1 Quality Control Program

2 Objectives To know: To know: –How the QC Program is Doing –Effect of Specification Changes on the QC Program –Contractor QC Plan Approval/ Revision/ Suspension Process –Roles and Responsibilities

Quality Assurance Procedure for Construction QAPC Personnel Qualification Final Project Materials Certification Independent Assurance Sampling Testing & Reporting Guide Lab Qualification CQC CTQP LQP Field Tests Lab Tests Mat. Cert. IA Procedure MM 5.4

4 QC Program…What did we learn?

Percentage of Projects Certified without Exceptions 2005  36% 2006  43% --OR-- Average number of Exceptions (per Projects with Exceptions) 2005   2.02 The overall result of the Program is fewer Exceptions

All Materials Overall, the exceptions for Documentation, Minimum Frequency, Non-Standard Material and Qualification are decreasing in occurrence. GOOD

Asphalt (Superpave) Material The occurrence of Minimum Frequency and Qualification reduced in 2006 GOOD

Concrete (Structural) Material The occurrence of Minimum Frequency reduced in 2006 GOOD

Earthwork Materials With the exceptions of Minimum Frequency, the numbers are going in the right direction GOOD

QC Samples Comparison QC Samples Comparison *QC Stabilized Subgrade samples have consistently increased comparison with V and R samples for the last 3 years GOOD Asphalt Concrete Embankment Subgrade Limerock

11 One thing we learned from the QC Program from a comparison standpoint… There have been some issues with the random number not coming up at the end of the concrete pour. In speaking with the State Concrete Engineer, the recommended process is to make the set of Independent Verification cylinders before the final truck leaves. In speaking with the State Concrete Engineer, the recommended process is to make the set of Independent Verification cylinders before the final truck leaves.

12 Technicians have the most difficulty in: 1. Capping Cylinders30% 2. Compressive Strength 25% 3. Drying of Aggregate 25% 4. Neoprene Caps 24% 5. LBR 21%

13 And now for something a little different

14 Remove Restrictions (R 2 ) Specifications & QC Program

15 Material Issues: Visual inspection for projects with less than 2000 tons of Type SP and FC (combined) Visual inspection for projects with less than 2000 tons of Type SP and FC (combined) 20-day LOT termination instead of 60-days 20-day LOT termination instead of 60-days District Independent Verification testing now includes a split sample District Independent Verification testing now includes a split sample No shutdown for QC MPR gradation failures on the #8 sieve No shutdown for QC MPR gradation failures on the #8 sieve Asphalt R 2 Specs

16 Asphalt R 2 Specs cont. Material Issues: TL-A mix design: paper verify only TL-A mix design: paper verify only Reduced aggregate requirements for TL-A & B Reduced aggregate requirements for TL-A & B Changed lab compaction for TL-B Changed lab compaction for TL-B 1% reduction in VMA for TL-A & B 1% reduction in VMA for TL-A & B No moisture testing for TL-A & B (use 0.5% anti-strip agent) No moisture testing for TL-A & B (use 0.5% anti-strip agent) New provisions for fractionated RAP New provisions for fractionated RAP

17 Acceptance issues: New acceptance option for TL-A & B New acceptance option for TL-A & B Option 1 – CQC as it now Option 1 – CQC as it now Option 2 – FDOT testing and reporting Option 2 – FDOT testing and reporting Contractor makes choice at pre- construction conference Contractor makes choice at pre- construction conference Asphalt R 2 Specs cont.

18 Acceptance issues: Option 2 specifics (TL-A and TL-B only) : Option 2 specifics (TL-A and TL-B only) : –FDOT samples randomly once/day –1 day = 1 SubLOT / 4 SubLOTs = 1 LOT –7-day max for a LOT –Randomly test one of the four SubLOTs –AC, gradation, density (no air voids) Asphalt R 2 Specs cont.

19 Asphalt R 2 Specs cont. Acceptance issues: Option 2 specifics (cont.): Option 2 specifics (cont.): –Uses acceptance table (two columns) –100% pay, no pay or remove and replace. –Reporting by FDOT. –No QC requirements. Plan, Lab, Personnel Plan, Lab, Personnel

20 Concrete R 2 Specs Spec 346 General effects: General effects: –Electronic delivery ticket –Either 4 x 8 inch or 6 x 12 inch cylinders are acceptable –Frequency changes Drilled Shafts: Drilled Shafts: –Slump range between 7.5 inches and 9.5 inches

21 Concrete R 2 Specs cont. Class I (Special) & II excluding Bridge Decks: Class I (Special) & II excluding Bridge Decks: –Fly ash or slag –Aggregate Gradations –Air entraining admixture is optional –Cementitious Material –Department may perform inspections in lieu of plastic properties test

22 Earthwork R 2 Specs For bike/shared use paths, sidewalks, & paved shoulders – –Reduces density test frequency by re- defining LOTs to 2000 ft or one day’s production (whichever is greater) – –“Witness & Hold” for Stabilizing Depth, Base Depth & Surface Irregularities – –Option to Eliminate LBR Sampling and Testing in Subgrade by using Pre-Designed Subgrade

23 Earthwork R 2 Specs cont. For all other roadway construction – –Allows Reduced Frequency for pipe backfill – –Eliminates Density Testing Outside Control Line – –Introduced “Witness & Hold” concept for Stabilizing Depth, Base Depth & Surface Irregularities

24 Break Time

25 Teleconference with Technical Experts

26 Contractor’s Quality Control Recap from the Puzzle Recap from the Puzzle Information from LIMS Information from LIMS EAR Process EAR Process Changes to QCP Changes to QCP QC Manager Philosophy QC Manager Philosophy Others: Who does what? Others: Who does what?

27 Contractor’s Quality Control Recap from the Puzzle Recap from the Puzzle Information from LIMS Information from LIMS EAR Process EAR Process Changes to QCP Changes to QCP QC Manager Philosophy QC Manager Philosophy Others: Who does what? Others: Who does what?

28 Laboratory Qualification Program Contractor’s QC Plan Producer QC Program Contractor QC Manual LIMS Access Constructio n Begins Certificatio n & Exceptions Testing Material Disposition Construction Begins

29 Contractor’s Quality Control Recap from the Puzzle Recap from the Puzzle Information from LIMS Information from LIMS EAR Process EAR Process Changes to QCP Changes to QCP QC Manager Philosophy QC Manager Philosophy Others: Who does what? Others: Who does what?

Contractor QCP Approval turn around time for Materials Offices Average Time (Days) 0ver 7 Days %No Statewide /63083/499

Suspended Plants of 408 plants suspended of 431 plants suspended

Category # 2005 # 2006 Total6564 Material not on Spec 33 Quality Control Plan Deficiency 41 Unapproved Source 63 Notified, No Action 00 Unidentified Reasons 5257 Untimely Info 00 Suspended QC Program

33 QC Test Reporting Time Days10.1% < 1 Day Days 9.45% < 1 Day DaysN/A

34 Contractor’s Quality Control Recap from the Puzzle Recap from the Puzzle Information from LIMS Information from LIMS EAR Process EAR Process Changes to QCP Changes to QCP QC Manager Philosophy QC Manager Philosophy Others: Who does what? Others: Who does what?

35 Defective Material on the Project Contractor Proposes to leave In place Contractor Forwards EAR & scope to PA PA confers with RE& Initiates DDM PA & RE Recommend Remove & Replace? PA fills out DDM Form section B Material is Removed & Replaced Yes

36 PA & RE Recommend Remove & Replace? No PA completes section B for forwards to DME DME determines EAR needed? Contractor Performs EAR & submits To PA PA forwards EAR To DME DME reviews And completes Section D Of DDM form DCE completes Section E Of DDM form Does DCE concur? DME finalizes Scope of EAR PA sends Approved scope to Contractor Yes

37 DME determines EAR needed? Does DCE concur? DCE completes Section E Of DDM form Yes Construction Determines Pay & PA completes Section G of DDM form No DME recommends Remove & Replace OR leave in place, & completes section C of DDM No Director, Office of Construction Completes section F of DDM

38 Contractor’s Quality Control Recap from the Puzzle Recap from the Puzzle Information from LIMS Information from LIMS EAR Process EAR Process Changes to QCP Changes to QCP QC Manager Philosophy QC Manager Philosophy Others: Who does what? Others: Who does what?

39 What do you include in the Contractor’s QC Plan?

40 Technicians Labs Producers Process Control Documentation Storage Material Handling Transportation Field Ops Failing Material Certification

41 Why is it important to change the QC Plan/ QC Program when there is a change?

Unresolved Deficiencies Technicians Labs Producers Process Control Documentation Storage Material Handling Transportation Field Ops Failing Material Certification Timely Info Repeated Failure Material Not controlled Non Responsive To Notice

43 Contractor’s Quality Control Recap from the Puzzle Recap from the Puzzle Information from LIMS Information from LIMS EAR Process EAR Process Changes to QCP Changes to QCP QC Manager Philosophy QC Manager Philosophy Others: Who does what? Others: Who does what?

44 QC Manager Role Overview Pre-Bid Pre- Construction Construction Post-Construction

45 Review Plan QC Needs Review Plan QC Needs Estimate QC Manpower Estimate QC Manpower Identify Qualified Subs Identify Qualified Subs Establish Rework Goals Establish Rework Goals QC Manager Role Overview Pre-bid QC Manager Role Overview Pre-bid

46 Prepare & Submit QC Plan Assure Techs, Labs, Plants are on the list Communicate with Department QC Manager Role Overview Pre-Construction QC Manager Role Overview Pre-Construction

47 Control the quality Administer QC Plan Monitor QC Activities & Evaluate Performance Provide Monthly Certification w/EXCEPTIONS Maintain Records Process DDM/EAR in time Assure LIMS data entry is up-to-date Provide Mfgr. certifications to the Dept. QC Manager Role Overview Construction QC Manager Role Overview Construction

48 Review completeness of Sampling/ Testing Review Completeness of LIMS reporting Assure all EAR’s/ DDM are closed Provide Final Construction Compliance with Specifications and Plans with EXCEPTIONS Warrantee Items QC Manager Role Overview Post-Construction QC Manager Role Overview Post-Construction

PA writes Deficiency Letters, copies SCTA QC Manager Suspension SCTA writes letter of warning to QC Mgr. Letter is valid for 365 days SCTA writes suspension letter to QC Mgr., notifies CTQP QC Mgr. Suspended* Yes 1 st letter of warning Deleted 2 nd warning letter within 365 days? No Yes Need for 3 rd letter w/in 365 days? No Both letters of warning Deleted

50 Contractor’s Quality Control Recap from the Puzzle Recap from the Puzzle Information from LIMS Information from LIMS EAR Process EAR Process Changes to QCP Changes to QCP QC Manager Philosophy QC Manager Philosophy Others: Who does what? Others: Who does what?

51 Producer Control the process Control the process Get Producer QC Program accepted Get Producer QC Program accepted Supply the material that meets contract requirements Supply the material that meets contract requirements Supply the material produced under approved QC Program Supply the material produced under approved QC Program Monitor & Update QC Program Monitor & Update QC Program Communicate with the Contractor QC Manager/ FDOT Communicate with the Contractor QC Manager/ FDOT

52 Project Administrator Prime Department contact Prime Department contact Coordinates & Administers Contractor QC Plan Coordinates & Administers Contractor QC Plan Assures QC sampling, testing, and documentation per contract Assures QC sampling, testing, and documentation per contract Prepares Project Administrator’s Material Statement w/ Exceptions Prepares Project Administrator’s Material Statement w/ Exceptions

53 Resident Engineer Contractor QC Plan Approval Contractor QC Plan Approval Contractor QC Plan Revision Approval Contractor QC Plan Revision Approval Contractor QC Plan Suspension Contractor QC Plan Suspension

54 District Construction Office Coordinates QC Manuals review Coordinates QC Manuals review Monitors disposition of defective material Monitors disposition of defective material Assures QC compliance by Contractor Assures QC compliance by Contractor

55 District Materials Office Provide technical support to PAs Provide technical support to PAs Assist in DDM/ EAR Assist in DDM/ EAR Accept & Administer Producer QC Program Accept & Administer Producer QC Program Review Contractor QC Plans & Manuals Review Contractor QC Plans & Manuals Maintain accurate Plant Information in LIMS Maintain accurate Plant Information in LIMS Add Producer QC Programs to MDMS Add Producer QC Programs to MDMS Perform IA activities Perform IA activities Assist in final project certification Assist in final project certification

56 State Construction Office Provide statewide support to QC Program Provide statewide support to QC Program Administer Contractor Quality Control Manual approval Administer Contractor Quality Control Manual approval Manage QC Manager Letters of warning & suspension Manage QC Manager Letters of warning & suspension

57 State Materials Office Provide statewide support to QC Program Provide statewide support to QC Program Mix Design Approval / Verification Mix Design Approval / Verification Producer QC Program approval Producer QC Program approval Final Project Material Certification (Full Federal Oversight) Final Project Material Certification (Full Federal Oversight)

58 Contractor Quality Control Information statematerialsoffice/

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60 Questions Questions? Questions? Comments? Comments?