1. Construction Management
Materials acceptance and quality assurance program (Qap)

2. Materials Acceptance & QAP
Reference:
LAPM Chapter 16.14
Caltrans QAP 2015

3. Quality Assurance Program
Sampling and testing program that provides assurance that the materials and workmanship are in conformance with the contract specifications
Main elements are acceptance testing and independent assurance sampling and testing

4. Quality Assurance Program
Requirements for the type of QAP depends on the project.
National Highway System (NHS) - Caltrans QAP
Non-NHS - Local agency may adopt their own QAP, or adopt Caltrans QAP.

5. NHS Projects Local agencies must follow Caltrans QAP
Independent Assurance Sampling and Testing (IAST) is performed by Caltrans
Consultant testing firms will participate in approved Caltrans correlation testing program
AMRL - AASHTO Materials Reference Laboratory
CCRL - Cement and Concrete Reference Laboratory
RSP - Caltrans Reference Samples Program

6. NHS Projects Methods for accepting material: Sampling and testing
Source Inspection
Certificate of compliance for manufactured products
Products must not involve structural integrity or safety to the public

7. Non-NHS Projects
Local agencies must adopt a QAP, may be Caltrans QAP. QAP must have as a minimum:
Manufactured Materials
Source Inspection
Job site inspection
Certificate of Compliance
Acceptance Testing
Regular testing of material to verify it complies with the contract
IAST - procedures
Verify that acceptance testing is performed correctly
Must be approved by the Public Works Director.
Non-registered PWDs must delegate to a City Engineer who is registered.

8. Sampling and Testing Preliminary Samples and Tests
Used to determine the ability of material or product to meet specifications
Indicate to contractor the extent of processing and control required
Acceptance Sampling and Testing
Should start on the first day material is delivered
Indicate to contractor the extent of processing and control required
Frequency tables are to be used as a guide.

9. Acceptance Testing (AT)
Initial results should be sent to RE at the earliest possible time
Maintain a testing log - identify re-testing of failed material
Samples should be taken where specified in the special provisions. If none is identified, sample where indicated in frequency tables

10. Reporting Test Results
Sieve Analysis, SE and CV - 24 hours after sampling at materials plant
Compaction and Maximum Density - 24 hours after sampling at the job site
Sieve Analysis, SE and CV - 72 hours after sampling at the job site
R-Value and asphalt concrete extraction within 96 hours after sampling

11. Source Inspection
Acceptance testing of manufactured and prefabricated materials at locations other than the job site for Tier 1 and 2 products
If local agency cannot perform, and qualified consultants are not available, the agency may request METS to sample
METS will only agree to the extent that their inspectors are available - Requires a cooperative agreement.
SIQMP - Source Inspection Quality Management Plan from inspection firm.

12. Tier System

13. Tier System

15. Certificate of Compliance
Acceptance of manufactured or prefabricated structural materials shall be based on either a Certificate of Compliance and/or source inspection.
Contract documents should specify which materials require a Certificate of Compliance.
Certified material lot number and project number shall be clearly identified on the certificate and on lot tags.

16. Independent Assurance Sampling and Testing
Purpose of IAST is to:
Verify the project sampling and testing is performed correctly;
Ensure that equipment is properly calibrated.

17. IAST Required on all NHS Projects Caltrans will perform IAST
RE shall schedule with IA engineer
Samples are taken and split for Acceptance Tester and IA tester
Results are compared between IA and acceptance tests
IA tests are not to be used for acceptance tests

18. IAST - Non NHS Projects
Local agency shall use the IAST procedures described in their approved QAP.
Consultant IA testers shall be free of conflicts of interest if also performing other acceptance testing work.

19. Materials Acceptance Process
Notice of Materials to Be Used CEM-3101
List all material to be incorporated into the project

20. Materials Acceptance Process
Determine products to sample and test, source inspect, or accept by certificate of compliance
Send CEM-3101 to source inspection firm for material to be source inspected. File copy in CAT 31.
Determine if initial sampling and testing is necessary
Schedule acceptance sampling and testing based on contractor’s schedule

21. Materials Acceptance Process
Notify Contractor of required Certificates of Compliance
Source inspector will send Notice of Inspection and Notice to furnish to suppliers/contractor, and report of inspection reports and material release to RE
Remove release tags from material and verify with report of inspection

22. Materials Acceptance Process
File release tags with Report of Inspection in CAT 41
File Certificates of Compliance with CEM in CAT 41
Material inspected at the project site - record on CEM in CAT 41

23. Materials Acceptance Process
File initial test results in CAT 29
File acceptance test results by item in CAT 37