudly announced: Two international companies joined forces to build a multimillion-dollar industrial plant.
A consortium of three major construction companies was formed to deliver it.
Engineering firms were hired to design their respective scopes:
- The process side followed ASME B31.3.
- The building side followed ASME B31.9.
One side had detailed P&IDs, isometrics, and piping specifications.
The other had only single-line schematics and partially adapted specifications translated to French to meet provincial regulations.
Contractors began installing piping while the engineers were still designing.
In this fast-tracked context, Kaizen Inspection was hired to perform mechanical verification before client acceptance — ensuring conformity to engineering specifications, client requirements, and provincial laws.
Discovering the Problem in the Field
Coming from a heavy industrial background rooted in ASME B31.3, stepping into a building systems world of HVAC, domestic water, glycol loops, and refrigeration — built to B31.9 — was a new experience.
During a field walk, something stood out:
A bolt on a condenser discharge flange.
Closer inspection revealed:
- Pipe: ASTM A53 Gr. B
- Flange: ASTM A105N (ASME B16.5, Group 1.1)
- Bolt: SAE Grade 5
Wait — SAE bolts?
ASME B16.5 requires bolts listed in Table 1B.
SAE Grade 5 bolts are not listed in Table 1B.
Was this an isolated incident?
Unfortunately, it was widespread across the site.
Raising the Red Flag
I raised the question:
- Project Manager: No idea.
- Contractor: No idea.
- Engineering Firm: No idea.
I searched through RFIs, submittals, and all available documentation.
No answer.
So I raised an RFI myself.
We received a vague response — but no corrective action was taken.
No engineering approval.
No material substitution documentation.
No NCR (Non-Conformance Report).
No CAR (Corrective Action Request).
Weeks went by.
I kept finding additional material compliance issues across different systems.
And then, my contract was terminated.
When leadership informed me I was being let go, the comment I received was chilling:
“If you hadn’t flagged it, no one would have noticed.”
Why This Matters
- Would a SAE bolt have survived? — Probably.
- Was it compliant? — No.
- Is compliance optional? — It shouldn’t be.
The point isn’t whether it would have failed.
The point is that it violated the design specifications, ignored code compliance, and bypassed basic material control procedures required by any standard Quality Assurance program.
When no one watches, these shortcuts accumulate.
Risk hides in silence.
Conclusion: Quality Is Built on Discipline
At Kaizen Inspection, we believe that compliance is not optional, and that small oversights can lead to big risks.
✅ We ensure construction is built to spec, to code, and with traceable materials.
✅ We believe that documentation, transparency, and action are essential pillars of industrial quality assurance.
Have a project where piping, mechanical systems, or HVAC compliance matters?
Contact Kaizen Inspection — your trusted partner for mechanical verification and quality assurance.