Quality oversights in the field often get reported late—after installation, after handoff, or after the invoice is paid. This blog provides a field-level snapshot of QA/QC issues that could have been avoided with better process rigor.
The Incident: IGU Failures in a Corporate Office Build
A distributor provided IGUs for an energy-efficient corporate HQ. Within six months, interior fogging appeared in 15 panels. A forensic analysis showed weak perimeter seals on a specific production batch—caused by outdated sealant materials that were not rotated in warehouse storage.
The defect was missed during QA because only visual inspection was performed—no adhesion tests or sealant batch tracking were included in the QA checklist.
Oversights Identified
QA process didn’t include sealant expiration tracking
No adhesion testing was performed on the day of production
Vendor sealant handling logs were never audited
The Fallout
Cost of replacement panels and installation: $90,000
Project awarded to a competitor for next three building phases
Internal QA audit uncovered multiple similar risks across other product lines
Reforms Enacted
Material Lot Expiry Tracking Enforced
All time-sensitive materials (sealants, interlayers, adhesives) are now tracked and rotated by lot.
Randomized QA Spot Testing Protocol Added
QA now includes destructive testing for bonding strength, not just surface review.
Vendor Material Logs Audited Quarterly
All vendors must submit and verify their own QA processes, reviewed by the distributor’s QA team.
Final Insight
QA is not just about checking products—it’s about validating processes. If materials aren’t verified at every stage, failures become inevitable.
