OUT-OF-STATE FACTORY BUILT BUILDING CERTIFICATION AND INSPECTION REQUIREMENTS
Manufacturer certification is an evaluation function. A certification has two primary purposes.
- To verify that the manufacturer is capable of producing modules that comply with the law and the rules, mandatory building codes and approved design package.
- To verify that the manufacturer's approved compliance control program will ensure compliance now and in the future.
A manufacturer with multiple production facilities shall have each facility that will be producing units for Arizona certified. Each facility shall have a design package, compliance control manual, and building plans approved for that specific facility.
Any/all modules shipped to or within Arizona shall be produced in a certified facility.
PRE-CERTIFICATION INSPECTION REQUIREMENTS
- The manufacturer's design package, compliance control manual and building plans for the building to be used as the certification example shall be submitted to the Arizona Department of Housing (ADOH) for review and approval prior to the beginning of the certification process. These approved documents must be available at the manufacturing facility during the certification inspection.
- The manufacturer must acquire the services of an ADOH approved Third Party Inspection Agency (TPIA). The TPIA will conduct certification of the manufacturing facility by inspecting and evaluating the manufacturing and compliance control process.
THIRD PARTY INSPECTION AGENCIES
- The manufacturer shall designate in writing to the Arizona Department of Housing (ADOH) the Third Party Inspection Agency (TPIA) that will be performing in-plant inspections. Only agencies accepted by ADOH may be designated to perform Arizona in-plant inspections. Changes in third party inspection agencies shall also be designated in writing to ADOH prior to the change.
- A manufacturer may designate more than one TPIA to perform in-plant inspections. However, once a TPIA has begun inspections on the modules for a project or building, the manufacturer shall not change inspection agencies for that project or building.
CERTIFICATION INSPECTION REQUIREMENTS
The TPIA shall spend as much time as necessary in the manufacturing facility to ensure that all aspects of the compliance control program are functioning according to the manufacturer's approved procedures. At least one module, containing all systems, or a combination of modules containing all systems, shall be observed during all phases of construction in the facility. The certification inspector shall inspect all units in production for Arizona during the course of the certification inspection. Similar units in production for other states may be inspected as an aid in the evaluation of the facility.
All non-compliance shall be resolved to the satisfaction of the TPIA and ADOH prior to certification of, or release of insignia to, the manufacturer. Corrective actions taken to resolve non-compliance shall be inspected by the TPIA. Revisions to plans, design package, or compliance control manual taken to correct non-compliance shall be reviewed and approved by ADOH prior to acceptance by the certification inspector.
CERTIFICATION INSPECTION PROCESS OUTLINE
- The manufacturer shall provide copies of the approved design package, building plans, compliance control manual and a suitable location in which to work during the duration of the certification inspection. The certification inspector will review in detail, and become familiar with the approved documents.
- The certification inspector shall inspect all phases of construction for compliance to the approved design package and to the mandatory building codes, and to assure that the manufacturer is following the approved compliance control procedures.
- The certification inspector shall witness system testing on one or more modules. All types of system test must be observed. Failure of a system test is not non-compliance. Failure to take action to correct the cause of the failure of the system test is a non-compliance and shall be documented as such. Failure to follow the approved procedures for performing the system test shall be documented as a non-compliance.
- The TPIA shall allow the manufacturer's compliance control personnel the opportunity to inspect and discover non-compliance to the approved design package or to the mandatory building codes in accordance with the procedures outlined in the manufacturer's compliance control manual. Non-compliances noted by the TPIA shall be brought to the attention of the designated manufacturer personnel after inspection by manufacturer personnel, but prior to the construction being covered in the normal process of construction. Failure of the manufacturer compliance control personnel to identify and initiate corrective action for non-compliances shall be documented as a failure of the manufacturer's compliance control program. Repetitive non-compliances or failure to follow approved procedures may require changes in the manufacturer's compliance control procedures.
- The certification inspection shall conclude when all phases of construction and all system testing has been witnessed by the TPIA, upon verification that all corrective actions on the certification units have been completed, and when enough data has been collected to fully evaluate all aspects of the manufacturing facility and process.
POST CERTIFICATION INSPECTION REQUIREMENTS
A certification report shall be issued by the TPIA to the manufacturer when all certification requirements have successfully been met. The TPIA shall be responsible for forwarding a copy of this report to ADOH. The manufacturer and the TPIA shall retain a copy of this report for their records. The certification report shall include the following:
- The name and facility address of the manufacturer. The name and address of the TPIA conducting the certification.
- The names and titles of key manufacturer personnel and any/all certification inspectors involved in the certification inspection process.
- The initial approval date of the manufacturer's design package, compliance control manual, and building plans.
- The serial or identification number of all modules inspected during the certification inspection.
- A description of any/all non-compliance discovered, and corrective actions initiated, during the course of the certification inspection.
- A description of the type of building system inspected (wood frame, steel, concrete, etc.).
- A statement by the TPIA that all requirements for certification have been met to the satisfaction of the TPIA and that the facility is considered certified for continuing production for the State of Arizona.
Upon successful completion of the certification process, and receipt by ADOH of the certification report, the manufacturer may order and affix Arizona insignia to completed modules. Insignia containing the complete plan approval and building serial numbers may be affixed only to modules that are complete to the factory's scope of work, and ready to ship. The date that the insignia is affixed to the module will be considered the date of manufacture. No module shall be shipped to or within the State of Arizona without having an AZ insignia affixed. Each module shall have an Arizona insignia affixed; this means if a building consists of seven modules, then seven insignia shall be affixed to that building.
CONDITIONS FOR CONTINUING CERTIFICATION
Once a manufacturer has successfully completed the certification process, the following conditions must be met to maintain that certification as valid:
- The first module after certification with any type of construction other than that described in the certification report shall require 100% inspection of that construction by the TPIA. This inspection is in addition to the normal in plant inspection required by the FBB In-Plant Inspection Process. Any modifications or additions to the compliance control manual must be submitted for approval prior to beginning construction. A report of the successful completion of this inspection shall be provided to ADOH and considered as an update to the manufacturer's certification, allowing further production of the new construction type for Arizona.
- A manufacturer shall comply with the requirements of the FBB In-Plant Inspection Process.
- All reporting requirements must be maintained and up to date. (Inspection reports, insignia assignment, etc.)
- A certification shall remain valid for six months from the date of manufacture of the last module manufactured for Arizona. If a manufacturer does not manufacture a module for Arizona for six months, then their certification will be considered as expired. Further production for Arizona shall require re-certification.
FBB CONTINUING IN-PLANT INSPECTION
After certification, inspections of the manufacturing facility are performed by the TPIA to assure that:
- The manufacturer continues to follow their approved compliance control procedures.
- The manufacturer continues to produce units that conform to the approved designs and codes in effect at the time of inspection.
- The units produced conform to the approved designs contained in the design package.
- Corrections are made if an inspection reveals non-compliance.
- When non-compliance to the approved design is discovered in one unit, other related units do not leave the facility with the same non-compliance.
- When the nature of the non-compliance is related to life safety, the manufacturer and OMH are notified so that preceding units may be corrected.
- The approved compliance control procedures prevent covering of non-compliances prior to corrections.
FREQUENCY OF INSPECTIONS
- The TPIA may conduct announced and unannounced inspections at the manufacturing facility at reasonable but varying intervals, at least once per calendar quarter, to review any and all aspects of the manufacturer's production and compliance control program. Inspection of every visible aspect of every module, currently in the production cycle for Arizona, may be made. Similar units in production for other states may be inspected as an aid in evaluating the facility. Inspection of system testing shall be made at least once every third inspection.
- The frequency of inspections shall be increased if a review of the last five inspection reports indicates two or more failures of the compliance control personnel to follow their approved procedures. The increased frequency of inspections may continue until the agency is satisfied that the problem has been corrected.
- The frequency if inspections may be increased if a review of the last ten inspection report indicates failure of the manufacturer to provide an approved design for a unit or units on two or more inspections. The increased frequency of inspections may continue until the agency is satisfied that the problem has been corrected.
- The frequency of inspections may be increased if a review of compliance control travelers for units that received an Arizona insignia since the last inspection displays a failure of the compliance control staff to document inspections in accordance with the manufacturer's approved procedures. The increased frequency of inspections may continue until the agency is satisfied that the problem has been corrected.
- The TPIA shall notify ADOH in writing of changes in the frequency of inspection and the reason for such changes.
Inspection procedures are applicable to all in-plant inspections, including re-inspections.
- The TPIA shall perform an entrance interview at the start of the inspection. During the interview the inspector shall inform the manufacturer:
- that the compliance control procedures must function normally as stated in the approved compliance control manual;
- that the compliance control documents (travelers) will be examined for all units that received an insignia since the last inspection;
- that every Arizona unit in the production process will be inspected. This may include units previously inspected;
- that system testing must be witnessed at least once every third inspection.
- The inspector shall request notification of changes to the approved design package and review the manufacturer's design package before beginning the inspection. The inspector shall also review the inspection reports from the last ten inspections and document uncorrected non-compliances on the present inspection report.
- The inspector shall inspect all visible aspects of every Arizona unit in the production process.
- Non-compliance shall be recorded on the in-plant inspection report. Non-compliance identified and corrected by the manufacturer's production or compliance personnel need not be recorded.
- The inspector may not inform the manufacturer of non-compliance on the units until the manufacturer's compliance control personnel have completed their inspections unless the non-compliance is about to be covered by other construction, or if the inspector has completed the inspection and the non-compliance will not be corrected before he/she leaves the plant.
- If non-compliance is discovered in a unit, then all Arizona units in production shall be inspected for the same non-compliance.
- Failure of the compliance control personnel to perform their required inspections prior to the construction being covered shall be documented as non-compliance.
- Failure of the compliance control personnel to follow their approved procedures shall be documented as non-compliance.
- The TPIA shall notify ADOH of repetitive non-compliance and receive instructions of further action to be taken.
- If the manufacturer does not have an approved design for a unit or units, then the TPIA shall not inspect until the manufacturer produces the necessary approvals. Lack of approved documents shall be recorded as non-compliance on the inspection report.
- The inspector shall review a reasonable sample of the compliance control checklists for units that received an insignia since the last inspection. Inadequate or incomplete compliance control checklists shall be recorded as non-compliance on the inspection report.
- The inspector shall conduct an exit interview at the completion of the inspection to discuss the inspection relative to non-compliance, corrective actions, and any compliance control problems that need to be corrected.
A report of each in-plant inspection shall be compiled by the TPIA. Copies shall be retained by the TPIA and by the manufacturer for a minimum of five years. The TPIA shall file a copy of the inspection report for each in-plant inspection with ADOH by no later than the tenth day of the month following the inspection. Failure to maintain reports current may result in delay in the issuance of Arizona insignia.
The inspection report must be neat and legible and provide enough information to allow someone who is not familiar with the approved design or the product to understand any non-compliance documented. Each report shall include the following:
- Unit serial number for each module inspected.
- OMH plan approval number for each module inspected.
- Production process station or phase for each module at the time module was inspected. Use a brief description of the station process, i.e. decked floor, open roof. Do not use a station number.
- Document and reference (by code, approved plan, etc.) any non-compliance observed and corrective action taken. Include serial number of non-complying unit.
- Document systems testing. Include serial number(s) of tested unit(s).
- A summary and evaluation of the manufacturer's compliance control program at the time of inspection. Include mention of any relevant changes in compliance control personnel.
INSTALLATION AND SITE INSPECTION PROCESS
The installation of Factory Built Buildings shall be inspected by ADOH or other government entities in agreement with ADOH.
Installation inspections of factory built buildings are performed to assure:
- Completion and attachment in accordance with mandatory building codes and the approved design package and on-site construction documentation.
- Completion and attachment in accordance with the foundation system design and unique on-site details that have been sealed by a registered Arizona engineer.
- That all tests required by approved on-site documentation, Arizona installation standards, and mandatory building codes are performed.
FACTORY BUILT BUILDING INSTALLATION PERMIT
A licensee or consumer shall obtain a permit before commencing any installation work and post the permit in a conspicuous location onsite (the following exceptions apply for buildings when not used by the public: single wide FBB's that are used for construction project office purposes; storage buildings of less than one hundred sixty eight square feet; equipment shelters). The licensee who contracts to install a unit or a licensed installer who subcontracts to perform the installation shall verify that a valid installation permit has been obtained before beginning the installation. Installation permit and plans shall expire six (6) months from the date the permit is issued. The Office may extend the permit and plans for good cause. A written request to extend the permit, and payment of an additional fee, shall be submitted to ADOH before the expiration date of the issued permit.
A Special Use Permit for factory built buildings used for special events of forty five (45) days or less may be obtained. The permit is temporary and shall expire forty five (45) days from the date of purchase. The unit shall be removed from the site upon expiration of the permit.
All installation work shall be performed by properly licensed contractors. All work performed shall be in compliance with the statutes and rules of OMH. The permit holder, owner, or contractor shall call for all required inspections. All work listed on the permit shall be accessible (opened) for inspection. Approved plans shall be available on site.
A licensee or consumer shall obtain a certificate of occupancy (COO) from this Department before occupying a commercial or residential factory built building.
INSTALLATION CERTIFICATE INSIGNIA
An installer (ADOH licensee) or a contractor (ROC licensee) shall affix and complete an Arizona Insignia of Approval to each single family Factory Built Building (R-3). An insignia shall be provided by each installer/contractor who performs work on the building and each insignia shall indicate the type of work performed by that installer/contractor.
INTER GOVERNMENTAL AGREEMENT (IGA)
Several cities and counties have entered into Inter Governmental Agreements with OMH to administer aspects of the state permitting and inspection program for factory built buildings. Within the boundaries of these jurisdictions, permitting and inspections will be conducted by these jurisdictions. See the department website for a current list of IGA's.