TABLE OF CONTENTS. MODULE CONTENTS Page. 1 Introduction Contractor Quality Control The QC Manager s Role and Responsibilities 3-1

Transcription

1

2 TABLE OF CONTENTS QC Manager MODULE CONTENTS Page 1 Introduction Contractor Quality Control The QC Manager s Role and Responsibilities QC Manager Tools Quality Control Plans Specifications 6-1

3 Module 1 - Introduction Welcome to the QC Manager Course November 2018 QC Manager Course Release 10, Module 1 1 Release 10 November

4 Module 1 - Introduction Introductions Tell us your Name, Who You Work for, Your Current Project Role, and Your Experience Level November 2018 QC Manager Course Release 10, Module 1 2 Release 10 November

5 Module 1 - Introduction November 2018 QC Manager Course Release 10, Module 1 3 Release 10 November

6 Module 1 - Introduction Top - current slide Bottom - notes November 2018 QC Manager Course Release 10, Module 1 4 Your manual is setup to enable you to follow along with the course and contains sufficient information to also serve as a resource document following completion of the course. Each slide displayed on the screen and shown in the book is numbered and the bottom of the manual page, may or may not contain additional information, drawings, specifications, etc. Release 10 November

7 Module 1 - Introduction 1 Welcome & Introduction 2 Contractor Quality Control 3 The QC Manager s Role and Responsibilities 4 QC Manager Tools 5 Quality Control Plans 6 Specifications 7 Appendix 8 Homework November 2018 QC Manager Course Release 10, Module 1 5 Release 10 November

8 Module 1 - Introduction Who is the QC Manager? The Contractor s Representative What are their responsibilities, in general? Management of the Quality Control of the Project November 2018 QC Manager Course Release 10, Module 1 6 Release 10 November

9 Module 1 - Introduction What is the purpose of this course? To provide you the basic knowledge and a working understanding of the role and responsibilities of a QC Manager. This course is based upon and includes industry recognized best practices for Quality Control management. November 2018 QC Manager Course Release 10, Module 1 7 Being assigned as a QC Manager for a project is a serious assignment that comes with a full range of responsibilities, from preparing QC Plans to the management and monitoring of conformance to the QC Plan. To be an effective QC Manager, it is imperative thatyou understand what is expected of you and what you will be held responsible for. Knowledge is power. Remember there are several QC managers involved on the typical roadway project: QC Manager for the Contractor QC Manager of the Asphalt Company Manager of Quality Control for the Concrete Company. Release 10 November

10 Module 1 - Introduction How do I get the QC Manager Qualification? Pass the 50 Question Written Exam (Passing Score 70%) Have at least one Level 2 Qualification: Asphalt Paving Level 2 Asphalt Plant Level 2 ECI Level 2 Concrete Field Level 2 Concrete Laboratory Technician Level 2 November 2018 QC Manager Course Release 10, Module 1 8 Release 10 November

11 Module 1 - Introduction Transportation Research Board (TRB) Circular 457 Definition of Quality: The degree of excellence of a product or service. The degree to which a product or service satisfies the needs of a specific customer. The degree to which a product or service conforms with a given requirement. November 2018 QC Manager Course Release 10, Module 1 9 Quality has many different definitions and each individual s expectation of quality can vary. What constitutes quality to one person may not be the basis of quality to another. Release 10 November

12 Module 1 - Introduction Meets or exceeds the expectations or needs of the customer. November 2018 QC Manager Course Release 10, Module 1 10 Quality happens to be in the eyes of the beholder. If 2 individuals get their cars painted, one might consider the paint job of high quality due to the shine, while another may use the absence of over spray as the mark of Quality. You the user, buyer, or owner determine what constitutes quality. Release 10 November

13 Module 1 - Introduction Define Quality Assurance (QA): NCHRP All those planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality. FDOT Quality Assurance is designing quality into processes. It is conformance to predetermined criteria established by laws, rules, and procedures governing the Department and/or functional work units. November 2018 QC Manager Course Release 10, Module 1 11 NCHRP National Cooperative Highway Research Program Release 10 November

14 Module 1 - Introduction Who performs these functions: Quality Control (QC) Manufacturer Producer Contractor Quality Assurance (QA) FDOT November 2018 QC Manager Course Release 10, Module 1 12 QC is the responsibility of the producing entity while QA is the responsibility of the FDOT. Quality Control is the responsibility of the Producer. It is incumbent uponthemtoproduceor achieve a degree of Quality that meets or exceeds their customer s expectations. Quality Assurance is the responsibility of the FDOT. It is incumbent upon them to assure that the Quality expected is there. Release 10 November

15 Module 1 - Introduction The Department believes that Quality must be engineered... it does not just happen. We must: Plan for Quality Organize for Quality Staff for Quality Check for Quality Verify for Quality Recheck for Quality Measure for Quality November 2018 QC Manager Course Release 10, Module 1 13 Quality doesn t just happen. It is something that takes significant planning, performance, and monitoring to ensure that it is achieved. Quality is achieved by people who are dedicated to seeing that the expectations are met. From the Level 1 technician to the Project Administrator and Project Superintendent, everyone needs to make it happen. Release 10 November

16 Module 1 - Introduction What influences quality? TIME Actual Life > Design Life SERVICEABILITY Ease of use and Maintenance COST Minimize User Cost RETURN ON INVESTMENT Optimize Life Cycle Cost November 2018 QC Manager Course Release 10, Module 1 14 Quality effects many areas of an item, such as a roadway. Without Quality, roadways don t last as long as expected, are difficult to maintain, have increased maintenance and upkeep costs, and the Department does not get a good return on their investment. Release 10 November

17 Module 1 - Introduction 23 CFR 637B Quality Assurance Procedures for Construction (QAPC) SPECIFIC REQUIREMENTS Laboratory Qualification Technician Qualification Sampling, Testing, & Reporting Guide Independent Assurance (IA) Final Project Materials Certification November 2018 QC Manager Course Release 10, Module 1 15 The 23 CFR 637B (Code of Federal Regulations) sets forth guidelines and requirements for Quality Assurance Procedures for Construction (QAPC). Florida adopted portions of these requirements and established the Construction Training Qualification Program (CTQP) to provide for the qualification of personnel. Specific requirements for Laboratory Qualification were also developed. Release 10 November

18 Module 1 - Introduction Do we pay the Contractor based on the QC Acceptance data? NO Pay is based on verified Contractor QC Acceptance data November 2018 QC Manager Course Release 10, Module 1 16 Release 10 November

19 Module 1 - Introduction Is Quality Rewarded? Incentives Reduction in QC testing frequency (or increase lot size) Contractor control of operations Increased pay Disincentives Reduced pay Disapproval of the QC Plan Shutting down one or more processes November 2018 QC Manager Course Release 10, Module 1 17 Examples: For Asphalt reduced pay is a consequence of failing to meet the requirements and is outlined in Pay Factors. Repeated unfavorable comparisons will result in the loss of the approved QC Plan. For Concrete, the FDOT allows for a reduction in testing frequency through increased lot size for 10 consecutive compressive strength tests that meet or exceed strength and absorption requirements ( Reduced Frequency for Acceptance Tests). Release 10 November

20 Module 1 - Introduction What materials are covered by the QC Plan? Hot Mix Asphalt Portland Cement Concrete (Structural) Earthwork Cementitious Materials Timber Steel and Miscellaneous Metals Galvanized Metal Products Prestressed and/or Precast Concrete Products Drainage Products Fiber Reinforced Polymer Products November 2018 QC Manager Course Release 10, Module Quality Control Program provides the list of materials. Only these materials are covered by the QC Plan. If these materials do not exist on a project, a QC Plan is not required. Aggregates are not on the list as they are controlled under a AdministrativeRule. Release 10 November

21 Module 1 - Introduction Any Questions? November 2018 QC Manager Course Release 10, Module 1 19 Release 10 November

22 This page left blank intentionally.

23 Module 2 Contractor Quality Control Contractor Quality Control November 2018 QC Manager Course Release 10, Module 2 1 Release 10 November

24 Module 2 Contractor Quality Control Quality Assurance for Construction What is Quality Assurance Processes for Construction Contractor Quality Control (CQC) November 2018 QC Manager Course Release 10, Module 2 2 Release 10 November

25 Module 2 Contractor Quality Control Module 2 Objectives Understand Quality Assurance Processes for Construction Understand the Components of Quality Control Plan Understand the major acceptance elements of a Materials Incorporated in Construction Projects November 2018 QC Manager Course Release 10, Module 2 3 These are the Learning Outcomes for this lesson. When the lesson is completed, you will be capable of accomplishing these. Release 10 November

26 Module 2 Contractor Quality Control Cooperative effort of FDOT, FHWA & Industry Quality Assurance for Construction Projects Contractor Quality Control (CQC) FDOT Verification (V) Resolution (R) Independent Assurance (IA) Laboratory Qualification Personnel Qualification November 2018 QC Manager Course Release 10, Module 2 4 In response to 23 CFR (Code of Federal Regulations) 637B, Quality Assurance Processesfor Construction, the FDOT developed a Quality Assurance Program (QAP) acceptable to FHWA. Development of this program was, and continues to be, a cooperative effort between FDOT, FHWA and Industry. The FDOT QAP includes all of the specific requirements of 23 CFR 637B as well as the optional provisions. A Quality Assurance Program establishes the core elements required for quality. It serves as the framework necessary for construction Quality Assurance (QA) implementation and clearly delineates the Department s role and the Industry roles for achieving quality. It also identifies specific requirements for qualifying both Department and Industry laboratories and personnel. The QA Program is comprised of six distinct, but separate, elements, each equally important, which are listed above and discussed in detail later in this course. Release 10 November

27 Module 2 Contractor Quality Control PARTNERING Contractor Quality Control Personnel Qualification Resolution Laboratory Accreditation Independent Assurance FDOT Verification November 2018 QC Manager Course Release 10, Module 2 5 The core elements of the Quality Assurance program may be compared to the structural elements of a suspension bridge. The two primary towers being Contractor Quality Control and Department Verification. Supporting elements include the Laboratory and Personnel qualification requirements, which ensure that the principal facilities and personnel conducting sampling, testing and inspection are capable of performing their functions. Additional support is provided by Independent Assurance, which provides an independent assessment of QC and Verification sampling and testing. Added to the strength of these two elements is the Resolution process, which is intended to reconcile differences between QC and Verification. An additional component that connects all of these elements is Partnering. Partnering is a tool that links the systems and supports them, which keeps them up and running smoothly. Partnering refers to a voluntary agreement between the Department and the Contractor to use a team based approach to management of the project. Release 10 November

28 Module 2 Contractor Quality Control CQC Source Code of Federal Regulations 23 CFR 637 B FHWA policy on the use of contractor s quality control test results for acceptance. Requires validation of all data not generated by the State Transportation Department. November 2018 QC Manager Course Release 10, Module Code of Federal Regulations 637 B is the source document used by State Highway Agencies including the FDOT to incorporate Contractor Quality Control, CQC, as part of the acceptance decisions made on Highway Construction Projects. Release 10 November

29 Module 2 Contractor Quality Control Code of Federal Regulations 23 CFR 637 B All Testing to be done by Qualified Personnel (CTQP) All Laboratories are to Qualified by FDOT (Specification 105) FDOT must validate (verification) A resolution process must be defined November 2018 QC Manager Course Release 10, Module 2 7 Details some of the elements included in 23 CFR 637 B. Release 10 November

30 Module 2 Contractor Quality Control Quality Control inspection, sampling and testing are those Contractor QC actions and considerations necessary to assess and adjust production and construction processes so as to control the level of quality being produced in the end product. Verification sampling and testing is used by the department to measure the effectiveness of the QC Program and the degree of compliance with the project documents. November 2018 QC Manager Course Release 10, Module 2 8 These definitions indicate the fundamental separation of QC and Verification. QC should be used for control of the process. Verification should be used to verify the QC results. Release 10 November

31 Module 2 Contractor Quality Control CQC = Contractor + Validation Contractor Quality Control Testing (QC) Quality Control Manager Quality Control Inspection Validation FDOT Verification Testing (VT) Independent Verification (IV) Dispute Resolution (R) Independent Assurance (IA) November 2018 QC Manager Course Release 10, Module 2 9 Points out the various elements included in QC and in Verification. Note the QC Manager is part of the Contractor s Quality Control. Verification, Independent Verification, Resolution, and Independent Assurance are all part of the CEI and FDOTs validation responsibility. Release 10 November

32 Module 2 Contractor Quality Control CQC General Concept Testing Level Who does it? Typical Volume Remarks Quality Control (QC) Contractor 100% Verification (V) Independent Verification (IV) Processes carried out by the contractor to document that materials used meet contract specifications CEI 25 % At project site Materials 25 % CEI or Materials 10% Resolution (R) Materials < 5 % Off site: producers (Asphalt Plants) and laboratory Typically asphalt (per specification) Infrequent to resolve disputes November 2018 QC Manager Course Release 10, Module 2 10 QC is generally responsible to perform test on 100% of the materials incorporated into the project. Verification tests about 25% of the same materials to verify QC results. Independent verification tests are run at frequencies out lined in the specifications or at the CEI or FDOT discretion. Test frequencies are designated in the Job Guide Schedule (JGS). The Job Guide Schedule is developed for every project and is the basis for who preforms the test, either QC or VT, and how frequently. Release 10 November

33 Module 2 Contractor Quality Control QC Plan is a Controlling Agreement November 2018 QC Manager Course Release 10, Module 2 11 The QC Plan must be submitted within 7 days prior to starting work on any QC material (Specifications 105) and approved by the Department within 10 days of submittal (CPAM 3.3). No work can begin until the QC Plan is accepted for that phase of work in MAC. Through a pre construction conference, all parties can resolve any quality issues before they become a problem. The QC Plan can change as needed if approved by the Engineer. Release 10 November

34 Module 2 Contractor Quality Control QCP required by specification 105 Input Into MAC Identify QC Manager & Personnel Laboratories Producers November 2018 QC Manager Course Release 10, Module 2 12 The QC Plan, prepared by the Contractor, must meet the requirements of Section 105 of the Standard Specifications for Road and Bridge Construction (SSRBC or Spec Book). QC Plan information is to be reported in MAC. Release 10 November

35 Module 2 Contractor Quality Control Department Verification Resolution Independent Verification November 2018 QC Manager Course Release 10, Module 2 13 Let s examine the various roles for the Contractor and the Department in the QA Process for Acceptance. We ll start with the Contractor. The contractor s personnel in the approved QC Plan perform QC Tests. The frequencies of the QC tests are spelled out in the JGS for the project. Contractors QC test results are input into MAC or kept in the QC Density Log book for earthwork. From January 2019 Specifications: Quality Control (QC) Inspection: Provide all necessary inspection to assure effective QC of the operations related to materials acceptance. This includes but is not limited to sampling and testing, production, storage, delivery, construction and placement. Ensure that the equipment used in the production and testing of the materials provides accurate and precise measurements in accordance with the applicable Specifications. Maintain a record of all inspections, including but not limited to, date of inspection, results of inspection, and any subsequent corrective actions taken. Make available to the Department the inspection records, when requested. Release 10 November

36 Module 2 Contractor Quality Control Contractor Performs Quality Control Tests Did QC test results meet requirements? NO 1. Process Control Investigation Initiated 2. Mitigation of Failing Material YES Material is Accepted by Contractor for Placement November 2018 QC Manager Course Release 10, Module 2 14 The Contractor performs all QC testing for acceptance. For example: The QC Density Inspector takes a density on each embankment LOT each LOT must have a passing QC Density. Unlike concrete and asphalt, there is no pay adjustment for earthwork not meeting the project/specification requirements. A QC density test result on embankment material that has been placed must achieve 100% of the Standard Proctor for that material. 99% doesn t make it, only passing material can be Verified. Release 10 November

37 Module 2 Contractor Quality Control Contractor QC Department Verification Resolution Independent Verification November 2018 QC Manager Course Release 10, Module 2 15 Let s look at Verification Testing by the Department. Verification testing is used to verify QC results. The frequency of verification testing is spelled out in the JGS. Comparison tolerances for QC and Verification are found in the SSRBC. Release 10 November

38 Module 2 Contractor Quality Control FDOT Performs Verification Testing VT Compare favorably with QC or pass Specs? NO Go to Resolution YES Material is Accepted November 2018 QC Manager Course Release 10, Module 2 16 Verification testing, which is performed by the Department, verifies the QC data, therefore, it is possible to accept something without having a passing VT Test. For example: Assume Maximum Dry Density is 115 pcf. QC Density Inspector takes a density on embankment LOT records a passing density of 100% of Maximum Dry Density (Dry Density pcf) This LOT just happens to be the random LOT VT is to test VT takes a density and gets a Dry density of pcf or 99% of Maximum Dry Density. the LOT (s) in question are not verified. The QC Inspector does a re test within 5 of the VT test and gets a Dry Density of or 100% of Maximum Dry Density. The LOTs are accepted and verified due to QC having a passing density and comparing within 2 3 lbs. per cubic foot to the Verification Test. However, as you can see, VT never had a passing test. But in keeping with QC Programs, the QC data was verified, which is what QC is based upon. Release 10 November

39 Module 2 Contractor Quality Control Contractor QC Department Verification Resolution Independent Verification November 2018 QC Manager Course Release 10, Module 2 17 Let s look at Resolution Testing by the Department. The resolution procedures for each of the materials, etc. varies and it is incumbent upon the personnel involved in Resolution to utilize the proper Resolution process. When there is a non favorable comparison between QC and VT testing, Resolution is the process used to determine which results will be used. Resolution is generally compared with QC results first if those results compare favorably, then QC is accepted and used. It is important for QC to retain samples for any materials that may have passed QC but are not yet verified by the FDOT for acceptance. Those samples will be used as partofthe resolution process. Release 10 November

40 Module 2 Contractor Quality Control Qualified Personnel & Lab Perform Resolution Test NO Did RT compare with QC? *RT/VT used for Acceptance & Payment YES Contractor Tests are Verified November 2018 QC Manager Course Release 10, Module 2 18 If Resolution compares with QC, then QC results are used for acceptance. For example: AN Earthwork Example : Under Section 125, Excavation for Structures and Pipe, QC and VT Maximum Densities (Proctors) did not compare within 4.5 pcf. The Department takes a Resolution sample. If the Resolution sample compares, within 4.5 pcf, with QC, then QC is verified and used. If not, VT results will be used. An Asphalt Example: If Resolution Lab results compare with QC Test results, then use QC Test results. If Resolution Lab results do not compare favorably with QC Test, then use Resolution test results. Release 10 November

41 Module 2 Contractor Quality Control Contractor QC Department Verification Resolution Independent Verification November 2018 QC Manager Course Release 10, Module 2 19 Let s look at Independent Verification Testing by the Department. The Independent Verification Test is performed by the Department and can be used any time the Department desires to check materials or areas that might be in question. Independent Verification test samples generally do not need to follow a random number. Some asphalt independent verification sampling may be generated using random numbers. Release 10 November

42 Module 2 Contractor Quality Control The Department reserves the right, as outlined in the specifications, to conduct Independent Verification (IV) testing whenever and where ever the need arises. November 2018 QC Manager Course Release 10, Module 2 20 Independent Verification is the Department s way of having the ability to perform sampling and testing when they believe there may be a problem. Independent Verification may also be useful when some lots may be in phase one of a project and some lots may be split into later phases of the project. Independent Verification tests can be performed say on lots 1 thru 4 that QC testing has already been performed and passed but the Verification Random Number Lot is not ready. Before lots 1 thru 4 are covered up by overlying materials lots 1 thru can be tested by Independent Verification. If the IV tests pass for lots 1 thru 4, that can be a consideration if the Verification tests performed later in Lots 5 thru 8 does not verify all the lots. Continuous IV problems may result in suspension of portions of the QC Plan or the QC Manager Release 10 November

43 Module 2 Contractor Quality Control FDOT performs IV tests in areas of concern NO Did IV test meet spec.? Apply Specific Requirements for Particular Material as Applicable. YES Contractor continues working. Regular QC and VT Testing for acceptance will be followed. November 2018 QC Manager Course Release 10, Module 2 21 If IV meets specification, then QC results are used for acceptance. For example: During the Initial Production LOT for embankment, the Contractor made 5 passes with the compactor, and the LOT was tested and verified. Later, during production LOTs, VT has just tested and verified LOT 5, the random LOT for verification of LOTs 5 8. The Contractor is observed putting only 2 passes on embankment LOT6.AnIVtestmaybeperformedonthesuspectLOTandtheresultsusedthesame as VT. For instance, if the IV failed, then LOTs 5 8, would not be considered verified. There are similar situations for Asphalt and Concrete. Release 10 November

44 Module 2 Contractor Quality Control Independent Assurance Checks Personnel Equipment QC, VT, and Laboratory When will IA be performed? Annual Goals set by FDOT Whenever it is needed System based, not project based, but expect to see it on most projects November 2018 QC Manager Course Release 10, Module 2 22 IA is typically done by District Materials Office or Designated person. IA procedures will be performed by Department personnel, or their designated agents, who do not normally have direct responsibility for project QC or Acceptance sampling and testing. Equipment other than that used for QC or Acceptance sampling and testing shall be used in the IA process. The system approach will be used. This approach bases frequency of IA activities on time, regardless of the number of tests, quantities of materials or numbers of projects being tested by the individual being evaluated. The federal regulation (23 CFR 637B) defined Independent Assurance (IA) as: Activities that are an unbiased and independent evaluation of all the sampling and testing procedures used in the acceptance program. The FDOT Materials Manual Section 5.5 (Appendix D) The IA program evaluates the performance of the qualified sampling and testing personnel and testing equipment. The program covers sampling procedures, testing procedures, and testing equipment. IA is generally performed on at least 90% of QC and Verification testing personnel annually. Failure to participate in the IA program can result in a strike for qualifiedqc or verification testing personnel. Release 10 November

45 Module 2 Contractor Quality Control YES Technicians and/or Equipment acceptable for use. IA performed on QC & Verification testing personnel & equipment Meet IA requirements? NO Technicians subject to follow-up review. Equipment not to be used on the project until corrective action is taken. November 2018 QC Manager Course Release 10, Module 2 23 Release 10 November

46 Module 2 Contractor Quality Control Someone must be the Champion for Quality and be responsible for the Contractor: Project Quality QC Plan Inspection Certification November 2018 QC Manager Course Release 10, Module 2 24 These are covered in detail in Lesson 3. A QC Manager is needed because Contractors doing business with the FDOT are responsible for Quality Control of materials and products on Department projects. Subsequently, it is imperative that the Contractor provides an empowered, responsible and knowledgeable person to oversee QC operations on projects and to act as the representative to the Department in these matters. A QC Manager must be familiar with highway materials, material characteristics and the measurement of quality standards for materials. It is the responsibility of the Contractor and QC Manager to certify the quality of materials on projects as outlined in the QC Manager specification and the various materials specifications. July 2019 Specifications: Quality Control (QC) Manager: Designate a QC Manager who has full authority to act as the Contractor s agent to institute any and all actions necessary to administer, implement, monitor, and as necessary, adjust quality control processes to ensure compliance with the Contract Documents. The QC Manager must speak and understand English. The QC Manager must be on site at the project on a daily basis or always available upon four hours notice. Ensure that the QC Manager is qualified as such through the Construction Training and Qualification Program. The QC Manager and the Superintendent must not be the same individual. Release 10 November

47 Module 2 Contractor Quality Control CQC Vital Components Trust Quality Communication November 2018 QC Manager Course Release 10, Module 2 25 CQC is built on the Speed of Trust. Communication is vital between the QC Manager as the Contractor s representative and the CEI and FDOT to keep the Quality Acceptance System effective and efficient. Release 10 November

48 Module 2 Contractor Quality Control True or False The Quality Assurance Program only applies at the Federal Government Level and Quality Control Plans apply at the State Level. True False True or False The State prepares the Quality Control Plan for the Contractor s approval. True False November 2018 QC Manager Course Release 10, Module 2 26 Release 10 November

49 Module 2 Contractor Quality Control True or False Under CQC, testing has increased. True False True or False Resolution Testing is only used to verify QC testing results. True False November 2018 QC Manager Course Release 10, Module 2 27 Release 10 November

50 Module 2 Contractor Quality Control Any Questions? November 2018 QC Manager Course Release 10, Module 2 28 Release 10 November

51 Module 3 QC Manager s Role & Responsibilities The QC Manager s Role and Responsibilities November 2018 QC Manager Course Release 10, Module 3 1 Introduction to Lesson 3, QC Manager s Role and Responsibilities. Release 10 November

52 Module 3 QC Manager s Role & Responsibilities Learning Outcomes Describe QC Manager s role & responsibilities Describe the QC Manager s duties Describe the QC Manager s reporting requirements November 2018 QC Manager Course Release 10, Module 3 2 Release 10 November

53 Module 3 QC Manager s Role & Responsibilities Plan QC Needs Est. QC Manpower Qualified Subs Establish Rework Goals Administer QC Plan Monitor QC Activities Provide Monthly Certification Maintain Records Evaluate Performance MAC Pre-Bid Pre-Construction Construction Post-Construction Prepare QC Plan Qualified QC Staff Qualified Labs Producer s QC Plan Verification Sampling/Testing Records Material Certifications MAC MAR Issues Resolved Warranty Items November 2018 QC Manager Course Release 10, Module 3 3 These are the major phases for the QC Manager s role and responsibilities of a project. The QC Manager should be involved in all phases, beginning with the pre bid phase. However, some of the work tasks within the major phases shown in the slide above may not be assigned to the QC Manager. The tasks assignments will be determined by the Prime Contractor. During the pre bid phase, QC Managers may interact with estimating to ensure QC inspection, sampling, testing and staffing is accounted for in the bid and to determine if the anticipated subcontractors and producers have the required FDOT qualifications/certifications. Once the contract is awarded, the QC Manager must bring together all of the project requirements and documents. The CTQP qualifications of the anticipated Inspection staff needs to be verified, and a schedule of manpower and equipment resources developed to ensure the project is properly staffed and equipped from a QC standpoint. During the construction or production phase, the QC Manager is responsible forensuring that the required inspection, sampling, testing and reporting is performed by the Inspection staff. They are responsible for the administration and supervision of the staff and coordinating and handling of deficient materials and QC, Verification and Resolution conflicts. Additionally, revisions to the QC Plan may be required based upon project needs. Each month, they must ensure the Contractor Certification is completed and submitted. They must ensure the QC personnel have access to the contract documents. As the old saying goes, it isn t over until the paperwork is done and construction is no different. The QC Manager must finalize all QC reports and documentation, together with material certifications, etc. Release 10 November

54 Module 3 QC Manager s Role & Responsibilities November 2018 QC Manager Course Release 10, Module 3 4 Unfortunately, as a QC Manager, you are more or less serving two bosses, your employer, (the Contractor) and the Department. Your concern is ensuring that the quality required for the project is met. You may find yourself pulled in two directions at once. Your desire to serve your firm and help production, while at the same time, meeting the Department s quality requirements. It is important that you maintain your integrity and not be pushed into doing something that can result in the suspension or revocation of your QC Manager Qualification. It is important to remember, if you do your job properly, you are an asset to both the Contractor and the Department. Release 10 November

55 Module 3 QC Manager s Role & Responsibilities Serve as Contractor s Quality Representative Enter and Maintain QC Plan in MAC Prepare and Maintain non standard Job Guide Schedule (JGS) for Lump Sum projects, including Design Build On system LAP Other non standard projects Administer and Monitor QC Operations Provide Monthly Certification November 2018 QC Manager Course Release 10, Module 3 5 Listed above are some of the functions of the QC Manager, which will be covered in detail in this lesson. Release 10 November

56 Module 3 QC Manager s Role & Responsibilities Who should the QC Manager report to? Prime Contractor s Senior Management - Area Manager - General Area Superintendent - Project Manager (Projects >$20 million) - Foreman - Superintendent Do they have any authority over the Production staff? YES, the QC Manager has the authority to stop work when the end quality is at risk. November 2018 QC Manager Course Release 10, Module 3 6 Release 10 November

57 Module 3 QC Manager s Role & Responsibilities Should the Inspectors report to the QC Manager? They should report to the QC Managershould not report to Production. Do the Inspectors have any authority to stop work? QC Inspectors may not have the authority to stop work or direct production - they should document and report any irregularities or non-compliant issues/tests to the QC Manager. November 2018 QC Manager Course Release 10, Module 3 7 Release 10 November

58 Module 3 QC Manager s Role & Responsibilities Review Contract Documents Plan QC Program Operations Identify QC inspection, sampling & testing requirements Identify potential Inspectors/Technicians Identify potential QC problem areas November 2018 QC Manager Course Release 10, Module 3 8 The QC Manager looks at the project from the QC program standpoint and somewhat begins to formulate answers to questions such as What inspection, testing and sampling is required?; What are the manpower resources needed to perform the QC inspection, sampling & testing?, etc. These all have an impact on the cost to the project, hence impacts the Bid. Though small in comparison to project materials, labor and equipment costs, but can range from 1 3% or more of a project. As a QC Manager your involvement in the pre bid process can be of a substantial benefit to the Contractor. QC costs money and depending upon project requirements can range from 1 3% of the project cost. If you begin to formulate what s required in the QC Program, you will find there are many questions that need to be answered such as: What inspection, sampling & testing is required? What Inspectors/Technicians are available? Are there any parts of the project that can create problems for QC? These all represent a cost a financial impact to the project. On the other hand, they may be opportunities for reduced frequencies of testing, thereby being able to effect some sort of savings. Release 10 November

59 Module 3 QC Manager s Role & Responsibilities Prepare QC Budget Estimate QC inspection, sampling & testing manpower, per phase Estimate QC Costs, per phase Provide the bid Estimators the QC Costs November 2018 QC Manager Course Release 10, Module 3 9 Attention needs to be paid to any special requirements, as these can impact costs also. For example, sampling structural concrete at the point of final placement may increase manhours. How is the construction planned. Will there be very large concrete pours, or multiple pours occurring simultaneously, requiring additional manpower? Estimating is relying on you to provide a fairly accurate estimate of QC costs for inclusion into the bid. What manpower resources are required, for each phase, for each construction type? How many Inspectors versus Technicians will you need? Will any CTQP training be needed for the QC Inspection staff to be capable of fulfilling the project inspection, sampling & testing needs? If subcontracting QC inspection, sampling & testing, obtain quotes from several qualified firms. Keep in mind that certain requirements, such as QC sampling for Maximum Density Test for Stabilizing (Section 160), where QC samples and splits for VT and RT, adds costs (Extra bags, time and large storage facility). Willtherebemultipleconcreteplacementsites,concurrently?Ifso,each must be staffed by a qualified technician. If not, one technician may be capable of handling concrete placements, depending upon project size and conditions. Following your assessment of the QC needs, develop an estimate of the QC costs and provide it to the Estimator for use in the bid. Release 10 November

60 Module 3 QC Manager s Role & Responsibilities Verify Qualifications/Certifications Verify Subcontractor/Producers QC Plan Acceptance Verify Inspector/Technician CTQP qualifications Verify Laboratory Qualification/Certification Evaluate past performance by subcontractors Coordinate Qualification Results with Estimating November 2018 QC Manager Course Release 10, Module 3 10 You will probably be charged with determining the qualification/certification of QC personnel, subcontractors and producers anticipated for use on the project. This may include anticipated suppliers/producers (including past performance of QC activities), QC Inspection staff, any additional CTQP training required, qualified/certified laboratories. You need to communicate with estimating especially if there appears to be some significant problems (For example: your firm is determined to use XYZ as the concrete producer, but they do not have an approved QC Plan or their plan was suspended, etc.) As a QC Manager, you should be charged with determining the qualification/certification of QC personnel, subcontractors and producers being considered for use on the project. You may need answers to the following questions: Do anticipated suppliers/producers meet the QC requirements for the project? If not, others should be sought or coordinate with the PA and producer to develop an action plan to make the facility acceptable by the time the material needs to be produced for the contract. Also, give thought to having back up subcontractors/suppliers, should problems arise with a particular subcontractor/supplier. Release 10 November

61 Module 3 QC Manager s Role & Responsibilities Does the QC Inspection staff have all of the required CTQP qualifications? IssomeCTQP training needed to meet the needs of the project? Will the qualifications expire during the contract time? Is the anticipated Laboratory qualified/certified? If not, another is needed. In addition to having any required qualifications, what has been the recent past performance, related to QC, of the anticipated subcontractors? Remember, astheprime, you are responsible for their actions. You want subcontractors that are as concerned about quality as is the Prime Contractor. Release 10 November

62 Module 3 QC Manager s Role & Responsibilities Establish Rework Goals Estimate rework potential, per phase Establish reasonable rework goals Original Activity Rework ID Rework Duration Standby Rework Gear up Continuation of Original Activity November 2018 QC Manager Course Release 10, Module 3 11 Rework Activities in the field that have to be done more than once in the field, or activities which remove work previously installed as part of the project regardless of source, where no change order has been issued and no change of scope has been identified by the owner. Very few, if any, transportation construction projects are completed that don t have some rework of something required at some point in time. As the QC manager, you need to estimate the potential amount of rework that may occur on each phase of the project, especially as it relates to and how it impacts QC (manpower, costs, etc.). A typical rework goal on medium to large projects here in Florida is 50 cents aman hour. Example If the job has 100,000 man hours to build the work, the goal of total rework allowed on the job would be $50,000.00, throughout the duration of the project. Tracking these costs, through a simple Excel spreadsheet is easy and provides a indication of whether the program is working or not. This goal also depends on the experience level of the people (craft) and supervision building the work. In today's labor market this is a big one. As shown above, rework costs money, in some cases substantial monies, especially if not accurately anticipated. Release 10 November

63 Module 3 QC Manager s Role & Responsibilities Human Resources Capability Unclear Instructions To Workers Inadequate supervision & Job Planning Late Design Changes Poor Document Control Engineering & Reviews Scope Changes Errors and Omissions Excessive Overtime Insufficient Skills levels Constructability Problems Late Design Input Construction Planning & Scheduling Leadership & Communications Ineffective Mgmnt of Project team Lack of Operations (End User) Perceives Buy-in Unrealistic Schedules Insufficient Turnover & Commissioning Resourcing Lack of Safety & QA/QC commitment Non-compliance With specifications Poor Communications Untimely Deliveries Materials not in right place when needed Material & Equipment Supply Contribute To Re-work Prefab & material not to Project Requirements November 2018 QC Manager Course Release 10, Module 3 12 Shown above is what is commonly referred to as a Rework Cause Classification Chart. As you can see, there are numerous potential causes that impact the amount of rework needed. On many construction projects, especially the large ones, there is someone assigned as a Rework Manager, who is responsible for tracking and managing rework tasks. Studies have been conducted and have shown that an increased emphasis is needed during the project s design and engineering phases to potentially avoid further field rework during the construction stage. Additionally, insufficient experience, training and expertise, on the Construction side, have resulted in increased rework items. With that in mind, the QC Manager, should thoroughly review the Contract documents and be alert for items that can effect rework. A QC Manager needs to be knowledgeable of Rework, especially how it relates and impacts QC inspection, testing and inspection. An effective QC program is the most effective way to minimize rework. In many instances, the rework task will have a QC component with it. There are many resources available to you, such as the Construction Industry Institute, which have educational material on this topic. Release 10 November

64 Module 3 QC Manager s Role & Responsibilities Establish Rework Goals Past job cost Experience level of personnel (Management & Craft) Suppliers past problems Subcontractor past problems November 2018 QC Manager Course Release 10, Module 3 13 The following items help establish Rework goals: Past Job Cost For each job, costs are summarized for all re work (Direct or Indirect) to provide a better understanding of actual impacts of re work. The cost is reported at the Foreman / Field Engineer level to Management and tied to the activities internal cost code. Project Management holds individuals accountable for reporting re work issues at all levels. These costs are maintained for each project, by work type, which forms a historical base, and is used by management in the estimate to account for future problems. Experience level of personnel (Management & Craft) This plays a big role in the amount of re work the job may experience. In today s market this must be considered, because you don t always have the A team sitting on the bench ready to go construct a project. You must use the tools that you have and, therefore, Management has developed a number or factor, which is applied during the estimate phase of the job. Suppliers past problems Based upon historical data, a number or factor is applied when using certain suppliers. The suppliers quote may be low at estimate time, but you know based on past experience that you will have certain problems that may require rework with certain suppliers. Subcontractor past problems (Same as Above) There is a number to anticipate when using certain subcontractors for building work. The subs quote may be low at estimate time, but you know based on past experience that you will have certain problems that may require re work with certain parts of the job. Release 10 November

65 Module 3 QC Manager s Role & Responsibilities Establish Rework Goals Past Owner relations issues Equipment availability problems Quality of Contract Plans November 2018 QC Manager Course Release 10, Module 3 14 Past Owner relations issues Owners often cause impacts and re work due to the lack of focus on what is best for the project. For instance, if they are aware of potential conflicts or problems, they often don t communicate these to the Contractor and await for the problem to arise during construction, possibly effecting the costs or schedule. These types of Owners have a number or factor applied to them during the Estimating phase. Equipment availability problems Equipment can often be a factor in determining re work goals. If you have limited numbers of equipment to build the job you may not always get the best. This is considered in the re work goal for the job (If your paving an interstateand your asphalt paver in not the best one you have in the fleet you may anticipate removinga few areas because of using older equipment). Quality of Contract Plans The condition of the contract plans often breeds re work on the job. Today's project sizes and complexities often produce multiple EOR s on the same contract and, as shown in many studies, they often fail to communicate effectively among themselves. Failure to compare each others design and how the pieces fit together on the job often causes re work. After considering all the above factors, a job re work goal is created in the estimatephase by the senior management. Release 10 November

66 Module 3 QC Manager s Role & Responsibilities November 2018 QC Manager Course Release 10, Module 3 15 Release 10 November

67 Module 3 QC Manager s Role & Responsibilities QC Plan Preparation Finalize Project QC requirements Prepare QC Administrative Tools Prepare Earthwork Record System Prepare LOT numbering system Determine if MAC access is needed November 2018 QC Manager Course Release 10, Module 3 16 You will need to finalize the QC requirements by construction type and prepare the QC Plan for the project and any QC administrative tools anticipated for use, such as checklists, Control Charts, filing system, etc. Your QC Plan is submitted to the Project Administrator for approval as discussed in Chapter 5. It is incumbent upon you to stay on top of the Approval process to ensure that it gets approved, including providing any additional information that might be requested for approval. The point is, just because you submitted it, you can t just sit back and wait. Remember, you basically cannot start construction on any QC program material without the Approved QC Plan. Hopefully you or one of your staff is familiar with the FDOT Plot Program for coding of the Earthwork Record System. This must be completed before construction starts, therefore it is something that needs to be an early assignment. Depending upon the size of theproject and the skills of the individual doing the coding, this may take some time. The Department offers training in the use of the Plot Program if needed. You then need to number the LOTs for all phases of construction, since LOT numbers are how areas of the material placed are identified. Account for tasks needing lead time, such as the coding of the Earthwork Record System in Earthwork and the numbering of LOTs for the various materials (concrete, asphalt, earthwork). MAC is the system used to record QC sampling and testing. You need to setup access for those required, get those trained that need it and ensure that everyone involved understands the importance of accurate, timely data entry. Release 10 November

68 Module 3 QC Manager s Role & Responsibilities Managing the LOT System LOT sizes/definitions are in SSRBC LOT numbers identify the locations of materials place Asphalt, Concrete and Earthwork have different LOT sizes/definitions LOT identification system is very important Communicate your LOT numbering system to all November 2018 QC Manager Course Release 10, Module 3 17 As a QC Manager, you might find it helpful to use one of the methods used by some ofthe most respected and successful QC managers in the industry today. On the next several slides we will review a very simple, complete, accurate and easily managed LOT numbering system used by some of the successful QC managers. Whatever method or system you use, you need to inform and educate all personnel who will be involved in their use. You may have to obtain approval from the Materials Office Materials Certification personnel for deviating from an approved numbering system. Within these materials are various subsections, such as concrete mix designs, embankment materials, etc. Each has it s own LOT Index, the system where the results for alotare recorded. Regardless of the system you use, it is important that you conduct a meeting prior to the start of production, and communicate the system to those involved. They must have an understanding of the system to make it work efficiently and effectively. Release 10 November

69 Module 3 QC Manager s Role & Responsibilities Concrete LOT numbers by Concrete Mix Design Per Contract Number Asphalt LOT numbers by tons Per Mix Design Per Contract Number Type II Bridge Deck (50 CY or 1 days production) Asphalt LOT 76 LOT 32 LOT 32 Sta Sta November 2018 QC Manager Course Release 10, Module 3 18 Concrete lots are tracked contract and mix design. In general, LOTs for concrete are typically 50 CY or a day s production, whichever is less. This is fairly straight forward, it then just becomes a matter of the placement of the mix design. The Sample Number/Lot Numbering system and report is designed to assist with tracking concrete lots and samples. Asphalt is set forth LOTs by tons per contract per mix design, therefore, asphalt LOT numbers come from the tons placed. Release 10 November

70 Module 3 QC Manager s Role & Responsibilities In summary; Put some thought into this If needed, seek help from successful QCMs or FDOT Be consistent Educate others November 2018 QC Manager Course Release 10, Module 3 19 Insummary,howyounumbertheLOTshasanimpactonyouandothers.Putsomethought into it. The District Materials and Research Office (DMRO) or State Materials Office (SMO) Materials Certification personnel may be contacted for assistance in numbering lots. Release 10 November

71 Module 3 QC Manager s Role & Responsibilities QC Awareness Conduct pre construction QC meeting Champion QC effort Provide QC Tools Review QC Process/Recording/Reporting November 2018 QC Manager Course Release 10, Module 3 20 Quality Control is one of those things that needs a Champion. Yes, you might have the title of QC Manager, but you need to Champion it, or it really doesn t happen. A Leader needs to Lead and you need to promote,design for,train for,plan for,and expound upon Quality Control. Conducting a pre construction QC meeting, not only for QC personnel but also production personnel if possible, can lead to a better understanding by the team members of QC requirements and goals. This leads to an increased chance of achieving the project QC goals. If there are any project specific requirements, discuss them with the Project Administrator early so you both are aware of the special requirements and how they will be incorporated into MAC. Provide all those in need, any QC tools that have been developed for the project. Ensure they understand the purpose and use of these tools and what you, as the QC manager, expect to gain by their proper use or completion of them. Review the process for recording, reporting and distribution of sampling and testing results and reports. Ensure that all QC Inspection personnel understand the proper procedures. Additionally, you will have arranged for MAC access at the appropriate levels for project personnel. Release 10 November

72 Module 3 QC Manager s Role & Responsibilities November 2018 QC Manager Course Release 10, Module 3 21 Construction is starting, so let s review the main QC functions during construction. Release 10 November

73 Module 3 QC Manager s Role & Responsibilities Administer QC Plan Update the QC Plan with addendums as necessary Provide interpretation of contract documents Assist in Internal Work Plan preparation Review QC Process/Recording/Reporting Results November 2018 QC Manager Course Release 10, Module 3 22 Part of administering the Quality Control is to monitor test results, detect anomalies, provide revised processes if needed, revise the QC Plan if needed, and assist in internal work plan development and assist in the interpretation of contract documents related to QC. Things such as structural concrete mix designs, personnel changes, etc. are causes for revisions to the QC Plan. Some Contractors have Project Supervision staff develop Internal Work Plans for all operations. These work plans include Budgets and Goals, Equipment and Crew needs, Cost Codes, Quality Requirements, Step by Step, Safety Provisions, Material Handling, Lay down Sketches, What If's (Plan B), Daily Schedule, Quality Analysis, etc. This is typically prepared by the engineer in charge of the operation and reviewed by the Project Manager, Job Sponsor and Quality Control Manager. The work plan is also reviewed with the crewweekly and revised to reflect any changes in the operation. The work plan is a good tool to use in any operation because it requires supervision to think about how the work is going to be built and put it on paper before the start of the operation. Release 10 November

74 Module 3 QC Manager s Role & Responsibilities November 2018 QC Manager Course Release 10, Module 3 23 There are a variety of forms that are to be completed by QC, some monthly and others daily. To access this list of forms the Contractor QC needs, visit the forms and procedures internet site Release 10 November

75 Module 3 QC Manager s Role & Responsibilities Administer Inspection Program Assemble Inspection staff; verify CTQP qualifications Ensure QC staffing manpower meets the schedule Provide training of Inspectors (internally) and arrange for external training to meet discipline requirements Manage Inspection staff November 2018 QC Manager Course Release 10, Module 3 24 As the QC Manager, a large portion of your duties involves the administration and supervision of the QC staff. You need to determine the qualifications of each individual and include the appropriate QC technicians on the Contractor QC Plan. This lets all know who is qualified for what and avoids unqualified personnel performing inspection, sampling or testingtasks. You also need to ensure that the proper manpower resources are available for the QC tasks required per phase. Based upon the QC staff, some internal or external training may be needed and asqc Manager, you will probably be responsible for arranging any required training and ensuring that qualifications are maintained. Release 10 November

76 Module 3 QC Manager s Role & Responsibilities Administer Inspection Program Ensure adherence to required specifications, procedures and methods for personnel & equipment Coordinate Verification and Resolution testing activity Ensure adherence to QC Operation elements by Inspection staff Conduct/Attend internal and external project meetings Conduct/Attend pre operations meetings November 2018 QC Manager Course Release 10, Module 3 25 As the QC Manager, you are responsible for the administration, management and evaluation of the QC Operations. You need to ensure that all personnel and equipment are current in any required qualifications or calibrations and develop a schedule, if needed, to maintain them. If Independent Assurance evaluations are performed on the QC Technicians, you need to take some active participation and ensure that the proper procedures and requirements of the test methods are being followed. You may need to provide coaching to evaluated QC technicians if they receive a strike. YoumayneedtogetinvolvedinQCvsVerificationissuesorproblems,orneedtocoordinate them. Recognize that Verification sampling and/or testing must be performed and incorporate that time into your schedule and plan. By fostering a working relationship with the Verification staff, unanticipated problems may be resolved quickly, without impacting the schedule or cost. Coordination between QC and VT is vital to ensure the sampling and testing is performed and identified under the appropriate MAC Specs. QC and VT must agree on the MAC Spec, category, type, sample purpose. As QC Manager, you may need to Release 10 November

77 Module 3 QC Manager s Role & Responsibilities coordinate communication with the PA to ensure the materials are proper identified. You may need to conduct or attend both internal and external meetings where QC issues are being discussed or resolved. Should you note that QC requirements are not being adhered to, you may need to schedule a meeting to get everyone back on track. You may also need to attend meetings to represent your company with the Owner to address QC issues. Pre operations meetings should be held and attended by QC and Production personnel prior to commencing an operation for the first time. Items such as new specifications, specification issues, memos, etc. can be discussed. Release 10 November

78 Module 3 QC Manager s Role & Responsibilities Evaluate QC Performance Monitor, Evaluate & Report QC performance Coordinate Resolution of MAR issues Record QC lapses & provide preventive solutions Track rework goals Evaluate current practices and recommend improvements Attend Project Progress meetings November 2018 QC Manager Course Release 10, Module 3 26 You will be responsible for the monitoring of QC inspection, testing, reporting and the evaluation of the results, together with the accurate and timely reporting of results. As discussed earlier, if you ensure that everyone understands the reporting and distributions requirements, there should be minimal problems associated with the reporting. In instances where material is not up to specification, but you want to leave itinplace,you may be responsible for initiating the Engineering Analysis Report (EAR) in anefforttohave the Department accept the material based upon an EAR. It will be your responsibility to provide solutions to problems encountered by QC. For instance, if density tests are not performed at the required frequencies, then you need to find out why and provide a solution. You need to follow up and ensure that when you have provided solutions to problems, there is a mechanism that permits you to determine whether or not the solution is working. The system you use for tracking rework goals should display the projected versus actual rework goals. Naturally, if there appears to be problems with current practices and procedures being used, it would be incumbent upon you to provide alternatives or solutions, which are acceptable to all parties, and hopefully impacts the schedule and costs minimally. Project Progress meetings offer an opportunity for all parties to discuss upcoming events, problems encountered and potential solutions that may be employed to resolve any conflicts or problems. Some of these meetings may be related to QC, some not, but it is important that you stay in the loop. Naturally, you should conduct QC meetings as appropriate. Release 10 November

79 Module 3 QC Manager s Role & Responsibilities Track Re work Costs Spreadsheet Tracking Prepare summaries of re work events Focus on improving processes to minimize re work November 2018 QC Manager Course Release 10, Module 3 27 The rule of thumb on concrete re work is that direct costs are approximately 285% above the cost to build it right the first time. The job management team uses spreadsheets on actual re work cost and impacts and compares these against the re work goal for the job. This is a good measure to seeifyour program is effective or if you need to improve on a certain area. Another good practiceisto put together a summary of the re work event and share with personnel of the job to learn from mistakes. This information can be sent to other projects in hopes of preventing of the same event somewhere else throughout the company. The intent of having goals on re work is What Gets Measured Gets Attention. If you see where you re having problems with re work, you can focus on improving the process to help the project be more financially successful and give the Owner the best product in the lowest amount of time. Release 10 November

80 Module 3 QC Manager s Role & Responsibilities Identify Process problems Identify QC problems Assist in meeting/improving processes November 2018 QC Manager Course Release 10, Module 3 28 Control charts can do a variety of things for the QC Manager and we will now look at a few examples where the use of control charts were beneficial to the contractor. In Lesson 4, we will see that control charts are effective tools that can be used by the QC Manager to monitor performance and improve processes during construction. They can assist in spotting problems, fine tuning processes and production, to the benefit of the Contractor. Release 10 November

81 Module 3 QC Manager s Role & Responsibilities Density / Moisture Relationship for 121 Proctor (T 180) November 2018 QC Manager Course Release 10, Module 3 29 This is an example of a control chart prepared by the QC Manager to monitor the Moisture and Density results for the previous slide. Control charts are a helpful tool for QC Managers to monitor Quality Control. More details on control charts will be covered in Chapter 4. Release 10 November

82 Module 3 QC Manager s Role & Responsibilities Engineering Analysis Report (EAR) Initiated by Contractor Submitted to Project Administrator Follow FDOT EAR Guidelines November 2018 QC Manager Course Release 10, Module 3 30 There are instances where material may not meet the project requirements but based upon analysis by a Specialty Engineer, may be left in place, though generally at a reduced payment. The Department has published guidelines for the development of an EAR, so you should take advantage of this document and ensure the Specialty Engineer utilized is aware of and follows these guidelines. Release 10 November

83 Module 3 QC Manager s Role & Responsibilities Release 10 November

84 Module 3 QC Manager s Role & Responsibilities Materials Acceptance Resolution (MAR) MAC records most materials acceptance issues as part of the Materials Certification (MC) Review in a process known as Materials Acceptance Resolution or MAR The PA coordinates with the Materials Office MC Reviewer If the material is designated to have an Engineering Analysis Report, the PA will notify the Contractor November 2018 QC Manager Course Release 10, Module 3 32 Defective Material not meeting specifications or project requirements, which the Contractor desires to leave in place is documented in MAC as part of the Materials Certification (MC) Review. The QC Manager is responsible for coordinating any Engineering Analysis Report (EAR) submittal to the Project Administrator in the case of defective material being left in place and accepted. If the MAR process determines that an EAR is needed, the PA will notify the Contractor. Outside of MAC, the Contractor submits the proposed scope of the EAR to the PA. The PA forwards the scope to the DMRE. The DMRE reviews the scope and may provide additional or revised requirements. The PA returns the scope to the Contractor who then has the Specialty Engineer perform the EAR and provides the final report to the PA. The PA attaches the final report to the MAR issue in MAC and the final resolution is recorded by the PA, DMRE, DCE and possibly the Director of the Office of Construction (when the DMRE and DCE do not concur). These resolutions are recorded in MAC. Release 10 November

85 Module 3 QC Manager s Role & Responsibilities Record Management Oversee MAC data entry Verify QC record completeness and submittal Verify completion & submittal of Certification Documents Consult on Final Estimate issues November 2018 QC Manager Course Release 10, Module 3 33 It isn t over until the paperwork is done. A truism in today s construction industry, especially as it relates to QC. The Department uses MAC for the storage of all sampling and testing information. The QC sampling and testing data must be entered into this system. You need to ensure that data entry personnel have the appropriate access and training to use the system. Untrained, inexperienced and careless personnel will only create problems in the data entry,whichare problems for you. Choose carefully. Each month you will be responsible for submitting the Contractor Monthly Certification(s), Forms & , certifying as to the accuracy and completeness of the sampling, testing and reporting performed. There are a number of other certification documents that are required for material acceptance that the contractor must submit to the PA. At times, material acceptance issues become payment issues; for example, a bonus on the asphalt for a Percent with Limit (PWL) result greater than 1.00 or a reduction in payment due to a structural concrete compressive strength failure within 500 PSI of the minimum compressive strength. The QC Manager may be asked to consult to ensure the testing data that created the payment issue is correct. Release 10 November

86 Module 3 QC Manager s Role & Responsibilities Contractor Certification of Compliance. Provide the Engineer with a notarized monthly certification of compliance with the requirements of this Section, to accompany each progress estimate, on a form provided by the Engineer. The Department may not authorize payment of any progress estimate not accompanied by an executed certification document. Final payment in accordance with 9-8 will not be made until a final notarized certification summarizing all QC exceptions has been submitted. November 2018 QC Manager Course Release 10, Module 3 34 SECTION 105 CONTRACTOR QUALITY CONTROL GENERAL REQUIREMENTS Contractor Certification of Compliance. Provide the Engineer with a notarized monthly certification of compliance with the requirements of this Section, to accompany each progress estimate, on a form provided by the Engineer. The Department may not authorize payment of any progress estimate not accompanied by an executed certification document. Final payment in accordance with 9 8 will not be made until a final notarized certification summarizing all QC exceptions has been submitted. Release 10 November

87 Module 3 QC Manager s Role & Responsibilities Release 10 November

88 Module 3 QC Manager s Role & Responsibilities What is the intent of this form? What is an Exception? November 2018 QC Manager Course Release 10, Module 3 36 This opening statement of the form is the Contractor and QC Manager certification that the QC sampling and test results were performed in substantial compliance with the specifications and Project QC Plan. Release 10 November

89 Module 3 QC Manager s Role & Responsibilities Exceptions For the Monthly Certification, List the Following: 1. QC samples that did not compare with VT samples and had VT results upheld by RT samples. 2. Any samples that had Engineering Analysis Report or Delineation Test(s) performed. 3. Any failed QC samples. 4. Any QC samples that do not have results entered into MAC. November 2018 QC Manager Course Release 10, Module 3 37 Exceptions: For the monthly certification, list the following: 1. QC samples that did not compare with VT samples and had VT results upheld by RT samples. 2. Any samples that had Engineering Analysis Report or Delineation Test(s) performed. 3. Any failed QC samples. 4. Any QC samples that do not have results entered into MAC. Release 10 November

90 Module 3 QC Manager s Role & Responsibilities Exceptions For the Monthly Certification, List the Following: 5. Any QC samples that were performed by unqualified technicians or laboratories. 6. Any materials placed without an approved QC Plan or when the QC Plan is suspended. 7. Any materials provided from an unapproved producer or supplier. 8. Results of any failing Chloride content limits as defined in Specification November 2018 QC Manager Course Release 10, Module Any QC samples that were performed by unqualified technicians or laboratories. 6. Any materials placed without an approved QC Plan or when the QC Plan is suspended. 7. Any materials provided from an unapproved producer or supplier. 8. Results of any failing Chloride content limits as defined in Specification The following would not be listed as an exception on the subject form: 1. QC samples that have been tested but not verified. 2. QC samples that have been tested and had verification test results that did not compare. For the final certification, all exceptions to QC sampling and testing must be shown on the certification. Release 10 November

91 Module 3 QC Manager s Role & Responsibilities Who signs this form? November 2018 QC Manager Course Release 10, Module 3 39 Quality Control Manager: Type the Quality Control Manager s name. Title: Type or print the title of the person signing the certification. Signed By: The electronic form allows for a digital signature when the you have completed the requirements for a digital signature identity. Contractor: Type the name represented by the signature in the Contractor signature block. This is an officer or director of the Contractor with an authority to bind thecontractor. Title: Type or print the title of the person signing the certification. Signed By: The electronic form allows for a digital signature when the you have completed the requirements for a digital signature identity. Release 10 November

92 Module 3 QC Manager s Role & Responsibilities What does signing this form mean to you? November 2018 QC Manager Course Release 10, Module 3 40 The signing of this form is a serious matter and not to be taken lightly. By signing this form you are certifying that everything was performed as it should be. If you sign this form, knowing that it is not true, you can be held liable and prosecuted under State and Federal laws. Also, the final version is a contract document and could hold payment and eventually lead to the Contractor s Certificate of Qualification being suspended. Release 10 November

93 Module 3 QC Manager s Role & Responsibilities Can your QC Manager Qualification be suspended? YES Can a QC Manager be disqualified? YES November 2018 QC Manager Course Release 10, Module 3 41 CTQM Chapter 7 covers the suspension process. Release 10 November

94 Module 3 QC Manager s Role & Responsibilities CPAM, Chapter 13.1 & CTQM Chapter 7.6 If the PA or Resident Engineer issues Deficiency Letter (DL) to Contractor as a direct result of deficient QC Operations due to the QC Manager s failure to properly apply the specifications and Quality Control procedures, a letter of warning (or suspension) must also be sent to the QC Manager. November 2018 QC Manager Course Release 10, Module 3 42 Requirements are documented in CTQP Chapter 7 and CPAM Chapter 13 CPAM describes issuing an DWL or DL. CTQM describes DLs issued as a direct result of deficient QC Operations due to the QC Manager s failure to properly apply the specifications and Quality Control procedures. Release 10 November

95 Module 3 QC Manager s Role & Responsibilities Qualification Suspension by a 3 letter system 1 st Letter of warning issued by the State Construction Training Coordinator (SCTC) 2 nd Letter of warning issued by SCTC within one year of first 3 rd Letter suspends qualification November 2018 QC Manager Course Release 10, Module 3 43 CTQM QC Manager Suspension Process Letters of warning written to a QC Manager could lead to qualification suspension in accordance with the following three step system: 1st Letter Documented letter of warning from the State Construction Training Manager. If no other letters are issued within one year (365 days), then the record of the 1st letter of warning shall be deleted from the Manager's qualification record. 2nd Letter Documented letter of warning from the State Construction Training Manager within one year of the 1st letter of warning. If no other letters are issued within one year (365 days), then the record of the 1st and 2nd letter shall be deleted from the Manager's qualification record. 3rd Letter Suspension of qualification in the TQDBS by the State Construction Training Manager. Should the need arise to send a 3rd letter within 365 calendar days of the 2nd letter of warning, the QC Manager s CTQP qualification shall be suspended. The State Construction Training Manager shall inform the CTQP Manager to suspend the Manager's qualification in the TQDBS via letter or e mail. Release 10 November

96 Module 3 QC Manager s Role & Responsibilities The suspension shall be for one calendar year (365 days). This decision may be appealed to the Director, Office of Construction. The Director s decision is final. Prior to having the qualification reinstated, the technician must meet all initial QC Manager qualification requirements including passing the QC Manager s examination. One copy of the suspension letter shall be given to the QC Manager, one copy to the manager's supervisor (or prime contractor's representative), one copy sent to the State Construction Training Manager, and the original shall be retained in the project files. This suspension shall apply to the QC Manager qualification only. These warning letters are not considered as strikes and they are not tracked in MAC.The State Construction Office maintains a tracking system to record when QC Managers receive warning letters and the number of letters received. Release 10 November

97 Module 3 QC Manager s Role & Responsibilities Project Completion Asphalt Amounts/Certifications/Reports MAC Sampling & Testing Material Certifications Earthwork Record System Resolve MAR Issues November 2018 QC Manager Course Release 10, Module 3 45 Upon completion of the project, the QC Manager has numerous responsibilities related to finalizing records, certifications and documentation. Shown above is a list of items, which is not to be considered all inclusive, that the QC Manager may need to deal with upon completion of the Project. Release 10 November

98 Module 3 QC Manager s Role & Responsibilities Any Questions? November 2018 QC Manager Course Release 10, Module 3 46 Release 10 November

99 Module 4 QC Manager Tools November 2018 QC Manager Course Release 10, Module 4 1 QC Managers rely on basic mathematical tools to track quality, detect changes in quality performance, detect trends, and keep the performance in the expected ranges. Release 10 November

100 Module 4 QC Manager Tools Learning Outcomes Statistical Concepts Variability Quality Characteristics Process Control November 2018 QC Manager Course Release 10, Module 4 2 This is a basic overview of what will be discussed in Module 4. Release 10 November

101 Module 4 QC Manager Tools Why Statistical Concepts? Quality Control deals with collection and treatment of data. Informed decisions concerning the process can be made. Can be used to reduce risks: seller/contractor ( α the risk rejecting good material) owner s risk ( β the risk of accepting bad material). Good Material (accept) Good Material reject ( α risk) Bad Material accept ( β risk) Bad Material (reject) November 2018 QC Manager Course Release 10, Module 4 3 The purpose of reviewing data analysis and statistical concepts for Quality Control of Materials is the QC Manager plays a vital role in providing materials that consistently meet the specification requirements. The statistical tools are useful for accepting good materials, meeting the specifications, and rejecting bad materials, not meeting the specifications. The QC Manager has an active part in adjusting the processes that produce bad materials and bringing the processes into conformance to produce consistently good materials. Good quality control practices will reduce the α risk to the contractor of rejecting good material and the β risk to the owner of accepting bad material. A good Quality Control Manager should have a fundamental understanding of the data and data indicators to reduce inefficiencies and delays related to materials used a the project. Release 10 November

102 Module 4 QC Manager Tools What we will learn about statistics Population Vs. Samples Determine means and deviations Describe Sources of variability Identify LOTs November 2018 QC Manager Course Release 10, Module 4 4 Release 10 November

103 Module 4 QC Manager Tools Population vs. Sample Population is all the material with common specific characteristics (4,500 psi concrete) Lot is a defined isolated quantity of population (50 CY of 4,500 psi concrete) Sample is a set of measurements that constitutes a part of the population or lot. November 2018 QC Manager Course Release 10, Module 4 5 1) Population, using the photo it may be all 4,500 psi concrete on the project. 2) Lot, may be all 4 trucks shown in the photo, 40 CY. Placed in one day. 3) Sample, may be the wheelbarrow size sample being prepared for testing in the bottom photos. It is impractical to test the entire population. The population is divided into lots of specific sizes and samples are then taken from lots at specified intervals. The sample size may be small in comparison to the lot size. The sample size may be very small compared to the size of the population. For example, the population on a project may be 2,000 cubic yards of 4,500 psi concrete. The 2000 CY population of 4,500 psi concrete may be divided into 40 Lots of 50 CY each. Each of the 40 Lots would have at least one QC sample the size of a wheel barrow. So, the 2000 CY Population would have 40 wheel barrow size samples. The actual number of samples would probably be greater than 40 due to actual placement not always being divided into 50 CY Lots. Release 10 November

104 Module 4 QC Manager Tools Statistical Tools Any one of several mathematical tools that are used to help QC Mangers understand the quality of product conformance to specifications: The Mean ( x) The Range (R) The Deviation The Variance (s 2 ) The Standard Deviation (s, ) The Percent Within Limits (PWL) November 2018 QC Manager Course Release 10, Module 4 6 For example, the Mean of all strength test results might be specified as the Quality Measure for a LOT of Portland cement concrete. Or, the Percent Within Limits (PWL) of all in place density test results might be used as the Quality Measure for asphalt in place density. PWL is the Quality Measure that is most often recommended for use in Quality Assurance Specifications. The standard deviation and mean are part of the PWL calculation. Release 10 November

105 Module 4 QC Manager Tools Mean The principal mathematical measure used to describe the central tendency of a distribution of measurements or test values. x = x i n = Mean/Average X 1 + X 2 + X 3 +. n November 2018 QC Manager Course Release 10, Module 4 7 Mean is another word for average. The mean of the population is generally designated as. The Sample mean is usually designated as X bar (an X with a bar over it) (x), and is called x bar. Release 10 November

106 Module 4 QC Manager Tools Sample Number x1 x2 x3 x4 x5 x6 x7 x8 x9 x10 x11 x12 x13 x14 Sum ( ) of test values: No. of Samples (n): Mean ( ): x Test Value November 2018 QC Manager Course Release 10, Module 4 8 Here is an example finding the average or mean for 14 different samples. It is the sum of the results of all 14 tests divided by the total number of tests, 14. The mean or average value is Release 10 November

107 Module 4 QC Manager Tools Range The difference between the highest individual value and the lowest individual value in a set of sample values. R = ( x High - x Low ) November 2018 QC Manager Course Release 10, Module 4 9 Range is used as an indication of spread or variability of the samples. Because of the simplistic nature of the range is does not provide the best estimate of variability. An example of the range not being a best estimate of variability is if one sample is very high or very low and the remaining samples are bunched close together. Release 10 November

108 Module 4 QC Manager Tools Sample Number x1 x2 x3 x4 x5 x6 x7 x8 x9 x10 x11 x12 x13 x14 Highest Sample Value (x high ): Lowest Sample Value (x Low ): Range (R): Test Value November 2018 QC Manager Course Release 10, Module 4 10 The Range in this example shows a spread of 6.1 between lowest and highest values. Release 10 November

109 Module 4 QC Manager Tools Deviation The difference between an individual sample value and the Mean of a set of sample values. X i - x November 2018 QC Manager Course Release 10, Module 4 11 A better measure of variability is deviation. The deviation is the variance of each individual sample from the sample mean. Release 10 November

110 Module 4 QC Manager Tools Variance A measure of dispersion in a set of sample values determined by summing the squares of all Deviations from the Mean and dividing by the number of samples less one. (x i - x) s 2 = 2 n - 1 November 2018 QC Manager Course Release 10, Module 4 12 The variance is the sum of the means squared of all individual deviations divided by the total number of samples minus 1. Most scientific calculators and spreadsheets have formulas to calculate the variance. It is seldom done by hand. Notice this variance is a calculation based on the samples, not the entire population to show the spread or dispersion of the values. The x bar and n symbols are good indications the deviation calculation is for the samples. x Release 10 November

111 Module 4 QC Manager Tools Sample Number x1 x2 x3 x4 x5 x6 x7 x8 x9 x10 x11 x12 x13 x14 s 2 = Test Value (x i - x )2 n - 1 Sum ( ) of Deviation Squared: No. of Samples Minus One (n-1): Variance (s 2 ): Deviation Deviation Sq. ( x i - x ) ( x i - x ) November 2018 QC Manager Course Release 10, Module 4 13 Most scientific calculators have buttons for calculation of deviation after the sample values are input. Release 10 November

112 Module 4 QC Manager Tools Standard Deviation A measure of the Variability of a Population or a Statistical Sample, and which is represented by the principal square root of the Variance. s= n (x i - x) 2 i=1 n - 1 or (x i - ) = n 2 i=1 n SAMPLES or POPULATION x November 2018 QC Manager Course Release 10, Module 4 14 The standard deviation is the most used indication of sample variability and to calculate the Percent within Limits (PWL). It is the square root of the variance. Here we have standard deviation formulas for the sample standard deviation and the population standard deviation. As the number of samples increase the values should tend to grow closer. Most scientific calculators have buttons to calculate the sample and the population standard deviations after the test data is input. MAC also has some standard deviation tools to help evaluate variability of test data. Release 10 November

113 Module 4 QC Manager Tools Variability Differences in measured test values for a given quality characteristic within a stable pattern due to chance,ordue to assignable causes. November 2018 QC Manager Course Release 10, Module 4 15 Quality Control assigns variability to two causes. 1) Chance Causes and 2) Assignable Causes. Assignable Causes are often easier to identify and correct. An example of an assignable cause might be it rained heavily the night before earthwork compaction operations were to begin. The compaction operation resulted in a number of failing density tests and high moisture contents were measured in a number of samples. The assignable cause can be corrected by drying the earth work and compacting at a lower moisture content. An example of chance cause would be if density tests are run after drying and recompacting successfully with all density values passing. The passing values are not all the same and variations in earth material, compaction efficiency, and moisture contents account for chance causes of the measured differences. Release 10 November

114 Module 4 QC Manager Tools Sources of Variability Materials Sampling Testing Production & Placement November 2018 QC Manager Course Release 10, Module 4 16 Remember sources of variability may be chance causes or assignable causes. Release 10 November

115 Module 4 QC Manager Tools Materials Natural Variation Non Homogeneous Non Uniform Contamination November 2018 QC Manager Course Release 10, Module 4 17 Natural variation, non homogeneous, and non uniform materials are usually classified as chance causes. Contamination of the material is a good example of an assignable cause. Release 10 November

116 Module 4 QC Manager Tools Sampling Process Variability Random Representative November 2018 QC Manager Course Release 10, Module 4 18 Sampling Variability is caused by variation that is allowed in the sampling methods described in ASTM, AASHTO, and Florida Methods. Even if the standard sampling procedures are followed, some amount of sampling variability will occur, because we are human. No two people will perform sampling identically. Release 10 November

117 Module 4 QC Manager Tools Testing Prescribed Methods Calibrated Equipment Accurate Calculations November 2018 QC Manager Course Release 10, Module 4 19 Variability of testing can relate to equipment, personnel, and/or not following test method procedures. Using prescribed methods for testing samples with calibrated equipment helps reduce assignable causes due to test errors. Data should be checked for accuracy and calculations should be checked for accuracy and proper recording. Only CTQP Qualified Technicians should be testing samples for FDOT projects. Release 10 November

118 Module 4 QC Manager Tools Production & Placement Uniform Process Weather Input Treatment November 2018 QC Manager Course Release 10, Module 4 20 It should be a goal of production and placement to have uniform processes that will reliably provide materials that meet the specified requirements. Deviations due to chance causes will occur. Deviations due to assignable causes should be avoided or corrected as quickly as possible. The following variables might impact production and placement: equipment, operators, methods, and weather. Release 10 November

119 Module 4 QC Manager Tools Why aren t the average values a good enough measure? A B Which is more variable? November 2018 QC Manager Course Release 10, Module 4 21 The tight pattern in target B shows a much smaller variation. The range difference between target A and target B is much greater for target A. The mean or average for target A and target B may be very close. This is a good example of the potential problem with using the average or mean as the sole indication of quality. Good quality control practices seek to reduce variability and keep the desired key quality characteristics on target. Release 10 November

120 Module 4 QC Manager Tools Biased Random November 2018 QC Manager Course Release 10, Module 4 22 QC is a randomly selected sample, VT is a randomly selected sample to check QC, and IV may be randomly selected or a biased selected sample depending on the material and circumstances. To measure a particular Quality Characteristic of a LOT or sub LOT, we could randomly obtain a sample from any part of the LOT. For example we want to test the compressive strength of 500 CY of PCC. We could test every yard, but then we wouldn t have much concrete left. This is called complete enumeration. Obviously, this is not practical or cost effective, therefore we obtain a Statistical Sample. Statistical Samples are those samples obtained from a LOT which can provide information that may be used to quantify the quality of the entire LOT. Release 10 November

121 Module 4 QC Manager Tools Biased Sampling Representative Sampling Uniform Interval Sampling Quota Sampling Selective Sampling Random Sampling November 2018 QC Manager Course Release 10, Module 4 23 There are a variety of sample types that can be obtained when sampling LOTs. Biased Sampling A sampling procedure whereby samples obtained from a LOT do not have an equal probability of being chosen. Representative Sample a non random sample which, in the opinion of the sampler, represents an average condition of a material or an item of construction. Uniform Interval Sampling a non random procedure in which samples are obtained at fixed intervals of material production or material quantity. Quota Sampling a non random procedure in which samples are obtained at the discretion and convenience of the sampler to satisfy the required number of samples for alot. Selective Sampling a non random procedure in which a sample is obtained only for informational purposes to guide Quality Control or Verification actions. Random Sampling each sample is obtained from the LOT has an equal probability of being selected. For Asphalt, LOTs are divided into smaller quantity amounts of uniform size, which are called sub LOTs. There are no sub LOTs in FDOT earthwork construction and concrete. Release 10 November

122 Module 4 QC Manager Tools Random Sampling is to be performed for both QC and Verification, VT, to eliminate biased samples. November 2018 QC Manager Course Release 10, Module Department Verification: The Engineer will conduct a Verification The Engineer will select test locations, including Station, Offset, and Lift, using a Random Number generator based on the Lots under consideration. Each Verification test evaluates all work represented by the Quality Control testing completed in those LOTs. (All other specifications have similar language) Random Sampling is to be performed for both QC and Verification, VT, to eliminate biased samples. Random sampling protects against known defects, unknown defects, cycles and patterns. It has a low inherent risk, low risk in unknown situations, and high reliability. Furthermore, it does not require a knowledgeable sampler (one who understands patterns, etc.) Random does not mean haphazard. It mean the sample is selected without bias. Release 10 November

123 Module 4 QC Manager Tools Random Sampling How Specified/Measured? Material Production Time (days) Produced Material Mass (tons) Volume (CY) In place Material Area (SY) Length (miles/feet) Thickness (inches) November 2018 QC Manager Course Release 10, Module 4 25 The goal of random sampling is to provide an unbiased measure of the quality of the materials tested. Random sampling means every truck, lift, station, etc., has an equal chance of being selected. When you decide the location, truck, LOT, etc. based on what or where you want to sample or test, it is biased. As an example, if Verification always chose the 4 th LOT of 4 consecutive LOTs of earthwork for density testing, it would be considered biased. Release 10 November

124 Module 4 QC Manager Tools Biased Sampling Picking every 4 th truck Picking every fourth LOT Picking the same truck every pour Picking the same station numbers each lift Independent Verification Any biased selection November 2018 QC Manager Course Release 10, Module 4 26 These are all examples of biased sampling. Good Quality Control would generally avoid these non random practices. Release 10 November

125 Module 4 QC Manager Tools Methods used to ensure the random selection of sampling and testing locations. November 2018 QC Manager Course Release 10, Module 4 27 There are a variety of methods for determining Random Samples. In all cases, the Standard Specs specifies that sampling and testing be performed at locations determined by a Random Number Generator. The specifications require the Engineer to provide the Random Number. TheQCManagerandtheirstaffshould bemadeawareofthesystemtobeusedto generate random numbers in advance of construction and all parties agree Example Random Number Generators: Random Number Chart FDOT 2006 ASTM D 3665 Standard Practice for Random Sampling of Construction Materials Computer/calculator capable of generating random numbers Throwing dice Random Number Table created through software, such as MS Excel or proprietary software available for purchase. In all cases the Standard Specs calls for sampling and testing performed at locations determined by a Random Number Generator Release 10 November

126 Module 4 QC Manager Tools 1. Pick a number between (row number) 2. Pick a number between 1 7 (column number) 3. Enter the chart based on row & column selected 4. Moving L to R, R to L or Up and Down, select unique random number for each sample or test. November 2018 QC Manager Course Release 10, Module 4 28 This is the Random Number Chart FDOT The following Random Number Chart and instructions can be obtained from the SMO website. The following slides have a full size of the chart and detailed instructionsonuse. Release 10 November

127 Module 4 QC Manager Tools Random Number Chart FDOT Obtained from the FDOT website Release 10 November

128 Module 4 QC Manager Tools These notes, instructions, and examples are also available with the Random Number Chart on the FDOT website. Random Number Sampling Plans A random number generator is to be used to help select random frequencies and locationsfor materials. Random number charts are published in a variety of publications and available on scientific calculators and computers. Other published random number charts and electronic generators are approved to use in order to generate a random sampling plan. Random Number Chart FDOT 2006 is published and available at the State Materials Office Web page. Asphalt plant and roadway quality control and verification sample random number locations are generated by the Composite Pay Factor worksheet. Suggestions for using Random Number Chart FDOT Determine the number of samples you plan on obtaining using the project documents. 1. Pick a number between 1 and 100. This is the row number you selected. 2. Pick another number between 1 and 7. This is the column number. 3. Enter the chart using the row and column numbers you selected. 4. Assign a unique random number from the chart for each sample you plan to obtain. You may go right to left, up or down, or left to right from the row and column you entered in Step 3. If you come to a random number that does not generate a valid location for sampling, skipthat number and move on to the next number in the sequence. 5. The random numbers can be used as a percentage or individual digits to select sample frequencies or locations. Release 10 November

129 Module 4 QC Manager Tools EXAMPLES: Concrete Plan for a 230 cy placement with a sample frequency of 1 per lot, 50 cy lot size. Expect 5 lots, 1 sample for each 50 cy lot. Pick 63 and 4 as row and column numbers to enter chart. Pick five numbers reading left to right. (0.1224, , , ) Using the percentage method: Lot 1 : 50 cy x = 6.12, select the truck at the 6 cy point Lot 2 : 50 cy x = 6.57, select truck at the 57 cy point ( for Lot 1 = 57) Lot 3: 50 cy x = 38.34, select truck at 138 cy point. ( for lots 1&2=138) Lot 4: 50 cy x = 30.70, select truck at 181 cy point. ( for lots 1,2&3=181) Lot 5: 30 cy x = 29.07, select truck at 229 cy point. ( for lots 1 thru 4 =229) November 2018 QC Manager Course Release 10, Module 4 31 EXAMPLES Concrete Plan for a 230 cy placement with a sample frequency of 1 per lot, 50 cy lot size. Expect 5 lots, 1 sample for each 50 cy lot. Pick 63 and 4 as row and column numbers to enter chart. Pick five numbers reading left to right. (0.1224, , , ) Using the percentage method: Lot 1 : 50 cy x = 6.12, select the truck at the 6 cy point Lot 2 : 50 cy x = 6.57, select truck at the 57 cy point ( for Lot 1 = 57) Lot 3: 50 cy x = 38.34, select truck at 138 cy point. ( for lots 1&2=138) Lot 4: 50 cy x = 30.70, select truck at 181 cy point. ( for lots 1,2&3=181) Lot 5: 30 cy x = 29.07, select truck at 229 cy point. ( for lots 1 thru 4 =229) Release 10 November

130 Module 4 QC Manager Tools EXAMPLES: Earthwork Stabilized Subgrade Contractor completes stabilization and compaction operations for a subgrade section of 1400 lineal feet with a width of 24 feet. Three Lots of stabilized subgrade. You plan for 3 density tests (1 location per Lot) and 9 stabilizing mixing depth (3 locations per Lot). Density locations: Pick 18 and 2 as row and column numbers to enter random number chart. Reading left to right: , , , , and Note 6 random numbers are selected as you need random distance locations from the beginning of the lot station and random width locations from the edge of the stabilized area. Lot 1: Length, 500 x = 320 Width, 24 x = 0.34 Select location 320 from beginning station of Lot 1 and 0.34 from the right side of the stabilized area. Lot 2: Length, 500 x = 485 Width, 24 x = 17.8 Select location 485 from beginning station of Lot 2 and 17.8 from the right side of the stabilized area Lot 3: Length, 400 x = 33 Width, 24 x = 13.5 Select location 33 from beginning station of Lot 3 and 13.5 from the right side of the stabilized area Mixing depth check locations can be selected in a similar manner using 3 locations per Lot November 2018 QC Manager Course Release 10, Module 4 32 Earthwork Stabilized Subgrade Contractor completes stabilization and compaction operations for a subgrade section of 1400 lineal feet with a width of 24 feet. Three Lots of stabilized subgrade. You plan for 3 density tests (1 location per Lot) and 9 stabilizing mixing depth (3 locations per Lot). Density locations: Pick 18 and 2 as row and column numbers to enter random number chart. Reading left to right: , , , , and Note 6 random numbers are selected as you need random distance locations from the beginning of the lotstationand random width locations from the edge of the stabilized area. Lot 1: Length, 500 x = 320 Width, 24 x = 0.34 Select location 320 from beginning station of Lot 1 and 0.34 from the right side of the stabilized area. Lot 2: Length, 500 x = 485 Width, 24 x = 17.8 Select location 485 from beginning station of Lot 2 and 17.8 from the right side of the stabilized area Lot 3: Length, 400 x = 33 Width, 24 x = 13.5 Select location 33 from beginning station of Lot 3 and 13.5 from the right side of the stabilized area Mixing depth check locations can be selected in a similar manner using 3 locations per Lot Release 10 November

131 Module 4 QC Manager Tools EXAMPLES: Earthwork Stabilized Subgrade (cont d) Tips : Enter the chart at a unique location each time it is used. Avoid starting at the top, (row 1, and column 1). And reading to the right like a book each for successive chart uses. Keep it simple! Close your eyes and point to a spot on the page to start if you can t decide which numbers between 1 and 100 or 1 and 7 are good starting points. Avoid the temptation to pick new random numbers just because you don t agree with the random selection. You can always use Independent verification ( IV) testing if the random selection is obviously missing an area of particular concern. Record all the test data for every test conducted. November 2018 QC Manager Course Release 10, Module 4 33 Tips : Enterthechartatauniquelocationeachtimeitisused.Avoidstartingatthe top, (row 1, and column 1). And reading to the right like a book each for successive chart uses. Keep it simple! Close your eyes and point to a spot on the page to start if you can t decide which numbers between 1 and 100 or 1 and 7 are good starting points. Avoid the temptation to pick new random numbers just because you don t agree with the random selection. You can always use Independent verification ( IV) testing if the random selection is obviously missing an area of particular concern. Record all the test data for every test conducted. Release 10 November

132 Module 4 QC Manager Tools Quality Characteristics for Asphalt & PCC November 2018 QC Manager Course Release 10, Module 4 34 Quality characteristics are properties that relate to performance that can be measured and quantified with good repeatability. Quality characteristics used for payment are considered more important than others. Quality Characteristics are capable of being measured with repeatability using ASTM, AASHTO or FM methods or procedures. The test methods can be simple or complex. Training is required to ensure test methods are followed with precision. Only CTQP Qualified Technicians are allowed to perform testing used for materials acceptance for FDOT projects. Release 10 November

133 Module 4 QC Manager Tools Quality Characteristics used by FDOT for Acceptance and Payment * *Typical, but not all inclusive November 2018 QC Manager Course Release 10, Module 4 35 The Job Guide Schedule, JGS, contains the tests used to measure the quality characteristics. A customized JGS is available in MAC for every FDOT project. The typical examples in the table above are only a few of the quality characteristics normally found on projects. Release 10 November

134 Module 4 QC Manager Tools True or False - Quality Characteristics selected for QC contribute either directly or indirectly to the long term performance of the product. True False True or False - With enough QC Testing, we can eliminate variability in sampling and testing. True False November 2018 QC Manager Course Release 10, Module 4 36 We are not able to eliminate variability due to chance causes. One important goal of QC Management is to detect variability due to assignable causes and correct the assignable cause. Controlling variability will lead to more consistent materials with reliable performance. Release 10 November

135 Module 4 QC Manager Tools LOT in CQC Specifications LOT material from a single source assumed to be produced essentially by the same controlled process with normally distributed properties. November 2018 QC Manager Course Release 10, Module 4 37 In Quality Assurance Specification, the term LOT is used to represent a Population of material (e.g. HMA, PCC, Soils, etc.) which is incorporated into the product. Standard Specs sets forth the size of a LOT, by construction type and material. The LOT size is intended to represent material which is indeed from the same source and which has been produced and placed essentially under the same controlled conditions. For Example Section 120 Excavation & Embankment a LOT is a single lift of finished material not to exceed 500 feet in length, or a single run of pipe connecting two structures, whichever is less. On some very small projects,the Standard Specs may define the LOT as the entire quantity of material produced an placed on that project. These special and partial LOT considerations are noted in the Standard Specs. Release 10 November

136 Module 4 QC Manager Tools LOT in CQC Specifications sublot an equal division or part of a LOT from which material is obtained to assess characteristics of the LOT. November 2018 QC Manager Course Release 10, Module 4 38 LOTs may be divided into smaller quantity amounts of uniform size, which are called sublots. A good example used in asphalt: Each lot is 4000 Tons. Each 4000 ton lot is subdivided into 4 sub lots of 1000 tons each. Release 10 November

137 Module 4 QC Manager Tools Random Sampling LOT Random Sampling Stratified Random Sampling SubLot November 2018 QC Manager Course Release 10, Module 4 39 Remember Random sampling ensures that each specimen in a LOT has the same chance of being selected for the sample. Stratified random sampling additionally involves the selection of two or more defined sublots of a given LOT. Stratified random sampling is used to ensure that the specimens for the sample are obtained from throughout the LOT, and are not concentrated in one portion or sublot of the LOT. It is possible, but not likely, that in a LOT all of the random numbers could have us sampling in the morning: we avoid this through the use of sublots. Release 10 November

138 Module 4 QC Manager Tools Material Hot Mix Asphalt Portland Cement Concrete Earthwork LOT Definition 4,000 tons sublot 1,000 tons Varies by usage (Class II Bridge Deck = 50 CY or one day s Production, which ever is less (No sublot) A single lift of finished material not to exceed 500 feet or a single run of pipe connecting two structures, whichever is less (No sublot) November 2018 QC Manager Course Release 10, Module 4 40 The LOT sizes for Asphalt, Concrete and Earthwork are defined in the Standard Specs. There is no need for dividing concrete or earthwork into sublot since the Standard Specs requires only one QC sample per Lot. Release 10 November

139 Module 4 QC Manager Tools Variability is: A. The Contractor s ability to vary their process. B. The differences in measured test values for a given quality characteristic. C. The differences in Contractor equipment. D. The difference between QC and VT Testing. Stratified Sampling is: A. A sampling procedure based upon the level of expertise by the individual sampling. B. The random sampling of strata in LOTs. C. A sampling procedure whereby samples are obtained randomly from each sublot. D. Combination of A & B. November 2018 QC Manager Course Release 10, Module 4 41 Release 10 November

140 Module 4 QC Manager Tools Defining Quality Characteristics Characteristics and/or Properties that Relate to Performance Can Be Quantified/Measured with Good Repeatability November 2018 QC Manager Course Release 10, Module 4 42 Key Quality Characteristics are selected because they are good indicators tomonitorand control production against specification targets and limits. Quality Control and verification sampling and testing are used to measure thequalityofthe constructed product. The specific material properties which are evaluated by QC and Verification sampling and testing are referred to as Quality Characteristics. Quality Characteristics which are specified are normally selected because they: Relate to initial and long term Performance Are quantifiable or measurable Can be measured with good repeatability Release 10 November

141 Module 4 QC Manager Tools A group of individual persons, objects, or items that possess some common specified characteristic(s) which can be measured. Example Population Common Characteristics ALL Structural Asphalt Air Voids ALL Structural Asphalt Asphalt Content % ALL Stabilized SubGrade LBR ALL 5000 psi PCC in a Structure Strength November 2018 QC Manager Course Release 10, Module 4 43 These are good examples of key quality characteristics we measure for FDOT highway construction materials. The complete list of key quality characteristics is found in the Sampling, Testing and Reporting Guide, (STRG). Release 10 November

142 Module 4 QC Manager Tools Why Process Control? Minimize Variability Provide Consistent Quality November 2018 QC Manager Course Release 10, Module 4 44 The goal of the QAP and QCP is to produce products that are consistently hitting the specified target and minimize variability within tolerance ranges. Products produced that are on target within tolerance ranges will have reliable characteristics. Release 10 November

143 Module 4 QC Manager Tools Control Charts A graphical plot of test results for a measured Quality Characteristic. Identify Variability of Process Chance Causes Assignable Causes November 2018 QC Manager Course Release 10, Module 4 45 One fundamental graphic tool for QC Managers is Control Charts. MAC has some Control Charts available for QC Managers and more capability is being added. Control Charts may have a variety of names including Run Charts, X Bar and R, (Averageand Range), and Statistical Control Charts. Control Charts are useful tools for monitoring and ensuring the quality of a product or process. Changes in the process or quality characteristic can be detected and assigned as chance causes or assignable causes. The assignable causes can be corrected quicklywhen they are detected. Control Charts can be used by the QC Manager as an aid in the Quality Control process. Some of their uses include: Early detection of trouble Detecting trends in the quality characteristic data Establishment of process capability Identify variability of production or process Permanent record of quality Assist in achievement of higher pay adjustments Record how changes improve or decrease quality Reduce rework due to poor quality materials Release 10 November

144 Module 4 QC Manager Tools Run Charts Used to record the results of individual Quality Control material samples for a specified period. Statistical Control Charts Used to plot the results for a subgroup of Quality Control samples. November 2018 QC Manager Course Release 10, Module 4 46 Run Charts plot quality characteristic test measurements against time. There are numerous software programs available on the market that will assist in developing Control Charts. Run Charts can be build using the tools available in EXCEL Graphs. There are more comprehensive software packages designed to interface with Excel. MAC has some Run Charts available and data needed to build run charts may be available in MAC. Many types of statistical control charts are available, one of the basic or simplest type, plots means of sample measurements against time or range of sample measurements against time. These charts are often referred to as X bar and R charts. Both Run Charts and Statistical Control Charts will easily detect wide swings in data that may be due to an assignable cause. Data trends are also useful to watch. Data trends may point out that the quality characteristic is headed out of tolerance in the future. Good Quality Control Managers can use the charts to help adjust the process. Care should be taken not to over adjust and careful monitoring is needed after adjustments are made to determine if the adjustment had the desired effect. Release 10 November

145 Module 4 QC Manager Tools Quality Limits These are the limits developed and validated for each Quality Characteristic. Typically these include: Specification Limits Engineering Limits Control Limits November 2018 QC Manager Course Release 10, Module 4 47 Quality Limits for acceptance are typically established based upon Control Limits defined during specification development. Specification Limits Are limits that are applied to test results when evaluating the quality of a LOT using the specified quality measures. They can be comprised of an Upper Specification Limit (USL) or a Lower Specification Limit (LSL), or both. It is important to recognize that since these are statistical limits, individual sample test results may fall outside of the limits when limits are established based on averages of multiple samples. Organic Content limits haveanaverage USL plus a USL for individual samples. Concrete generally has a LSL for compressive strength that includes average compressive strength for two cylinders but nouslorlslfor individual cylinders. Engineering Limits Are sometimes used in conjunction with Specification Limits and sometimes not. Engineering Limits may fall beyond the USL and LSL and may be used to evaluate materials outside the Specification Limits. Control Limits Control Limits are set from the actual standard deviations of the measured quality characteristic. The Upper Control Limit (UCL) is established at 3 standard deviationsabove the mean and Lower Control Limit (LCL) at 3 standard deviations below the mean. Having Control Limits inside of the Specification Limits assures near full acceptance of the material based on that quality characteristic. Release 10 November

146 Module 4 QC Manager Tools Highway Materials typically follow a Normal Distribution Mean/Average? IS IT THIS MUCH??? OR THIS MUCH???? OR MAYBE THIS MUCH? November 2018 QC Manager Course Release 10, Module 4 48 The Blue curve and the Green curve have the same Mean. The difference is variability. Both are Normal Distribution Curves. Which curve would deliver more consistent material quality? Which curve would have a wider range of measures of the quality characteristic? Release 10 November

147 Module 4 QC Manager Tools Variance: Standard Deviation (s) = Mean s = Mean + s = = = s +1s x = ( x -1s = 93.8) ( x+1s = 97.0) 99 November 2018 QC Manager Course Release 10, Module 4 49 Refer back to slide 13 for test data. Using the slide table, the Standard Deviation (s) for our 14 tests was determined by finding the square root of the variance. Most scientific calculators are capable of calculating standard deviation. The Normal Distribution curve has lines at the mean and +/ 1s sample standard deviation from the mean. Release 10 November

148 Module 4 QC Manager Tools Statistical Control Charts Picture a normal distribution placed on its side Target ( mean) is the average value desired Upper and Lower Control Limits are set at 3 standard deviations from the target (mean) Individual measurements are plotted against time (test no.) axis November 2018 QC Manager Course Release 10, Module 4 50 The basic of the Statistical Chart setup begins with rotating the normal distribution or Bell Curve on it s side.. There is software available on the market for producing control charts, and also educational material available in libraries and on the internet. The FHWA is also has available on line course work and training information for Materials Control and Acceptance using control charts. Properly constructed control charts can provide a QC Manager with valuable information concerning the process. We ll see some examples later. The key element of these charts is the proper designation of the Control Chart Limits, which may not be the same as those used for Acceptance. They are defined as: Action Limits; statistically derived boundaries applied to a Control Chart in controlling material production or placement. These are expressed as Upper Control Limit (UCL) and the Lower Control Limit (LCL). When values of the material characteristics fall within these limits, the process is under control. When values fall outside the limits, there is an indication that some Assignable Cause is present causing the process to be out of control. The Control Limits, UCL and LCL,arenot the same a specification limits. The Specification Limits are defined by the particular material specifications. This chart relies on the fact that we may assume that the distribution of measurements surrounding the Mean value occurs within a ±3 Standard Deviations of the Mean. Therefore, think of it as a bell shaped curve turned on its side, as shown above. Release 10 November

149 Module 4 QC Manager Tools MAC Test Data, AIR Void Report (truncated) Company MAC Sample # Contract # Project Number FDOT Sample Number Mix Design Mix Texture Blank Construction Company Proj. District Mng. District Date Sampled Result Pass / Fail Sample Level A E8P D005X SP A FINE /1/ P PCX A E8P D013X SP A FINE /2/ P PCX A E8P D009Q SP A FINE /2/ P Q A E8P D014X SP A FINE /2/ P PCX A E8P D010Q SP A FINE /3/ F Q A E8P D010V SP A FINE /3/ P V A E8P D006Q SP A FINE /6/ P Q A E8P D007Q SP A FINE /7/ P Q A E8P D002I SP A FINE /8/ P IV A E8P D008Q SP A FINE /8/ P Q A E8P D002S SP A FINE /8/ P PCS A E8P D011Q SP A FINE /9/ P Q A E8P D015X SP A FINE /9/ P PCX A E8P D011V SP A FINE /9/ P V A E8P D003I SP A FINE /10/ P IV A E8P D003S SP A FINE /10/ P PCS A E8P D012Q SP A FINE /10/ P Q A E8P D009V SP A FINE /13/ P V A E8P D009Q SP A FINE /13/ P Q A E8P D006X SP A FINE /13/ P PCX A E8P D007X SP A FINE /14/ P PCX A E8P D008X SP A FINE /15/ P PCX A E8P D010Q SP A FINE /15/ P Q A E8P D016X SP A FINE /16/ P PCX November 2018 QC Manager Course Release 10, Module 4 51 This is a report from MAC we will use to build control charts and analyze the data. It contains more than 30 data entries so it should give a good statistical basis to use. The report is truncated in order to fit on one slide. There is more data available in MAC than is shown on the slide. This report is for the quality characteristic of air voids for structural asphalt. It is possible to refine the test data to look at individual mix designs, separate QC from VT, IV, or Process Control and so forth. The complete data set was used to build the Run Chart in the following slide. Release 10 November

150 Module 4 QC Manager Tools 7 Chart of Air Voids Target AV = Individual Value UCL=4.893 _ 4 X=3.62 LCL= Observation Master Production Range ; Upper 6.0 Master Production Range ; Lower 2.0 November 2018 QC Manager Course Release 10, Module 4 52 Here is a run chart of the air voids we pulled from the MAC report. Note the average air void is 3.62% which indicates the process is not targeted to deliver air voids as the specified value of 4%. The 3.62% air voids may be what that asphalt design is intended to deliver, or what the contractor established as a target for production. The Run Chart also shows the USL and LSL based on the Standard Specs of +/ 2% from the target of 4% as the Master Production Range. This chart also shows the Control Chart UCL and LCL based on three standard deviations from the actual mean at 3.62%. Notice how the actual control limits are shifted to the lower side of the specification limits. Notice the chart is built from points of the air void test results vs. individual observations left to right. Release 10 November

151 Module 4 QC Manager Tools Variability of Air Voids Historical data suggests checking control if: one or more points fall outside limits 9 consecutive points all fall above or below average 6 consecutive points increasing or decreasing 14 consecutive points alternating from one side to the other November 2018 QC Manager Course Release 10, Module 4 53 By examining Control Charts, QC Managers may be able to detect potential problems, such as out of control or changes in control. Some simple rules for checking control charts to detect trends as indications of process changes, out of control points, or abnormal data are shown in the slide. There are several other tests available in quality control publications. Release 10 November

152 Module 4 QC Manager Tools 7 Chart of Air Voids Target AV = 4.0 Individual Value or more points increasing 6 UCL=4.893 _ 4 X=3.62 Any point LCL=2.347 outside 2 limits Observation Master Production Range ; Upper 6.0 Master Production Range ; Lower 2.0 November 2018 QC Manager Course Release 10, Module 4 54 Looking at the air void chart again we can test for out of control or shifting control. One out of control observation is easily detected. The shifting control area is a little more subtle. But if you were actually plotting this control chart beginning with the first observation and plotting each observation at the time it was made, it would have been easy to notice six consecutive points increasing. Most of the observations indicate a chance cause of variation is occurring. Which observation most likely have an assignable cause? Again, Quality Control should use caution to not attempt to overcontrol or make constant adjustments in a process that is in good control and producing the targeted outcomes. Release 10 November

153 Module 4 QC Manager Tools November 2018 QC Manager Course Release 10, Module 4 55 Also from MAC. Here is data on compressive strength for drilled shaft concrete. There are 18 samples. Next slide shows a run chart. MAC data can be refined to chart individual mixes, separate QC from VT, or other quality characteristics of value to the QC Manager. Release 10 November

154 Module 4 QC Manager Tools 8000 Drilled Shaft Concrete Compressive Strength Minimum Strength Required : 4000 psi UCL= Individual Value _ X=6167 LCL= Observation November 2018 QC Manager Course Release 10, Module 4 56 Notice on this slide we only have a LSL. It s set at 4000 psi. There is no USL generally on concrete compressive strengths. Notice we still have UCL and LCL set by the graphing software. Here the mean is well above the LSL as it should be. Release 10 November

155 Module 4 QC Manager Tools Variability Concrete Compressive Strength Historical data suggests checking control if: one or more points fall outside limits 9 consecutive points all fall above or below average 6 consecutive points increasing or decreasing 14 consecutive points alternating from one side to the other November 2018 QC Manager Course Release 10, Module 4 57 Again here are tools for reviewing control charts. By examining Control Charts QC Managers may be able to detect potential problems, such as out of control or changes in control. Some simple rules for checking control charts to detect trends as indications of process changes, out of control points, or abnormal data are shown in the slide. There are several other tests available in quality control publications. Release 10 November

156 Module 4 QC Manager Tools 8000 Drilled Shaft Concrete Compressive Strength Minimum Strength Required : 4000 psi UCL= Individual Value All Good _ X=6167 LCL= Observation November 2018 QC Manager Course Release 10, Module 4 58 Nothing is indicated by the rules to be of concern. What type of variation is most likely represented by the graph? (Chance Cause) Release 10 November

157 Module 4 QC Manager Tools Coming Soon to MAC November 2018 QC Manager Course Release 10, Module 4 59 MAC is being revised to include some control charting functionality. Here is a n example of a run chart of concrete compressive strength and standard deviation among compressive strength test samples. This 5,500 psi concrete Range is (11,100 psi 5,000 psi) or 6,100 psi. It is easy to see fluctuations of short periods of time. The Quality Control Manager may be able to match the fluctuations to changes in aggregate, changes in cement, temperature, or some other cause. Watch MAC for further development of the charting capability. Release 10 November

158 Module 4 QC Manager Tools Percent Within Limits (PWL) A measure of the percentage of tests results that are with the Specification Limits for a Quality Characteristic, which relates to Pay Adjustments. Applicable to FDOT Asphalt construction Pay Factors are assigned to each PWL value See Section 334 for details November 2018 QC Manager Course Release 10, Module 4 60 Detailed instructions for PWL calculations for Asphalt on FDOT projects, is outlined in Section , of the Standard Specifications. Pay adjustment calculation based upon PWLs only applies to Hot Mix Asphalt, not Concrete or Earthwork. QualityAssurancetypeSpecificationshavepayadjustmentproceduresthat are linked to the computed quality level for each Quality Characteristics. To compute the quality level, the Quality Level Analysis (QLA) Standard Deviation method, is used. This mathematical procedure estimates the percentage of a LOT that is within the Specification Limits or PWL. Typically, the PWL for each Quality Characteristics is calculated using the Mean and Standard Deviation of the Acceptance sample test results for a given LOT of material. A specific Pay Factor is assigned for each PWL and this is subsequently applied to the LOT quantity and corresponding contract unit price to compute a pay adjustment. Release 10 November

159 Module 4 QC Manager Tools Asphalt Air Void Specification target values grouped about the mean. Lower Limit 2.0% Data Mean 4.0% Upper Limit 6.0% 2.5% of Data 2.5% of Data Normal Distribution for Establishing Limits November 2018 QC Manager Course Release 10, Module 4 61 Normal distributions with a 95% acceptance limit will have Specification Limits set at points where 95% of the data is expected to fall within the specification Limits. 2.5% of the data is expected to fall below the lower limit and 2.5% of the data is expected to fall above the upper limit. Many FDOT materials specifications are founded on a 95% acceptance limit. This helps limit the potential alpha and beta risk to the contractor and owner. Establishing Limits for QA Specs expect to achieve the desired result if measured data falls within the established limits of our target value 95% of the time. Release 10 November

160 Module 4 QC Manager Tools Percent Within Limits Asphalt Specification (1) November 2018 QC Manager Course Release 10, Module 4 62 The next 3 slides are actual excerpts from the Standard Specs asphalt specifications. They are intended to show the actual application of PWL for pay adjustments on asphalt. No need to dwell on detail. They are available in the Standard Specs for QC Managers that need to apply them. You can point out how the means and standard deviations are derived from the same formulas we covered earlier in this module. Release 10 November

161 Module 4 QC Manager Tools PWL (2) November 2018 QC Manager Course Release 10, Module 4 63 This is a continuation of the PWL for asphalt. The PWL uses an upper quality index and lower quality index to help adjust for the number of samples included in the calculation. More tolerance in allowed as the number of samples increase. Release 10 November

162 Module 4 QC Manager Tools PWL (3) (truncated) November 2018 QC Manager Course Release 10, Module 4 64 Note the PWL number increases as number of samples increases. This is an indication that data becomes more reliable with increasing numbers of samples. The actual table is truncated in order to fit on this slide. The Standard Specs contains the entire table. Release 10 November

163 Module 4 QC Manager Tools EXERCISES IN APPLICATION TO HIGHWAY CONSTRUCTION November 2018 QC Manager Course Release 10, Module 4 65 Here are some practice exercises in determining sampling by use of a Random Number Generator. Release 10 November

164 Module 4 QC Manager Tools Asphalt Example LOT 5 Size 4,000 Tons Sub LOTs per LOT 4 sub LOTs per LOT Sample Location Truck at the Plant Samples per sub LOT 3 split samples LOT begins at 12,000 Tons November 2018 QC Manager Course Release 10, Module 4 66 Asphalt Example: Suppose a contractor s technician is to sample a bituminous mixture to obtain material for determination of AC content. The LOT size is 4,000 Tons and the sample consists of 3 split samples per 1,000 Ton sublot. If we assume that the LOT begins at the 12,000 th Ton, then we can use a random number table to select the Tons from which the samples will betaken and; therefore, we can determine from which truck to take our sample. Release 10 November

165 Module 4 QC Manager Tools From what tonnage are samples taken? First Random numbers are generated. sublot 1 sublot 2 sublot 3 sublot Numbers in decimal form are used as percentage of the total value of the LOT measure November 2018 QC Manager Course Release 10, Module 4 67 Here random numbers are generated by an Excel spreadsheet. The spreadsheet then takes these numbers and performs the computations that determines which ton is sampled for each sublot. Release 10 November

166 Module 4 QC Manager Tools Second Calculate sublots beginning & ending tonnage. 4,000 tons 1,000 tons 1,000 tons 1,000 tons 1,000 tons LOT 5 sublot 1 sublot 2 sublot 3 sublot 4 12,000 tons 13,000 tons 14,000 tons 15,000 tons 16,000 tons November 2018 QC Manager Course Release 10, Module 4 68 Remember, the beginning tonnage of the LOT (sublot 1) was 12,000 tons and each sublot size was 1,000 tons. Therefore, the end of sublot 1 (beginning of sublot 2) would be 13,000 tons, the end of sublot 2 (beginning of sublot 3) would be 14,000 tons, the end of sublot 3 (beginning of sublot 4) would be 15,000 tons, and the end of sublot 4 (end of the LOT) would be 16,000 tons. Release 10 November

167 Module 4 QC Manager Tools Third Calculate the tons sampled for the LOT. Sub LOT 1 Sub LOT 2 Sub LOT 3 Sub LOT 4 12,740 th ton 13,600 th ton 14,010 th ton 15,270 th ton November 2018 QC Manager Course Release 10, Module 4 69 Which tons are to be sampled for each sublot? sublot tons x = tons Sample the th ton in the sublot Therefore, sample the ton overall sublot tons x = tons Sample the th ton in the sublot Therefore, sample the ton overall sublot tons x = tons Sample the th ton in the sublot Therefore, sample the ton overall sublot tons x = tons Sample the th ton in the sublot Therefore, sample the ton overall sublot tons x 0.74 = 740 tons Sample the 740 th ton in the sublot Therefore, sample the 12,740 th ton overall sublot tons x 0.60 = 600 tons Sample the 600 th ton in the sublot Therefore, sample the 13,600 th ton overall sublot tons x 0.01 = 10 tons Sample the 10 th ton in the sublot Therefore, sample the 14,010 th ton overall sublot tons x 0.27 = 270 tons Sample the 270 th ton in the sublot Therefore, sample the 15,270 th ton overall Release 10 November

168 Module 4 QC Manager Tools Fourth Determine which truck contains the tons sampled. Contractor takes a sample that is split into QC, VT & RT samples for testing November 2018 QC Manager Course Release 10, Module 4 70 Based upon the truckload quantities, the trucks to be sampled would be determined. Truck #?? contains the 740 th ton for sublot 1 Truck #?? contains the 600 th ton for sublot 2 Truck #?? contains the 10 th ton for sublot 3 Truck #?? contains the 270 th ton for sublot 4 Release 10 November

169 Module 4 QC Manager Tools Which sub LOT is used for Verification? 4,000 tons sublot 1 sublot 2 sublot 3 sublot 4???? Draw Random Number November 2018 QC Manager Course Release 10, Module 4 71 Which sublot is used for Verification? Answer: Whichever the Random Number Generator selects. Contractor takes random samples from each sublot that is each split into QC, VT, & RT samples. Then, the Department randomly selects one of the sublots for Verification (VT) testing Verification uses the random number generator also for selecting test/sample locations, etc. Release 10 November

170 Module 4 QC Manager Tools Concrete Example LOT Size 50 CY LOTS for Acceptance 4 LOTS Sample Location Truck at the Site Samples per Lot 3 Cylinders Lot 13 Begins at CY 600 November 2018 QC Manager Course Release 10, Module 4 72 Review the given data on the slide for this exercise with Portland Cement Concrete. Release 10 November

171 Module 4 QC Manager Tools From what truck are samples taken? First Random numbers are generated. Lot 13 Lot 14 Lot 15 Lot Numbers in decimal form are used as percentage of the total value of the LOT measure November 2018 QC Manager Course Release 10, Module 4 73 These random numbers are generated by an Excel spreadsheet, random number table, or any other approved random number generator. As we cover this in class, write them in. Release 10 November

172 Module 4 QC Manager Tools Second Calculate LOTs beginning & ending Cubic Yard. 200 CY 50 CY 50 CY 50 CY 50 CY Lot 13 4 CONCECUTIVE LOTS Lot 14 Lot 15 Lot CY 650 CY 700 CY 750 CY 800 CY November 2018 QC Manager Course Release 10, Module 4 74 Determine the beginning and end of the sublots in tonnage. Remember, the beginning cubic yards of LOT 13 was 600 cy and each LOT size was 50 cy. Therefore, the end of LOT 13 (beginning of LOT 14) would be 650 cy, the end of LOT 14 (beginning of LOT 15) would be 700 cy, the end of LOT 15 (beginning of LOT 16) would be 750 cy, and the end of LOT 16 would be 800 cy. Remember, the beginning cubic yards of LOT 13 was 600 cy and each LOT size was 50 cy. Therefore, the end of LOT 13 (beginning of LOT 14) would be cy, the end oflot14 (beginning of LOT 15) would be cy, the end of LOT 15 (beginning of LOT 16) would be cy, and the end of LOT 16 would be cy. Release 10 November

173 Module 4 QC Manager Tools Third Calculate the CY to be sampled for the LOT. Lot st CY Lot th CY Lot th CY Lot st CY November 2018 QC Manager Course Release 10, Module 4 75 Determine which CY are to be sampled for each LOT. LOT cy x = cy Sample the cy in the LOT Therefore, sample the CY overall LOT cy x = cy Sample the cy in the LOT Therefore, sample the CY overall LOT cy x = cy Sample the cy in the LOT Therefore, sample the CY overall LOT cy x = cy Sample the cy in the LOT Therefore, sample the CY overall LOT cy x 0.42 = 21 cy Sample the 21 st cy in the LOT, Therefore, sample the 621 st CY overall LOT cy x 0.14 = 7 cy Sample the 7 th cy in the LOT, Therefore, sample the 657 th CY overall LOT cy x 0.59 = 29.5 cy Sample the 30 th cy in the LOT, Therefore, sample the 730 th CY overall LOT cy x 0.81 = 40.5 cy Sample the 41 st cy in the LOT, Therefore, sample the 791 st CY overall Release 10 November

174 Module 4 QC Manager Tools Fourth Determine which truck contains the CY to be sampled for QC testing. Contractor makes 3 QC cylinders and 1 hold cylinder. November 2018 QC Manager Course Release 10, Module 4 76 Based upon the truckload quantities, the trucks to be sampled would be determined. Truck #?? contains the 621 st CY for LOT 13 Truck #?? contains the 657 th CY for LOT 14 Truck #?? contains the 730 th CY for LOT 15 Truck #?? contains the 791 st CY for LOT 16 If Verification is going to test the same load then, QC technician casts one additional cylinder from the same sample, the QC hold cylinder Release 10 November

175 Module 4 QC Manager Tools Department uses random number generator to determine which LOT to verify 200 CY LOT 13 LOT 14 LOT 15 LOT 16 Lot 14 selected for Verification???? November 2018 QC Manager Course Release 10, Module 4 77 Verification uses the random number generator also for selecting test/sample locations, etc. Verification randomly selects one of the 4 LOTs where QC obtained a sample and will independently perform plastic properties test and cast a set of cylinders from a separate sample from the same load of concrete as the Contractor s QC sample. Verification casts one additional hold cylinder from each sample. Release 10 November

176 Module 4 QC Manager Tools Maximum Density (Proctor) for Stabilized Subgrade LOT Length 500 feet LOT Width 20 feet Number of LOTs in question 8 Sample Location Roadway Samples per 2 LOTs 3 split samples LOT begins at Sta November 2018 QC Manager Course Release 10, Module 4 78 Let us review the given data on the slide for this exercise with Earthwork. Suppose a contractor s technician is to collect material to take to the lab for maximum density determination (Proctor). The maximum the LOT size can be is 500 ft, which is what we have here. The frequency of sampling is one per two consecutive LOTs (QC) and one per 8 consecutive LOTs (VT). If we assume that the LOTs in question begin at station and 13 RT of C/L Construction. Then the QC technician can use a random number table to select the stations and offsets from which the samples will be taken. Release 10 November

177 Module 4 QC Manager Tools At what station & offset are samples taken? First Random numbers are obtained. Station Offset Offset Offset LOTs 1 & 2 LOTs 3 & 4 LOTs 5 & 6 LOTs 7 & Numbers in decimal form are used as percentage of the total value of the LOT measure. November 2018 QC Manager Course Release 10, Module 4 79 The random numbers are generated by an Excel spreadsheet, random number table, or any other approved random number generator. When sampling material for a Proctor, you are to obtain 3 samples, randomly, at a station, and combine them for a composite sample. Write in the Station and first Offset Random Numbers. Release 10 November

178 Module 4 QC Manager Tools Second Determine beginning & ending stations. 1,000 feet 1,000 feet 1,000 feet 1,000 feet LOT 1 LOT 2 LOT 3 LOT 4 LOT 5 LOT 6 LOT 7 LOT November 2018 QC Manager Course Release 10, Module 4 80 Next you must determine where LOTs begin and end. Determine the beginning and end of the LOTs. Remember, the beginning station of the LOT 1 was and each LOT size was 500 feet. LOT Beginning Station Ending Station Release 10 November

179 Module 4 QC Manager Tools Third Calculate the sample stations and offsets. LOTs 1 & 2 3 & 4 5 & 6 7 & 8 Station Offset (Rt. C/L Const.) November 2018 QC Manager Course Release 10, Module ft. X 1,000 ft. (2 LOTs) Determine station and offset for each 2 consecutive LOTs. LOTs 1 & 2 Y 1000 feet x 0.18 = 180 feet (124+78) = (Station) X 20 feet x 0.89 = 17.8 feet = 30.8 Rt. C/L Const. LOTs 3 & 4 Y 1000 feet x 0.53 = 530 feet (134+78) = (Station) X 20 feet x 0.46 = 9.2 feet = 22.2 Rt. C/L Const. LOTs 5& 6 Y 1000 feet x 0.80 = 800 feet (144+78) = (Station) X 20 feet x 0.74 = 14.8 feet = 27.8 Rt. C/L Const. LOTs 7 & 8 Y 1000 feet x 0.48 = 480 feet (154+78) = (Station) X 20 feet x 0.15 = 3.0 feet = 16.0 Rt. C/L Const. Release 10 November

180 Module 4 QC Manager Tools Fourth Obtain the sample. Obtain enough material to split into QC, VT & RT samples. November 2018 QC Manager Course Release 10, Module 4 82 QC obtains enough material to split into QC, VT, & RT samples (3 way split). Then, the Verification technician randomly selects one of the 4 split samples for Verification (VT) testing. It is important to retain all samples until the Verification sample is tested and verification of QC samples is complete. Do not discard the RT samples until the QC Samples are Verified by VT testing. Release 10 November

181 Module 4 QC Manager Tools Summary Data and Analysis: Can be used to reduce risks: seller/contractor ( α the risk rejecting good material) owner s risk ( β the risk of accepting bad material). There is variability in materials and processes we can control, but not eliminate Lot definitions vary by materials Random sampling and testing is required for QC and VT Control Charts can help to make informed decisions on material quality November 2018 QC Manager Course Release 10, Module 4 83 Although not perfect in every sense, the sampling and testing requirements of the Standard Specs follow the thought process and theory presented in this lesson. The is still some risk of rejecting material passing the specifications, α risk, or accepting failing material, β risk. The risk on both sides is reduced and less conflicts will occur if QC Managers take an active part in controlling quality of the project materials. Release 10 November

182 Module 4 QC Manager Tools Any Questions? November 2018 QC Manager Course Release 10, Module 4 84 Release 10 November

183 Module 5 Quality Control Plans November 2018 QC Manager Course Release 10, Module 5 1 Release 10 November

184 Module 5 Quality Control Plans Section Topics: The purpose and importance of the Contractor Quality Control (QC) Plan Contractor QC Plan submittal QC Plan approval process QC Operation suspension process November 2018 QC Manager Course Release 10, Module 5 2 Release 10 November

185 Module 5 Quality Control Plans What is the Contractor s Quality Control Plan? It is a framework for the Contractor s process for delivering quality construction in accordance with the plans and specifications, which define the expected results or outcome. November 2018 QC Manager Course Release 10, Module 5 3 This is the Contractor s game plan for achieving the quality required for the project. This is the who, what, when, where, and how of the QC inspection, sampling, testing, and reporting for the project. Release 10 November

186 Module 5 Quality Control Plans Standard Specification, Quality Control Program states: Submit a QC Plan prepared in accordance with the requirements of this Section to the Engineer QC Plan must be approved by Engineer prior to use of materials November 2018 QC Manager Course Release 10, Module 5 4 Release 10 November

187 Module 5 Quality Control Plans What materials are covered under the QCP? Hot Mix Asphalt Portland Cement Concrete (Structural) Cementitious Materials Earthwork Timber Prestressed and/or Precast Concrete Products Fiber Reinforced Polymer Products Drainage Products Steel and Miscellaneous Metals Galvanized Metal Products November 2018 QC Manager Course Release 10, Module 5 5 Release 10 November

188 Module 5 Quality Control Plans What is the Contractor s responsibility? Submit the QC Plan to the Department s database Provide a QC Manager Provide Qualified Technicians Provide Approved Material Producers Revise Plan 5 days prior to implementation of changes Stay in contact with FDOT November 2018 QC Manager Course Release 10, Module 5 6 The Department is responsible for providing verification (VT) technicians, approving QC plans, monitoring QC plans, and performing resolution. Release 10 November

189 Module 5 Quality Control Plans QC PROGRAM Contractor s QC Plan Producer s QC Program November 2018 QC Manager Course Release 10, Module 5 7 Release 10 November

190 Module 5 Quality Control Plans Contractor s QC Plan Contractor submitted via MAC Project Administrator Accepted Acceptance is contract specific November 2018 QC Manager Course Release 10, Module 5 8 Release 10 November

191 Module 5 Quality Control Plans FDOT Contract QC Program Material? No No QC Manager or Contractor QC Plan (CQCP) needed Yes QC data entry creates initial entry for material type Material other than asphalt, earthwork, or structural concrete? Yes QC data entry selects Submit when entry is complete and ready for FDOT review Status of original submittal is Submitted PA reviews but does not need to accept or reject. Status remains as Submitted. Additional production facilities needed? No CQCP material type complete Yes No QC data entry creates an addendum QC data entry submits the addendum PA reviews but does not need to accept or reject. Status remains as Submitted. Structural Concrete? Yes No Go to page 2 Asphalt_Earth work Go to Page 3 Structural Concrete November 2018 QC Manager Course Release 10, Module 5 9 Release 10 November

192 Module 5 Quality Control Plans Asphalt_Earth work PA reviews original submittal Okay? Yes PA accepts original submittal Status of original submittal is Accepted No PA rejects original submittal Status of original submittal is Rejected, Returned for Corrections PA makes comment on what needs to be revised on the original submittal QC data entry makes revisions QC data entry resubmits original submittal Status of original submittal is Corrections Made, Ready for Review Okay? No CQCP material type complete Yes QC data entry creates an addendum QC data entry submits the addendum Status of addendum is Submitted Okay? Yes PA accepts addendum Status of addendum is Accepted No PA rejects addendum Status of addendum is Rejected, Returned for Corrections PA makes comment on what needs to be revised on the addendum QC data entry makes revisions QC data entry resubmits addendum Status of addendum is Corrections Made, Ready for Review November 2018 QC Manager Course Release 10, Module 5 10 Release 10 November

193 Module 5 Quality Control Plans DMRO Concrete personnel review material availability All mix designs designated as PMU Reviewed? Yes PA reviews original submittal Okay? Yes PA accepts original submittal Status of original submittal is Accepted No No PA rejects original submittal Status of original submittal is Rejected, Returned for Corrections PA makes comment on what needs to be revised on the original submittal QC data entry makes revisions QC data entry resubmits original submittal Status of original submittal is Corrections Made, Ready for Review Yes Okay? No CQCP material type complete QC data entry creates an addendum QC data entry submits the addendum Status of addendum is Submitted Okay? Yes PA accepts addendum Status of addendum is Accepted No PA rejects addendum Status of addendum is Rejected, Returned for Corrections PA makes comment on what needs to be revised on the addendum QC data entry makes revisions QC data entry resubmits addendum Status of addendum is Corrections Made, Ready for Review November 2018 QC Manager Course Release 10, Module 5 11 Release 10 November

194 Module 5 Quality Control Plans Producer QC Program Producer submitted to State Materials Office for acceptance of: cementitious materials, steel and miscellaneous metals, galvanized metal products, aggregates, and fiber reinforced polymer products Producer submitted to District Materials Office for acceptance of: hot mix asphalt, Portland cement concrete (structural), earthwork, timber, prestressed and/or precast concrete products and drainage products Acceptance is Statewide November 2018 QC Manager Course Release 10, Module 5 12 July 2019 Specifications: Compliance with the Materials Manual. Producers of Flexible Pipe shall meet the requirements of Section 6.1, Volume II of the Department s Materials Manual Producers of Precast Concrete Pipe shall meet the requirements of Section 6.2, Volume II of the Department s Materials Manual Producers of Precast Concrete Drainage Structures shall meet the requirements of Section 6.3, Volume II of the Department s Materials Manual Producers of Precast/Prestressed Concrete Products shall meet the requirements of Sections 8.1 and 8.3 of the Department s Materials Manual Producers of Precast Prestressed Concrete Products using Self Consolidating Concrete shall meet the requirements of Section 8.4, Volume II of the Department s Materials Manual Producers of Incidental Precast/Prestressed Concrete Products shall meet the requirements of Section 8.2, Volume II of the Department s Materials Manual Producers of Portland Cement Concrete shall meet the requirements of Section 9.2, Volume II of the Department s Materials Manual Producers of Structural Steel and Miscellaneous Metal Components shall meet the requirements of Sections 11.1, 11.2, 11.3, 11.4, 11.5 and 11.6 of the Department s Materials Manual Producers of Fiber Reinforced Polymer Composites shall meet the requirements of Section 12 1, Volume II of the Department s Materials Manual Link to each section of the Materials Manual are available in the Specifications. Release 10 November

195 Module 5 Quality Control Plans Producer QC Program (continued) Producer must have an accepted QC Program in order to supply material/products to a project. Producer s with suspended QC Programs may result in Contractor not being able to place material. November 2018 QC Manager Course Release 10, Module 5 13 Release 10 November

196 Module 5 Quality Control Plans Producer QC Program (continued) Defined in the Section Includes Producer s QC Plan & other requirements Producers compile Producer s QC Plans based on Section 105 November 2018 QC Manager Course Release 10, Module 5 14 Release 10 November

197 Module 5 Quality Control Plans Governing Documents for Contractor s QC Plan: Specification Section 105 CPAM Section 3.3 Materials Manual Materials Specifications Contract November 2018 QC Manager Course Release 10, Module 5 15 Release 10 November

198 Module 5 Quality Control Plans QC Plan Acceptance and Review MAC provides some feedback on the proposed data acceptability at the time of submittal. The Project Administrator will use the Quality Control Plan Review Checklist from CPAM 3.3 as a guide for acceptance. The Department will accept or reject QC Plans within 10 calendar days. November 2018 QC Manager Course Release 10, Module 5 16 Release 10 November

199 Module 5 Quality Control Plans CPAM 3.3 QC PLAN CHECKLIST November 2018 QC Manager Course Release 10, Module 5 17 Release 10 November

200 Module 5 Quality Control Plans Personnel Qualifications November 2018 QC Manager Course Release 10, Module 5 18 Release 10 November

201 Module 5 Quality Control Plans Production Facilities November 2018 QC Manager Course Release 10, Module 5 19 Release 10 November

202 Module 5 Quality Control Plans Structural Concrete Mix Designs November 2018 QC Manager Course Release 10, Module 5 20 Release 10 November

203 Module 5 Quality Control Plans Testing Laboratories November 2018 QC Manager Course Release 10, Module 5 21 Release 10 November

204 Module 5 Quality Control Plans Notification of Placing Order November 2018 QC Manager Course Release 10, Module 5 22 Release 10 November

205 Module 5 Quality Control Plans General: Provide qualified personnel Personnel must maintain qualifications Can NOT use until qualifications are verified QC Manager Full authority Speak and understand English On-site or available upon 4 hours notice Administers, implements, monitors, and adjusts QC Processes Different individual than the Superintendent Qualified thru CTQP November 2018 QC Manager Course Release 10, Module 5 23 Release 10 November

206 Module 5 Quality Control Plans QC Plans Frequently Asked Questions And Answers! November 2018 QC Manager Course Release 10, Module 5 24 Release 10 November

207 Module 5 Quality Control Plans Question: Can a Contractor have an approved QC Plan without having a contract with the Department? Answer: No, the QC Plan is a Contract Specific Document. November 2018 QC Manager Course Release 10, Module 5 25 Release 10 November

208 Module 5 Quality Control Plans Question: What if a Contractor submits a supplier s name who is not on the approved list? Answer: The Contractor s operations can be suspended. November 2018 QC Manager Course Release 10, Module 5 26 Release 10 November

209 Module 5 Quality Control Plans Question: Does the Contractor have to submit a QC Plan for each contract? Answer: YES and NO! The contract has QC Materials then a QC Plan is required. A QC Plan is not required if no QC Materials will be incorporated into the project. November 2018 QC Manager Course Release 10, Module 5 27 Release 10 November

210 Module 5 Quality Control Plans Question: Who does a Producer submit a QC Program to? Answer: District Materials Office or State Materials Office November 2018 QC Manager Course Release 10, Module 5 28 Producer submits to State Materials Office for acceptance of: cementitious materials, steel and miscellaneous metals, galvanized metal products, aggregates, and fiber reinforced polymer products Producer submits to District Materials Office for acceptance of: hot mix asphalt, Portland cement concrete (structural), earthwork, timber, prestressed and/or precast concrete products and drainage products Release 10 November

211 Module 5 Quality Control Plans Question: Who does the Contractor submit the QC Plan to? Answer: Project Administrator via MAC November 2018 QC Manager Course Release 10, Module 5 29 Release 10 November

212 Module 5 Quality Control Plans Question: What role does the District Materials Office play in approving the Contractor s QC Plan? Answer: Review material availability on mix designs. November 2018 QC Manager Course Release 10, Module 5 30 Release 10 November

213 Module 5 Quality Control Plans Question: Where can I find my responsibilities as a QC Manager? Answer: Specification Section 105 November 2018 QC Manager Course Release 10, Module 5 31 Release 10 November

214 Module 5 Quality Control Plans Question: What are Raw Materials vs. Final Product in Section 105? Answer: Examples: Raw Materials Final Product Mine N/A Aggregate Plant Aggregate Concrete at Plant/Truck Contractor Concrete in field In place/slab/structure November 2018 QC Manager Course Release 10, Module 5 32 Release 10 November

215 Module 5 Quality Control Plans Who must be Qualified? All technicians performing sampling and testing in the Acceptance Process Who does the Qualification? CTQP through Providers When can a company work for a Contractor and FDOT? Follow the Conflict of Interest Specification Section 8 5 November 2018 QC Manager Course Release 10, Module Qualifications of Contractor s Personnel. Provide competent, careful, and reliable superintendents, foremen, and workmen. Provide workmen with sufficient skill and experience to properly perform the work assigned to them. Provide workmen engaged on special work, or skilled work, such as bituminous courses or mixtures, concrete bases, pavements, or structures, or in any trade, with sufficient experience in such work to perform it properly and satisfactorily and to operate the equipment involved. Provide workmen that shall make due and proper effort to execute the work in the manner prescribed in the Contract Documents, or the Engineer may take action as prescribed below. It is prohibited as a conflict of interest for a Contractor to subcontract with a Consultant to perform Contractor Quality Control when the Consultant is under contract with the Department to perform work on any project described in the Contractor s Contract with the Department. Prior to approving a Consultant for Contractor Quality Control, the Contractor shall submit to the Department a Certificate from the proposed Consultant certifying that no conflict of interest exists. Whenever the Engineer determines that any person employed by the Contractor is incompetent, unfaithful, intemperate, disorderly, or insubordinate, the Engineer will provide written notice and the Contractor shall discharge the person from the work. Do not Release 10 November

216 Module 5 Quality Control Plans employ any discharged person on the project without the written consent of the Engineer. If the Contractor fails to remove such person or persons, the Engineer may withhold all estimates that are or may become due, or suspend the work until the Contractor complies with such orders. Protect, defend, indemnify, and hold the Department, its agents, officials, and employees harmless from all claims, actions, or suite arising from such removal, discharge, or suspension of employees. Release 10 November

217 Module 5 Quality Control Plans Disqualification or Qualification Suspension A Technician s Qualification can be Suspended for Lack of Proficiency in Sampling, Testing, and Reporting. A Technician can be Disqualified for Falsification of Records. CTQM Sections Qualification Revocation Based On Lack of Proficiency Qualification Revocation Based On Falsification of Records November 2018 QC Manager Course Release 10, Module 5 34 Release 10 November

218 Module 5 Quality Control Plans Accreditation & Qualification Which labs have to be qualified and accredited? All Labs involved in the Acceptance Process must be qualified. Resolution labs must be AASHTO accredited. What equipment must be certified? All equipment used in the Acceptance Process will be certified by the FDOT. November 2018 QC Manager Course Release 10, Module 5 35 Laboratory accreditation for those labs doing business with the FDOT is performed by AMRL, CMEC, or other approved programs. Laboratory qualification is performed by the FDOT once those labs are accredited. WHICH LABS HAVE TO BE QUALIFIED? State Materials Office District Materials Offices Area/Project Laboratories Materials Field Laboratories Commercial Laboratories Contractor Laboratories Vendor Laboratories WHAT ABOUT EQUIPMENT? Testing equipment will be certified according to their specific schedule. Release 10 November

219 Module 5 Quality Control Plans Any Questions? November 2018 QC Manager Course Release 10, Module 5 36 Release 10 November

220 This page left blank intentionally.

221 Module 6 - Specifications Specifications November 2018 QC Manager Course Release 10, Module 6 1 Release 10 November

222 Module 6 - Specifications Describe the basic QC and VT testing process for Asphalt, Concrete and Earthwork Describe basic reporting requirements November 2018 QC Manager Course Release 10, Module 6 2 Release 10 November

223 Module 6 - Specifications The QC Manager must be knowledgeable of the Specification Method of Acceptance requirements for: Asphalt Concrete Earthwork November 2018 QC Manager Course Release 10, Module 6 3 This chapter is intended to provide a brief overview of some of the specifications, which provides them a snapshot of how QC and VT sampling and testing interact on various materials. The QC Manager must be knowledgeable of the Specification requirements for sampling and testing for these materials. This is not intended to provide detailed in depth review of specifications, but a snapshot of how and when QC and VT interact during sampling and testing for various materials. Release 10 November

224 Module 6 - Specifications Asphalt CQC Specifications November 2018 QC Manager Course Release 10, Module 6 4 Introduction to pertinent QC Asphalt specifications. Release 10 November

225 Module 6 - Specifications Contractor obtains hot mix asphalt from FDOT approved Asphalt Production Facility ONLY using asphalt mix designs specifically assigned to that production facility. November 2018 QC Manager Course Release 10, Module General. Obtain Superpave Asphalt Concrete from a plant that is currently on the Department s Production Facility Listing. Producers seeking inclusion on the list shall meet the requirements of Section 105. Producers must meet the requirements of Section 320 for plant and equipment and the general construction requirements of Section 330. Release 10 November

226 Module 6 - Specifications Contractor lists asphalt field inspectors, laboratories, and production facilities in the QC Plan In addition to what s listed in 105 Contractor assumes full responsibility for QC Operations and Contract requirements Contractor performs QC activities Contractor is responsible for performing QC inspections Failure to have adequate QC Operations or meet Contract requirements, that portion of the work can be suspended November 2018 QC Manager Course Release 10, Module 6 6 Contractor QC responsibilities include performing QC activities and ensuring producers perform QC activities. Failure to have adequate asphalt QC Operations can lead to the asphalt operations being suspended. Release 10 November

227 Module 6 - Specifications Contractor Performs Quality Control Tests Did QC test results meet requirements? NO 1. Process Control Investigation Initiated 2. Mitigation of Failing Material YES Material is Accepted by Contractor for Placement November 2018 QC Manager Course Release 10, Module 6 7 We saw this flow chart earlier. This is the general flow for QC testing. Release 10 November

228 Module 6 - Specifications QC and VT must compare on multiple components Non comparison results in Resolution being performed on non comparing component(s) only Resolution determines if QC or Resolution results will be used for acceptance and payment Material is acceptable if Composite Pay Factor is greater than or equal to 0.80 and all other specification method of acceptance requirements are met November 2018 QC Manager Course Release 10, Module 6 8 Comparison in asphalt is on multiple components. A non comparison on any component will result in Resolution being performed. Resolution is only performed on the component(s) that did not compare. Resolution will determine if the QC test results or RT test results will be used to calculate the individual and composite pay factors. CPF is used to determine final payment and defines if the material is acceptable. A CPF lower than 0.80 is considered non standard material. Also, any portion of 334 that requires disposition of defective material may result in the material being considered nonstandard. Examples are failing QC or IV tests. Release 10 November

229 Module 6 - Specifications Structural Concrete CQC Specifications November 2018 QC Manager Course Release 10, Module 6 9 Introduction to pertinent QC Concrete specifications. Release 10 November

230 Module 6 - Specifications Contractor obtains structural concrete from FDOT approved Structural Concrete Production Facility ONLY If facility s approval is suspended: (Materials Manual 9.2) Contractor is responsible to obtain another approved facility or Await re approval of facility No changes in contract time or completion dates Contractor bears all delay costs November 2018 QC Manager Course Release 10, Module Description. Obtain concrete from a plant that is currently on the list of Producers with Accepted Quality Control Program and Chapter 9.2 of the Materials Manual Structural Concrete Production Facilities Guidelines, which may be viewed at the following URL: smanual/documents/v1 section92 clean.pdf If the concrete production facility s approval is suspended, the Contractor is solely responsible to obtain the services of another approved concrete production facility or await the re approval of the affected concrete production facility prior to the placement of any further concrete on the project. There will be no changes in the contract time or completion dates. Bear all delay costs and other costs associated with the concrete production facility approval or re approval. Release 10 November

231 Module 6 - Specifications Contractor lists structural concrete field inspectors, laboratories, and production facilities with structural concrete mix designs in the QC Plan Additional personnel may be required for contracts with certain types of structural concrete bridges In addition to what s listed in 105 Contractor assumes full responsibility for QC Operations and Contract requirements Contractor performs QC activities Contractor responsible for performing QC inspections Failure to have adequate QC Operations or Contract requirements, that portion of the work can be suspended November 2018 QC Manager Course Release 10, Module 6 11 Contractor QC responsibilities include performing QC activities and ensuring producers perform QC activities. Failure to have adequate structural concrete QC Operations can lead to the structural concrete operations being suspended. Release 10 November

232 Module 6 - Specifications Contractor (QC) performs initial properties test, w/c ratio and insp. on intial delivery of each mix each day Int. Prop. Complies? NO Air, temp., w/c complies YES NO Reject Load Initate New LOT YES Accept load QC Tests each LOT Can Slump be adjusted? YES Add water and mix revolutions NO Reject remainder of load- Terminate LOT NO QC tests Pass? YES Continue Placement VT tests, 1 of 4 LOTS Perform Plastic Properties Test November 2018 QC Manager Course Release 10, Module 6 12 Basic sampling and testing in the field for structural concrete. Release 10 November

233 Module 6 - Specifications QC and VT must compare on compressive strength Non comparison results in Resolution Resolution is performed on the QC hold cylinder (sample level QR) and VT hold cylinder (sample level VR) A Resolution investigation is performed by the District Materials and Research Office Recommends which results to use for acceptance, QC, VT or RT Material is acceptable if results used are passing minimum strength November 2018 QC Manager Course Release 10, Module 6 13 Structural concrete comparison is performed on the average compressive strength test results. Non comparison results in a Resolution Investigation performed by the District Materials and Research Office. Resolution includes comparing the average compressive strength test results of the QC hold cylinder to the original QC average compressive strength test results and the VT average compressive strength test results to the VT hold cylinder average compressive strength test results. This does not determine the final resolution. The DMRE makes a recommendation for final resolution based on the Resolution Investigation. Resolution will determine if the QC, VT or RT test results will be used to determine material acceptance. Acceptable material is defined as the average compressive strength test results determined by comparison (QC) or Resolution (whichever results are upheld) meeting the minimum compressive strength of the mix design. Release 10 November

234 Module 6 - Specifications Earthwork CQC Specifications November 2018 QC Manager Course Release 10, Module 6 14 Introduction to pertinent QC Earthwork specifications. Release 10 November

235 Module 6 - Specifications Contractor obtains base products and riprap from FDOT approved Aggregate Production Facility ONLY In addition, the Aggregate production facility must have at least one approved product for the material that is being delivered to the project Base production facilities must have at least one approved base product Riprap production facilities must have at least one approved riprap product November 2018 QC Manager Course Release 10, Module 6 15 Aggregate production facilities and products are governed by the Aggregate Control Program, not Contractor Quality Control. Aggregate production facilities status and product statuses are managed by the State Materials Office. When aggregate production facilities are identified in the Contractor QC Plan, they must be in a production facility status of approved with at least one product that is approved for the material they are supplying. Release 10 November

236 Module 6 - Specifications Contractor lists earthwork field inspectors, and laboratories, in the QC Plan List aggregate production facilities for base and riprap In addition to what s listed in 105 Contractor assumes full responsibility for QC Operations and Contract requirements Contractor performs QC activities Contractor responsible for performing QC inspections Failure to have adequate QC Operations or Contract requirements, that portion of the work can be suspended November 2018 QC Manager Course Release 10, Module 6 16 Contractor QC responsibilities include performing QC activities and ensuring producers perform QC activities. Failure to have adequate earthwork QC Operations can lead to earthwork operations being suspended. Release 10 November

237 Module 6 - Specifications Comparison between QC and VT is based on all the tests on the samples in the comparison package Any test may have a non comparison and result in the comparison package status of Does Not Compare QC and VT may not compare on more than one test on the same package Action must be taken on each non comparison Material acceptance depends on the specific material, FDOT Specification and sample purpose November 2018 QC Manager Course Release 10, Module 6 17 Comparison in soils samples is on multiple components. A non comparison on any component will result in Resolution being performed. Action must be taken on each noncomparison. Resolution will determine if the QC test results or RT test results will be used to calculate the individual and composite pay factors. CPF is used to determine final payment and defines if the material is acceptable. Non standard material is different depending on the comparison. The Soils Specifications (120, 125, 145, 200 and 548) define non standard material and what action must be taken. Release 10 November

238 Module 6 - Specifications Soils/Earthwork Test Comparison Criteria Test Definition Comparison Criteria for QC TO VT QC to RT = Pass or Compares QC to RT = Fail or Doesn't Compare AASHTO M 145 Soils Classification QC Soil Utilization = VT Soil Utilization Use QC's Soil Utilization Symbol Use VT's Soil Utilization Symbol AASHTO T 27 and FM 1 T 011 Sieve Analysis for Earthwork QC Tests Pass & VT Tests Pass QC Results Upheld Remove and Replace AASHTO T 89/90 Liquid Plastic Limit QC Tests Pass & VT Tests Pass QC Results Upheld Remove and Replace FM 1 T 267 Organic Content QC Tests Pass & VT Tests Pass QC Results Upheld Remove and Replace FM 1 T180 Modified Proctor QC & VT within ± 4.5 pcf Use QC's Proctor Use VT's Proctor FM 1 T99 Standard Proctor QC & VT within ± 4.5 pcf Use QC's Proctor Use VT's Proctor FM LimeRock Bearing Ratio QC Tests Pass & VT Tests Pass QC Results Upheld Reprocess LOTs in question FM ph for Earthwork QC Tests Pass & VT Tests Pass QC Results Upheld Remove and Replace FM Resistivity in Soil and Water QC Tests Pass & VT Tests Pass QC Results Upheld Remove and Replace FM Chloride in Soil and Water QC Tests Pass & VT Tests Pass QC Results Upheld Remove and Replace FM Sulfate in Soil and Water QC Tests Pass & VT Tests Pass QC Results Upheld Remove and Replace FM AC by Ignition Oven for Earthwork QC Tests Pass & VT Tests Pass QC Results Upheld Remove and Replace FM 1 T 238 Nuclear Density QC Tests Pass & VT Tests Pass QC Results Upheld* Rework and Retest* *RT field density test is performed by VT technician November 2018 QC Manager Course Release 10, Module 6 18 Each Soils/Earthwork MAC Spec has a different set of test definitions for each category and type and sample purpose. The QC Manager needs to be familiar with combination of tests and comparison criteria for each MAC Spec. If any of the comparison criteria is not met, than the sample is considered not to compare and Resolution is needed even if the other comparison criteria is met. Action must be taken for Resolution for any and all noncomparisons. Release 10 November

239 Module 6 - Specifications The Contractor is responsible for reporting QC sampling and testing. November 2018 QC Manager Course Release 10, Module 6 19 It is the Contractor s responsibility to report QC sampling and testing results. In some instances, such as Class 1 Non Structural Concrete or guardrail, there is also a certification completed and/or obtained by the Contractor. It is the Contractor s responsibility to collect and submit any producer or manufacturer certifications that are required to meet the material method of acceptance. In some materials, like guardrail, the Contractor must also complete and submit a certification to meet the material method of acceptance. The manufacturers certify the acceptance of individual guardrail components. The Contractor certifies the components were installed correctly. Release 10 November

240 Module 6 - Specifications Contractor reports QC results to FDOT FDOT reports VT results to the Contractor Resolution Lab reports results to both Who does the official QC/VT comparison? November 2018 QC Manager Course Release 10, Module 6 20 Release 10 November

241 Module 6 - Specifications Contractors use MAC to report QC data The FDOT will assist the Contractor in: - Setting up the system - Entering data - Understanding the report November 2018 QC Manager Course Release 10, Module 6 21 To insure good communications on projects, Contractor will provide QC test data directly into the Department s Materials Acceptance and Certification system (MAC). The Dept. provides training in setting up the system, entering data, and understanding the report. Release 10 November

242 Module 6 - Specifications Describe the basic QC and VT testing process for Asphalt, Concrete and Earthwork Describe basic reporting requirements November 2018 QC Manager Course Release 10, Module 6 22 Release 10 November

243 Module 6 - Specifications Any Questions? November 2018 QC Manager Course Release 10, Module 6 23 Release 10 November