Evolution of TxDOT s Quality Assurance Programs
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1 Evolution of TxDOT s Quality Assurance Programs Design-Bid-Build, Design-Build, and Concession Projects 2009 AASHTO Subcommittee on Materials Meeting Anchorage, Alaska J. Jeffrey Seiders, Jr., P.E. Director, Materials & Pavements Construction Division TxDOT
2 Quality Assurance Program (QAP) Components The QA Program utilizes a combination of quality procedures to meet program goals: Quality Control Testing (QC) Quality Assurance Testing (QA) Owner Verification Testing (OVT) (D-B & Concessions only) Referee Testing (RT) Independent Assurance Testing (IA)
3 Definitions Quality Control (QC) Internal procedures used by the Contractor, Suppliers, and Subcontractors to ensure that development work meets project plans and specifications Quality Assurance (QA) Inspection, testing, auditing, documenting, and reviewing of all materials, operations, and processes Owner Verification Testing (OVT) Sampling and testing performed to validate the results of the QA acceptance sampling and testing, using statistical analysis Referee Testing (RT) Dispute resolution tests using split samples to resolve testing discrepancies Independent Assurance Testing (IA) An unbiased and independent evaluation of the sampling and testing techniques used in the Acceptance Program
4 High 5 interchange DESIGN-BID-BUILD (D-B-
5 Baytown Cable Stay DESIGN-BID-BUILD (D-B-B)
6 DESIGN-BID-BUILD Quality Assurance Program Summary DESIGN-BID-BUILD TxDOT utilizes this project delivery method throughout the state for most of its projects Typically, no contractor QC for acceptance, but will be considered for very large complex projects with compressed construction schedules. Acceptance testing performed at Guide Schedule frequency by independent QA laboratory, most cases TxDOT Personnel & equipment must be qualified/certified System approach independent assurance (IA) program annual personnel & equipment evaluations
7 Quality Assurance Program DESIGN-BID-BUILD * Modeled after 23 CFR 637 B and TxDOT Quality Assurance Program Independent Assurance Program Acceptance Program System Approach Project Testing Testing personnel and equipment must be qualified under the Quality Assurance Program Evaluates sampling, testing, personnel, equipment used as a part of the acceptance decision Job Control (Quality Control) No Location or Frequency defined (Do not require on TxDOT Projects) Acceptance Location and Frequency defined in Guide Schedule of Sampling & Testing (random sampling) Referee As necessary for dispute resolution Annual evaluations by split or proficiency sample testing Performed by Designated IA Laboratory (must be AASHTO accredited) Performed by Contractor Performed by Independent QA Laboratory Performed by CSTM&P
8 SH 130 segments 1-4 DESIGN-BUILD-MAINTAIN (D-B-M)
9
10 DESIGN-BUILD Quality Assurance Program Summary DESIGN-BUILD Quality Assurance Program for Design- Build Projects with an Optional 15-Year Capital Maintenance Agreement Utilizes Contactor Acceptance testing to manage schedule risk without individual QC/QA specifications Developer Construction Quality Management Plan (CQMP) Developer/contractor acceptance testing at Guide Schedule frequency by independent Construction Quality Acceptance Firm (CQAF-AASHTO or ISO 17025) Owner Verification Testing & Inspection Plan (OVTIP) Owner verification testing (OVT) by the Owner s independent OVT testing firm - Required by 23CFR637B, complies with FHWA Technical Advisory Minimum 10% frequency of QA testing - Statistical validation of QA testing using F- and t-testing analysis - Quarterly statistical validation report to FHWA Dispute resolution (referee) Personnel & equipment certification System approach independent assurance (IA) program annual personnel & equipment evaluations
11 Quality Assurance Program DESIGN-BUILD * Ref. 23 CFR 637 B, TxDOT Quality Assurance Program, & TA Independent Assurance Acceptance Program System Approach Project Testing Testing personnel and equipment must be qualified under the project Quality Assurance Program Evaluates sampling, testing, personnel, equipment used as a part of the acceptance decision Annual evaluations by split or proficiency sample testing Job Control (Quality Control) No Location or Frequency defined Acceptance Location and Frequency defined in Guide Schedule of Sampling & Testing (random sampling) Verification Validates Acceptance Testing using statistical analysis, when contractor s results used for acceptance Referee As necessary for dispute resolution Performed by Designated IA Laboratory (must be AASHTO accredited) Performed by Contractor Performed by Independent CQAF Lab Performed by OVT Laboratory Performed by CSTM&P
12 Original Design-Build Owner Verification Approach One Verification Approach F- & t- Test Verification on All Analysis Categories - Started at α = Updated to α = 0.01 OV Testing Frequency ~ 10% of QA Testing Frequency Quarterly FHWA Reporting
13 Updated Design-Build Owner Verification Approach Three-Tiered Verification Approach Level 1: Continuous F- & t- Analyses Almost Real-Time Verification ~10% of QA Test Frequency Allows for a = 0.01, 0.025, 0.05 Based on Importance Level 2: Independent Verification Level 3: Observation Verification Start-Up and Quarterly Split-Sample Tests Quarterly FHWA Reporting
14 Inspection and Materials Management System (I2MS) Owner Verification Application Developed Collaboratively By TxDOT, FHWA, and HDR Testing and Inspection Verification Automated Statistical, Data, and Trend Analysis Web-Based Application Robust Security Features Robust Search Capabilities Satisfies All FHWA Requirements
15 SH 130 segments 5&6 CONCESSION (D-B-F-O)
16 CONCESSION Quality Assurance Program Summary CONCESSION Variation of the Quality Assurance Program for Design-Build Projects based on risk analysis on a per project basis Developer Facility Management Plan (FMP) QC testing by Concessionaire s D-Ber Design-Builder Construction Quality Management Plan (CQMP) Acceptance testing at Guide Schedule frequency by D-Ber s Lab (AASHTO or ISO 17025) Owner verification testing (OVT) by Independent Engineer (IE) firm - Required by FHWA Technical Advisory % frequency of QA testing (frequency based on how much verification the concessionaire is performing) - Validation of QA testing using F- and t-test statistical analysis - Quarterly statistical validation report to FHWA Dispute resolution (referee) & independent assurance (IA) by IE firm Personnel & equipment certification
17 Design-Build vs. Concessions TRADITIONAL DESIGN-BUILD CONCESSIONS Design Subs TxDOT Design-Builder Construction Subs Financial Markets, TxDOT, and LGs Furnish Money TxDOT Concessionaire Design-Builder Independent Engineer Design Subs Construction Subs
18 Concession Quality Assurance Structure TxDOT Quality Assurance Program Facility Management Plan (FMP) Concessionaire Construction Quality Management Plan (CQMP) Design-Builder
19 Quality Assurance Program CONCESSIONS Independent Assurance Acceptance Program System Approach Project Testing Testing personnel and equipment must be qualified under the project Quality Assurance Program Evaluates sampling, testing, personnel, equipment used as a part of the acceptance decision Annual evaluations by split or proficiency sample testing Performed by IE Firm (AASHTO Accredited) Job Control (Quality Control) No Location or Frequency defined Performed by Concessionaire Acceptance Location and Frequency defined in Guide Schedule of Sampling & Testing (random sampling) Performed by Concessionaire (AASHTO or ISO Accredited) Verification Validates Acceptance Testing using statistical analysis, when contractor s results used for acceptance Performed by IE Firm (AASHTO Accredited) Referee As necessary for dispute resolution Performed by a different IE Firm (AASHTO Accredited)
20 Concession Owner Verification Approach Three-Tiered Verification Approach Similar to Design-Build Approach Modify Analysis Category Level and/or Alpha Table Based for each Concession Project s specific Risk Profile E.g., Some Level 1 Analysis Categories may be Moved to Level 2
21 References TxDOT Quality Assurance Program for Construction TxDOT Quality Assurance Program for Design-Build Projects 23 CFR 637 B Quality Assurance Procedures for Construction FHWA Technical Advisory Use of Contractor Test Results in the Acceptance Decision, Recommended Quality Measures, and the Identification of Contractor/Department Risks TxDOT s Quality Assurance Program for Design-Bid-Build TxDOT s Quality Assurance Program for Design-Build ftp://ftp.dot.state.tx.us/pub/txdot-info/cst/qap_design_build.pdf
22 Special Thanks James Travis - FHWA Texas Div. (Austin) Darrin Grenfell - FHWA (Kentucky) Dennis Dvorak - FHWA (RC -Illinois) Weng On Tam - HDR Engineering (Austin) Paul Bowen - HDR Engineering (Austin) Greg Cleveland - HDR Engineering (Austin) Tim Weight - TxDOT (Austin District) Robert Stone - TxDOT (TTA) David Belser - TxDOT (CST-M&P) Darren Hazlett - TxDOT (CST-M&P) Questions?
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