experience with the qc/qa/ov program on the dfw connector · 2017. 1. 4. · experience with the...
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Experience with the QC/QA/OV Program on the DFW
Connector M Kim Soucek, PE Gordon Peterson, PE Jon Green, PE Robert Schenck, PE
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• DFW Connector
Project • Project Organization • Quality Control • Quality Acceptance • Owner Verification • When ”IT” Happens
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The DFW Connector
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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
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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
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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
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Production & QC responsibility
Quality Acceptance
Independent Assurance
Typical TxDOT - Quality Process
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TxDOT Owner
NorthGate Constructors
Developer
NorthGate Constructors
QC – Quality Control
PSI QA – Quality Acceptance
Jacobs Engineering GEC
PaveTex OVT – Owner Verification
Testing
Comprehensive Development Agreement (CDA) Quality Organization
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Production Quality Control Quality
Acceptance Oversight
Design Build - Quality Process
Independent QA Firm TxDOT & Consultants
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Production Quality Control Quality
Acceptance Oversight
Design Build - Quality Process
Independent QA Firm TxDOT & Consultants
Gordon Peterson, PE
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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
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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
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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
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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
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Production Quality Control Quality
Acceptance Oversight
Design Build - Quality Process
Independent QA Firm TxDOT & Consultants
Jon Green, PE
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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
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• 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
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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
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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
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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
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Steel Checklist Approved by TxDOT References
QA Reinforcing Steel Checklist
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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
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Concrete pour checklists Referencing specs for TxDOT Specs 420 & 421
QA Concrete Pour Checklist
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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.
QA Concrete Pour Checklist
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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.
QA Concrete Pour Checklist
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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
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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
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Electronic Test Data Collection
In the Field, Real Time On Hand Held,
Internet Enabled Devices – 3G, 4G, Cellular connections
Quality Acceptance
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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
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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
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Program Benefits
Transparency Results within 24 hours Auditable Electronic Access to Drawings and Specifications
Quality Acceptance
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Production Quality Control Quality
Acceptance Oversight
Design Build - Quality Process
Independent QA Firm TxDOT & Consultants
M Kim Soucek, PE
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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
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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
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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
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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
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When things don’t go per plan…
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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
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Review Comment Resolution Meeting
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Request for Information
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Request for Information
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Notice of Design Change
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Non Conformance 654
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Field Design Change
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Additional layer of insulation
Check ambient temperature
Monitoring Plan
Revise Thermal Control Plan
Corrective Actions
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Daily Emails – Temperature Alerts
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Group Initiating Non Conformances
Design, 1
Production 339 QA 219
QC 60
TxDOT, 10
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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
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TxDOT Owner
NorthGate Constructors
Developer
NorthGate Constructors
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
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Quality Process
Production Quality Control Quality
Acceptance Oversight
Independent QA Firm TxDOT & Consultants
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