experience with the qc/qa/ov program on the dfw connector · 2017. 1. 4. · experience with the...

Experience with the QC/QA/OV Program on the DFW

Connector M Kim Soucek, PE Gordon Peterson, PE Jon Green, PE Robert Schenck, PE

• DFW Connector

Project • Project Organization • Quality Control • Quality Acceptance • Owner Verification • When ”IT” Happens

The DFW Connector

Typical Design Bid Build 12-15 years

estimated schedule

Design Build 5 years from

Design to Completion

Over a year ahead of Schedule

Project Stats

Project Quality Stats

Ride Quality Concrete Pavement Spec requirement 75, achieving 63, minimums of 45 No Bonus Incentive

http://static.tti.tamu.edu/conferences/tsc12/presentations/materials-2/SoucekVideo-DFW4.wmv

Traffic Control and Detours 160,000 vehicles a day DFW airport traffic

- 8th Busiest Airport in the world Minimal complaints Many compliments

Project Quality Stats

Production & QC responsibility

Quality Acceptance

Independent Assurance

Typical TxDOT - Quality Process

TxDOT Owner

NorthGate Constructors

Developer


QC – Quality Control

PSI QA – Quality Acceptance

Jacobs Engineering GEC

PaveTex OVT – Owner Verification

Testing

Comprehensive Development Agreement (CDA) Quality Organization

Production Quality Control Quality

Acceptance Oversight

Design Build - Quality Process

Independent QA Firm TxDOT & Consultants





Gordon Peterson, PE

Quality Management Plan

QUALITY MANAGEMENT

PLAN QUALITY SYSTEM

PROCEDURES

DQMP CQMP

Design Records

DQP QCP QAP

Construction Records

Systems Records

Construction Quality Management Plan Quality Acceptance Procedures Quality Control Procedures

ISO 9000:2001 Systems

Reputation If it Looks Bad, It is Bad

Attitude – Pride in Your Work Attack Your Problems

Do It Right The First Time Finish as We Go

Work Area – Drainage, Material Handling, Access

Quality Control

Inspections Quality Designate on every

crew Sanity Checks by QC

Inspectors Field Testing Densities, lime gradations, Structural concrete slump &

air Laboratory Aggregates, Sulfates, Class P

Concrete

Process Control

Quality Control

Work Plans Pre Activity Meetings Initial Inspections Daily Checklists Material Receiving Punchlists

Audited by QA

Construction Quality Control Procedures

Quality Control

Robert Schenck, PE Jon Green, PE





Jon Green, PE

Overview QA Role

AASHTO R-18 Accredited Lab

TxAPA Certified Inspectors and Testers

Managers are PE’s

Construction Quality Acceptance Manager

Deputy Construction Quality Acceptance Manager

Grading/Drainage Engineer

Paving Engineer

Quality Acceptance

Quality Acceptance

• Testing per TxDOT Minimum Sampling and Testing Guide Schedule

• Inspection/Documentation per plans and specs • Hold Points • Inspection Checklists approved by TxDOT

Quality Acceptance

Quality Acceptance

Concrete Pour (Entrained Air Testing) 3 outcomes

- Air within limit Continue pour

- Air 1½% to 3% over Inspector contacts CQAM

- CQAM reject, or - CQAM Engineer Judge, take cylinders accept if strength is good, or - If strength is low, issues NCR, needs Design evaluation

- Air over 3% Inspector Rejects

Example of QA Process

Quality Acceptance

Engineering Judgments (With TxDOT Concurrence) Can make material and construction judgments

Cannot make Design Changes Can issue Non Conformances to get disposition

Audited by TxDOT and OVT

Quality Acceptance Process

Quality Acceptance

Documenting the daily operations inspected Work being referenced to

the approved construction drawings and TxDOT specifications.

Documenting any nonconformances or deficiencies that were observed and/or corrected.

This report is in reference to NDC 350 and NCR 654.

QA Daily Observation Report

Steel Checklist Approved by TxDOT References

QA Reinforcing Steel Checklist

Steel Checklist Approved by TxDOT References TxDOT Specs

- i.e. 440.3.C refers to storage of materials and cleanliness when placed.

QA Reinforcing Steel Checklist

Concrete pour checklists Referencing specs for TxDOT Specs 420 & 421

QA Concrete Pour Checklist

Concrete pour checklists Referencing specs for TxDOT Specs 420 & 421 i.e. 420.4.G.8 states that concrete must have a free fall of less than 5 feet.


Concrete pour checklists Referencing specs for TxDOT Specs 420 & 421 i.e. 420.4.G.8 states that concrete must have a free fall of less than 5 feet. i.e. 421.4.A states max water/cement ratio is not exceeded.


Concrete truck log report Shows each truck’s info i.e. Ticket/Truck # CY/CY Placed Time in Truck Test Results Water Added Cylinders Made

QA Concrete Truck Log Report

Quantity tracking report

Documents the amount of material installed to help track the testing frequency meets the TxDOT Guide Schedule of Sampling & Testing

- i.e. 27 Cubic Yards of Concrete was placed and 1 Random Test was performed for this structural concrete pour.

QA Quantity Tracking Report

Quality Acceptance

Electronic Test Data Collection

In the Field, Real Time On Hand Held,

Internet Enabled Devices – 3G, 4G, Cellular connections

Quality Acceptance

Day to Day Use

Data Going In Directly to Electronic System Concrete Testing Nuclear Density Testing Sample Pickups Asphalt Sampling Inspection Reports Checklists

Ready to Review Ready to Interface

Some Benefits in the Field

Immediate Data Entry – Can summarize a draft of failing density tests for retests

Nuclear Density Testing – Choose proctor from lab results – no copying errors – Calculated % Compaction

Concrete Testing – Cylinders registered automatically – lab knows about them

Sample Pickup – Automatically register lab tests

All Data Entry Recorded, Auditable Quality

Acceptance

Program Benefits

Transparency Results within 24 hours Auditable Electronic Access to Drawings and Specifications

Quality Acceptance





M Kim Soucek, PE

TxDOT Responsibility to FHWA

Audit QA processes, lab, equipment, personnel

Verify Appropriate Inspection by QA per the contract documents and QAP

Verify QA test results Required for FHWA reimbursement Produce a Quarterly Report for FHWA Level 1, 2, 3 – Owner Verification Analysis

Purpose of Oversight

Oversight

Oversight Verification

Level Frequency Test or Observation Examples

Risk of Failure Past 15 Year Maintenance

Terms

1 10%

Testing Continuous Statistical Analysis

- Soil, Base, and Hot Mix Densities

- Concrete Depth, Slumps, Air, & Strength

Higher Residual Risk

2 1 per Quarter

Testing Independent Verification

- Proctors - Aggregate Gradation

Lower Risk

Secondary Indicator of performance

3 1 per Quarter

Observation Verification

- Moisture Density - Tex 114

Lowest Risk

Levels for Analysis Level 1 Level 2 Level 3

EMBANKMENTS, SUBGRADES, BACKFILL, AND BASE COURSES

MATERIAL OR PRODUCT TEST FOR TEST NO.

TxDOT RECOMMENDED

EMBANKMENT (CUTS & FILLS)

Liquid Limit Tex-104-E 2

Plasticity Index Tex-106-E 1

Linear Shrinkage Tex-107-E 2

Gradation Tex-110-E 2

Moisture/Density Tex-114-E 3

In-Place Density Tex-115-E 1

Are the average values of the QA & OVT the same value? T-Test

Is the spread of results the same between the QA & OVT? F-Test

What Statistics Are We Using?

Oversight

When things don’t go per plan…

Key Design Build Quality Processes

RFI (Request for Information)

NDC (Notice of Design Change)

FDC (Field Design Change)

NCR (Non Conformance Report)

Corrective Actions

All go through Designer, Developer, and TxDOT

Concurrence QA and QC has Authority to

Stop Work

Review Comment Resolution Meeting

Request for Information

Notice of Design Change

Non Conformance 654

Field Design Change

Additional layer of insulation

Check ambient temperature

Monitoring Plan

Revise Thermal Control Plan

Corrective Actions

Daily Emails – Temperature Alerts

Group Initiating Non Conformances

Design, 1

Production 339 QA 219

QC 60

TxDOT, 10

Open & Transparent Quality is Everyone’s Job Fast Construction & Innovations Contractual Balance of Control Respect & Trust

• Professional Engineers

• Firm’s License

• Reputation

• The Next Job

Summary - TxDOT Perspective

TxDOT Owner


Developer


QC – Quality Control

Contractor

PSI QA – Quality Acceptance

Area Office

Jacobs Engineering GEC

PaveTex OVT – Owner Verification

Testing

District Office Typical Role on TxDOT

project

Comprehensive Development Agreement (CDA) Quality Organization

Quality Process




Experience with the QC/QA/OV Program on the DFW�ConnectorSlide Number 2Slide Number 3The DFW ConnectorProject StatsProject Quality StatsProject Quality StatsTypical TxDOT - Quality ProcessComprehensive Development Agreement (CDA)�Quality OrganizationDesign Build - Quality ProcessDesign Build - Quality ProcessQuality Management PlanFundamentals of QualityProcess ControlConstruction Quality Control ProceduresDesign Build - Quality ProcessQuality AcceptanceQuality AcceptanceExample of QA ProcessQuality Acceptance ProcessQA Daily Observation ReportQA Reinforcing Steel ChecklistQA Reinforcing Steel ChecklistQA Concrete Pour ChecklistQA Concrete Pour ChecklistQA Concrete Pour ChecklistQA Concrete Truck Log ReportSlide Number 28Slide Number 29QA Quantity Tracking ReportElectronic Test Data CollectionDay to Day UseSome Benefits in the FieldProgram BenefitsDesign Build - Quality ProcessPurpose of OversightOversight Verification Slide Number 38What Statistics Are We Using?When things don’t go per plan…Key Design Build Quality ProcessesSlide Number 42Review Comment Resolution MeetingRequest for InformationSlide Number 45Request for InformationNotice of Design ChangeNon Conformance 654Field Design ChangeSlide Number 50Slide Number 51Corrective ActionsDaily Emails – Temperature AlertsSlide Number 54Group Initiating Non ConformancesSummary - TxDOT PerspectiveSlide Number 57Slide Number 58Comprehensive Development Agreement (CDA) Quality OrganizationQuality Process