Download - CALTRANS EXPERIENCE WITH WARRANTIES
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CALTRANS EXPERIENCE WITH WARRANTIES
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WHY WARRANTY
The Right Strategy at the Right Time
•Shift Responsibility of Quality Control to Contractor
•State Responsibility to select good projects for warranty
•Failure Avoidance
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Failure Avoidance
Repair work done by State Maintenance crews.
Severely Bleeding Pavement
Repair work done by State Maintenance crews.
Severely Bleeding Pavement
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Repairs Done By the State after Contract Acceptance
• 20 projects in last 3 years failed to meet expectations
• Over $2.8 million in repairs by the state
• Pavement defects include chip seals and overlays
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HISTORICAL PERSPECTIVE
• FIVE-YEAR WARRANTY REHAB PROJECT IN DISTRICT 2 (1993)
• THREE-YEAR WARRANTY REHAB PROJECT IN DISTRICT 11 (1994)
• SEVERAL FORM 42 MAINTENANCE PROJECTS (1998)
• 2 1/2-YEAR CAP-M WARRANTY PROJECT IN DISRICT 11 (1999)
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HISTORICAL PERSPECTIVE
• TWO-YEAR WARRANTY MAINTENANCE PROJECT IN DISTRICT 2 (2001)
• ONE-YEAR WARRANTY MAINTENANCE PILOT PROGRAM (ON GOING)
• FIVE-YEAR WARRANTY REHABILITAION PILOT PROGRAM (ON GOING)
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DISRICT 2 REHAB PROJECT
• Built in 1993• TWO INVOATIONS:
– Innovative SHRP Mix Design in One Direction– Reduced Thickness Design Over PCC
• Asphalt Rubber Hot Mix Gap Graded (RAC-G)• Five-Year Warranty• It is Now 5-Years after Warranty Period Expired • Performing Well• Mtce Cost Data is Limited to Minor Crack Seal• No Major Maintenance is Currently Planned
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D2-Sha-5 (BUILT IN 1993)
ASPHALT RUBBER HOT MIX - GAP GRADED (RAC-G)
5 YEAR WARRANTY - 5 YEARS AFTER WARRANTY PERIOD
Sha-5-56.2/60.5
•• 1993 REHAB (Warranty)1993 REHAB (Warranty)
•• Maintenance Crack SealingMaintenance Crack Sealing
•• Road Currently in Good ConditionRoad Currently in Good Condition
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Imperial-111-PM 38.0-40.8
(3 Year Warranty)
•Completed Construction 1994 (RAC Type-G)
•Awarded for $1.7 Million
•Preventive PME Chip Seal 2000
•Little or No Maintenance Costs prior to PM Chip
•Continuing to perform well
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FORM 42 MAINTENANCE PROJECTS
•Several Projects By Emergency Contracts
– Built in 1998 •District 11 - AR Chip Seal (1 Year)•District 11 - AR Type G (2 Years)•District 11 - AR Type G (1 Year)• District 7 - AR Type G (1 Year)
– Performing Well
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FORM-42 (2-yr Warranty)
San Diego-54-PM 14.8-16.1
Asphalt Rubber (Type G)
•Construction Completed 1998
•No Maintenance Cost to date
•Performing well
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FORM-42 (1 year Warranty)
San Diego-94-PM 9.9-10.5
Asphalt Rubber (Type G)
•Construction Completed 1998
•No Maintenance Cost to date
•Little to no cracking present
•Good Candidate for addition PM Seal coat
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FORM-42
Los Angeles-138-PM 0.0-2.6
Asphalt Rubber (Type-G)
•Project constructed in 1998•Continues to show excellent performance with little to no cracking
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Form-42 (1-yr Warranty)
Imperial-78-PM 34.8-42.8
Asphalt Rubber Chip Seal
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Form-42 (1-yr Warranty)
Imperial-78-PM 34.8-42.8
Asphalt Rubber Chip Seal
•Constructed in 1998•Note resistance to reflective cracking•Little to no cracking in the travelway.•Performing well
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ONE-YEAR WARRANTY PILOT PROGRAM
• Purpose – Improve Quality of Surface Treatments
Without Significantly Increasing Initial Cost
– Shifting QC Responsibility to the Contractor
– Preventive Maintenance Projects
• Over 30 Projects are Planned• Warranty Pilot began 1998
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ONE-YEAR WARRANTY PILOT PROGRAM
• Preventive Maintenance Strategies– Seals
• AR Chip Seal• Slurry & Microsurfacing• PME/PMA Chip Seal
– Overlays• Conventional AC – Dense Graded/Open
Graded/PBA• Rubberized AC – Open Graded/High Binder
– Experimental• Bonded Wearing Course/Various
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ONE-YEAR WARRANTY PILOT PROGRAM
• Developed Specifications Jointly with Industry
• Preventative Maintenance Projects• Minimum Exclusions (Less than 15%)• Good Performance• No Claims
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ONE-YEAR WARRANTY PILOT PROGRAM
• 6 Projects – Constructed & Out of Warranty Period
• 4 Projects – Constructed & Still in the Warranty Period
• 7 Projects – Bid & Pre-Construction Rating was Performed
• 7 Projects – Planned for 03/04 FY
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ONE-YEAR PILOT PROJECT PROGRAM
• CONTINUOUS EVALUATION• FIELD PERFORMANCE• COST COMPARISON - WARRANTY PROJECTS VS.
NON-WARRANTY PROJECTS• COST DURING CONSTRUCTION - WARRANTY VS.
NON-WARRANTY• COST INCURRED BY CONSTRUCTION DURING
WARRANTY PERIOD• COST INCURRED BY MAINTENANCE DURING FIRST
YEAR AFTER CONSTRUCTION• COST PER LANE MILE - WARRANTY VS. NON-
WARRANTY
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D6-Fre-5
OPEN GRADED ASPHALT RUBBER - HIG BINDERWarranty Started on 12/08/00
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Lessons LearnedContractor Vs. Dept. of Transportation
SBD-5 [RAC High Binder (Type-O)]
• Quality Control (New Mix)– Numerous Trial Mix Designs – Aggregate Plant modified to keep up
with needed production– Temperature Sensitive and haul time
• Contractor Cost• increase material by $3.33 per ton• cost per lane mile $37,000/ln-MI
• Risks– State concurrence for exclusions– Mobilize Rubber plant for repairs– Possible demands for multi-repair
mobilization– Performance Measures– High Binder
• Transfer risk to contractor
• Select the right project to warranty
• Designers and Engineers need better understanding of specifications
• Exclusions shown on the plans
• Contractor and Engineer need more time to review project
• All projects need Pre and Post Evaluations
• Specs needed modification– rut depth specified
– exclusion from cracks
• Improved Materials and Workmanship– no claims and only minor repairs
Contractors State
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D8- SBD Route 40
OPEN GRADED ASPHALT RUBBER - HIG BINDERWarranty Started on 7/19/01
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Lessons LearnedContractor Vs. Dept. of Transportation
SBD- Route 40 [RAC High Binder (Type-O)]
• Request for exclusions
• Issues over the rut depth specified
• Contractor requested exclusion of all ruts. Average (rut depth 8-9mm)
• Issue with unknown stability of mix
• Existing pavement Crack issue• 30% of project was warranted
• Designers and Engineers need better understanding of specifications
• Exclusions shown on the plans• Contractor and Engineer need
more time to review project• All projects need Pre and Post
Evaluations• Specs needed modification
– rut depth specified
– exclusion from cracks
• 100% of project benefited from warranty
• No claims performing well.
Contractors State
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ONE-YEAR PILOT PROJECT PROGRAM
– SOME FINDINGS:• PERFORMING WELL - NO WARRANTY
FAILURES • NO CLAIMS• COST INCREASE (4% TO 14%)• CONTRACTORS TOOK EXTRA EFFORT• NO PROBLEMS ENCOUNTERED WITH THE
SPECIFICATION
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ONE-YEAR PILOT PROJECT PROGRAM
– SOME FINDINGS:• PERFORMING WELL - NO WARRANTY
FAILURES • NO CLAIMS• COST INCREDASE (4% TO 14%)• CONTRACTORS TOOK EXTRA EFFORT• NO PROBLEMS ENCOUNTERED WITH THE
SPECIFICATION
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Contract Items for Preparatory Work
• Need good up-front engineering– Good strategies– Good estimates
• Need pay items– Dig outs– Grinding– Etc.
• Excluded work and work limits must be clear
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Performance is a Department Goal
• Warranties require performance specifications– Means and methods specifications and
warranties aren’t compatible– “As directed by the Engineer” is out– “As needed to guarantee the work” is in
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Quality Control is the Contractor’s Business
• Cultural shift for contractor and State• Contractors decide the outcome
– Chip seal spread rate– Atmospheric temperature during placement– Smoothness– Etc.
• How much control is needed to meet minimum quality for warranty period?
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Work Completion/Warranty Switchover
• Need process to switch from completed work to warranty period– Performance bond to warranty bond– Construction to monitoring– Similar to plant establishment period?
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Performance vs. Warranty Bonds
• AB 1745 Public contracts: bonds. – Would require a state department to
provide the contractor the option of either submitting a separate warranty bond to the department upon completion of the work or permitting the department to retain the contractor's performance and payment bonds until the end of the warranty period.
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Who decides if warranty repair work is needed?
• Resident Engineer (RE)– REs continue to be the State’s
Representative during warranty period.– REs move on to other contracts
• Maintenance Supervisor?– Drive the roadway every day– Vested interest– Knowledgeable
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FIVE-YEAR WARRANTY PILOT PROGRAM
• REHABILITAITON PROJECTS (10-YR DESIGN LIFE)• MINIMUM 15% ASPHALT RUBBER• THE SPEC IS OPEN TO ALL PROCESSES• FIVE PROJECTS• ONE PROJECT CONSTRUCTED IN D-7 ON ROUTE
150• FOUR PROJECTS WILL BE CONSTRUCTED IN 03/04
– D2 - Route 395– D6 - Route 33– D10 - Route 140– D11 - Route 75
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How to get quality product by low bid?
• Improve up front engineering• Performance specifications• Warranty• Contractor’s prepare and follow
quality control plan
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ALTERNATIVE ACCEPTANCE
DISTRICT 11 CAP-M PROJECT• Built in 1999 on ROUTE 8 - IMPERIAL COUNTY• CAP-M (5-YEAR DESIGN LIFE)• ASPHALT RUBBER HOT MIX - GAP GRADED
(RAC-G)• IT WAS NOT BID AS A WARRANTY PROJECT• CONTRACTOR FAILED COMPACTION• 2 1/2 WARRANTY PERIOD• CONTRACTOR CHOSE TO WARRANTY
PAVEMENT INSTEAD OF PAYING PENALTY• IT WILL BE OUT OF WARRANTY IN OCT 2003• performing Well
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SUMMARY
• LIMITED EXPERIENCE WITH WARRANTIES• LIMITED NUMBER OF PROJECTS• REHAB AND MAINTENANCE PROJECTS• EXPERIMENTAL AND INNOVATIVE PROJECTS• TO ENSURE AGAINST FAILURE WHEN SPECS
ARE NOT MET DURING CONSTRUCTION• TO TRY A NEW REPAIR STRATEGY • TWO PILOT PROGRAMS:
– ONE-YEAR WARANTY ON PREVENTIVE MAINTENANCE PROJECTS
– 5-YEAR WARRANY ON RAC-G REHABILITATION PROJECTS