Design-Builder Quality Control System Paul Moyer, P.E., Gill Engineering. July 17, 2011

Transcription

1 Design-Builder Quality Control System Paul Moyer, P.E., Gill Engineering July 17, 2011

2 Project Quality Assurance Program Quality Assurance All those planned and systematic actions necessary to provide confidence that a product or facility will perform satisfactorily in service (TRV Circular E-C037/AASHTO R10-06)

3 Project Quality Assurance Program Two Primary Components 1. Quality Control DB Responsibility 2. Acceptance Agency Responsibility

4 Quality Assurance - Contract Provisions Design QA Program White Kiewit MassDOT Design Quality Control System Design Acceptance System Construction QAProgram White Kiewit MassDOT Contractors Construction Quality Control System Construction Acceptance System Independent Assurance Dispute Resolution System Qualified/Accredited Labs Qualified/Certified Inspection & Testing

5 I93F14 QC System Unique Challenges Schedule Establish QC System Fast Rigorous but Efficient QC System Design Project Right the First Time Build Project Right the First Time D/B work proceeds during QC System Development Numerous Stakeholders

6 W-K Quality System Manual (QSM) 1. Introduction 2. Quality Control Organization and Roles 3. Document Management and Control 4. Design Quality Control 5. Construction Quality Control

7 QSM Development Process Weekly Meetings: January 27 May 6 Participants W-K QC Team W-K Design Production W-K Construction Production MassDOT Boston MassDOT District FHWA Reach Consensus Fast Final Rev. 2 - Conformed June 14 QC Procedures Implemented during Development

8 QSM - 2. Quality Control Organization QC Administrator: Paul Moyer, PE Design QC Manager: Mark Negrotti, PE Design QC Team 14 Design Components Construction QC Manager: Andrea Burke Field Inspectors Shop Inspectors Independent Testing

9 QSM - 3. Document Mgmt & Control Electronic Filing System Expedition Sharepoint DB Team Sharepoint MassDOT

10 QSM 4. W-K Design Quality Control Targeted QC Review Procedures by Document Type Guiding Principles 1. Rigorous QC Review Procedures 2. Eliminate Unnecessary Review Steps 3. PE-Stamped Deliverables: Full QC Review 4. Other Deliverables: Streamlined Technical Review

11 W-K Design QC PE-Stamped Docs Design Docs & Construction Procedures Full QC Review Technical Review - Design Production Team Design QC Review Discipline Coordination Review Construction QC Review Documentation Design Review Comment Resolution (RCR) Form Discipline Coordination RCR Form Construction RCR Form Quality Control Checklist (QCC)

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15 W-K Design QC Unstamped Docs Permit Applications, Schedule Updates Technical Review Design and/or Construction Production Team Documentation - QC Cover Sheet Preparer Reviewer Project Engineer (or designee) QC Administrator

16 W-K Design QC Construction QC Plans Prepared by Construction QC Manager Technical Review by QC Administrator Review Documentation - QC Checklist Construction QC Mgr QC Administrator

17 W-K Design QC Shop Drawings Constructability Review by Project Engineer Technical Review by Design Production Team Documentation: Constructability: Acceptance Stamp Technical: Shop Drawing Stamp

18 W-Q Design QC Early Release Work Starts Prior to Final Design Acceptance Early Release Packages Structural Steel & Bearings Beam Seats & Substructure Repairs Temporary Crossover Sawcutting, Median Barrier Deployment Highway Lighting

19 W-Q Design QC Early Release Draft Early Release Submittal Page-Flip Review Meeting Final Early Release Submittal W-K Proceeds at Risk Except: Construction Involving Moving Traffic Delivery of Major Components to I-93 Site

20 W-Q Design QC Early Release Shop Drawing Approval Early Release Approval Re-review and Approval after Final Design Acceptance

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22 QSM 5. W-K Construction Quality Control Project Produced Materials Fabricated Materials Standard Manufactured Work Items

23 W-K Constr. QC Project Produced Materials Construction QC Plans Earthwork Bridge Substructure Repairs, Beam Seats Bridge Superstructure Bridge Bearings and Composite Deck Members Bridge Deck Closure Concrete Bridge Deck Membrane & Strip Seals Portland Cement Concrete Other Hot Mix Asphalt Pavement Field Inspection Independent Field Testing Mobile Lab

24 W-K Constr. QC Fabricated Materials Fabricator Quality System Manuals Bridge Bearings - DS Brown Structural Steel Structal (w/greiner & Michelman) P/C Modular Structural Elements - Jersey Precast W-K Inspectors in Fabrication Shops Structal Jersey Precast Fabrication Shop Testing

25 W-K Constr. QC Standard Manufactured Work Items Manufacturer s Quality System Manuals Manufacturer Testing Project Site QC Inspection and Testing

26 W-K Constr. QC Inspection & Testing W-K Shop Inspection Structal: Steel Jersey P/C: PMSE W-K Field Inspection Independent Testing Mobile Laboratory

27 W-K Constr. QC Non-Conforming Work Nonconformance Report (NCR) Non-Conformance Disposition Sign-off W-K QC Administrator W-K Design Engineer MassDOT Corrective Action Verification W-K QC MassDOT RE

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29 DB QC System Critical Success Factors Weekly Meetings during QSM Development All Stakeholders Attend Get Everyone s Input Make Decisions Reach Consensus Anticipate Everything, Have Plan in Place Targeted QC Procedures Early Start: Development & Implementation Keep Team Educated During Development

30 Questions? GILL ENGINEERING Paul Moyer, P.E Vice President eng.com.