Improved Regionalization Of Quality Assurance (QA .

Improved Regionalization of QualityAssurance (QA) Functions(a.k.a. Sharing Inspection Resources)Eshan Dave, Michael Kotowski, Rasool NematiJo Sias Daniel, Ricardo Medina, Alan Perkins17 October 2017Department of Civil and Environmental EngineeringUniversity of New Hampshire

Outline§ Study Motivation and Objectives§ Review of New England QA processes forPSE/PCE§ Proposed Regionalized QA Process§ Logistics for Regionalization2

Background of QA Procedures for PCE/PSE§ CFR Title 23 Part 637– QA processes ensure that desired level of quality ismaintained throughout the manufacturing andconstruction processes§ AASHTO R38 gives the minimum requirements§ Significant cost savings can be realized ifregionally accepted procedures are developed:– Inspection and testing resources can be shared– Streamlines producer operations when supplying tomultiple agencies§ Differences exist between QA procedures ofvarious agencies3

1. List of Fabricators Currently (recently)Supplying PSE/PCE to NE DOTs§ PCI Certified SuppliersStateNo. of PCI Cert.FabricatorsCT3MA6ME1NH1RI5VT31316354

1. List of Fabricators Currently (recently)Supplying PSE/PCE to NE DOTs§ NPCA Certified SuppliersStateNo. of NPCACert. FabricatorsCT3MA6ME1NH3RI1VT31336315

Study Scope and Objectives§ Review of current QA process used by NewEngland DOTs for PCE/PSE– Literature review– QA Specifications– Interviews§ Propose regionalized QA process for PCE/PSEto be used by NETC constituents§ Explore cost-sharing mechanism to accompanythe common acceptance standards6

Review Methodology§ Information Gathering– Preliminary specification review– Questionnaire– Interviews with constituents§ Detailed specification and QA processreview– Fabricator visits (Oldcastle, J.P. Carrara)§ QA process§ Feedback7

Review Methodology§ Information Processing– Master table of the QA process activities§ Able to develop similarities and differencesamongst the agencies.– Information was sorted and aspects of QA processwere identified that would be most impacted byregionalization§ Comparisons were made on these aspects andrecommendations are generated8

Review of State Practices§ Brief summary is presented here:1. Qualification and Certification ofPlant/Fabricator2. Fabricator QC Requirements3. QA Process (Agency Inspection)4. Curing Requirements5. Miscellaneous9

1. Qualification and Certification ofPlant/Fabricator§ Pre-stress (PSE) FabricatorsPCIPCI Agency AuditAgency Prequalification10

1. Qualification and Certification ofPlant/Fabricator§ Non pre-stress (PCE)PCIPCI/NPCA AgencyAuditAgency AuditNone11

1. Qualification and Certification ofPlant/Fabricator: Inspector Office§ Inspector Office/Facilities Requirements– RIDOT have the most comprehensivespecification detailing the officerequirements– Other agencies have similar requirements12

2. Fabricator QC Requirements§ Quality Control Manual/QualityService Manual– PSE§ PCI MNL-116 for all agencies– PCE§ PCI MNL-116 (MA)§ NPCA (MA, ME, NH, VT)§ Agency specified requirements (RI)13

2. Fabricator QC Requirements§ Qualification of QC Technician– PSE§ PCI Level 2 (All States)– PCE§ ACI Level 1 or 2 (MA, CT, ME)§ PCI Level 2 (NH)§ No requirement (RI, VT)14

3. QA Agency Inspection§ Employee versus Consultant InspectorsBothConsultantsEmployees15

3. QA Agency Inspection§ Inspector QualificationAgencyPrestressed InspectorQualificationPrecast InspectorQualificationCTMAMENHRIACI level 1 equivalentPCI Level 2PCI Level 2PCI Level 2ACI level 1 equivalentPCI Level 1, 2, or 3PCI Level 2In-House CertificationPCI Level 1In-House CertificationPCI Level 1VT16

3. QA Process: Inspection§ Pre-Pour (PSE/PCE)– The processes showedstrong similaritiesamongst the six states§ Comparison of thepre/post pour checklistsprovided by eachagency.17

3. QA Process: Agency Testing§ Plastic Concrete Testing– Frequency of Plastic Concrete Tests§ CY, load, lot size, etc.AgencySpreadAir ContentTemperatureCTWitness QC ResultsMAOnce per pourMEFirst two (2) loads, then at discretion of QAI on basis of consistencyNHPer sublot (typ. 1/item)RIOnce per 150 CY or each day’s productionVTFirst load whenever cylinders are castNHDOT also require w/c ratio testing using microwave method.18

4. QA Process: Inspection§ Post-Pour (PSE/PCE)– The checklists provided by each state variedslightly§ Maine DOT has the most comprehensive postpour checklist– Watching the element get loaded on transportrequirement varies19

4. QA Process§ Additional Hardened Concrete Testing– Maine and New Hampshire DOT – Permeabilitytesting using AASHTO T-358, “Surface ResistivityIndication of Concrete’s Ability to Resist ChlorideIon Penetration.”20

4. Curing Requirements§ Ranged from well-prescribed requirements to notbeing included in the QA process.AgencyCTMAME NHRIVTCuring RequirementsNot Inspected – Follow MNL-116Procedures Under DevelopmentMNL-116 with exceptions.Temperature gain 40 F/hr.Initial set determined by ASTM C403Maximum temperature of 160 FMinimum temperature of 120 FUntil 80% of design strength is achievedItem SpecificAccelerated curing allowed for PSE21

5. Miscellaneous§ Fairly consistent requirements for IA– Inspectors are typically IA’ed once per year§ Estimated Inspection Cost– The agencies provided an hourly rate estimate forconsultant inspectors.– It was found that the hourly rate ranged from 50/hour to 100/hour.§ The lower end of the spectrum does not includetravel reimbursement while the higher rangeincorporates additional costs for travel.22

QA Process Review Summary§ Attributes that are most dissimilar betweenagencies:– Sampling frequencies– Inspector qualification§ Prestressed concrete element QA processesare more similar between agencies§ Preliminary recommendations are made forregionalized QA process23

QA Cost Share Mechanisms§ At present no formal mechanism existsbetween other States DOTs§ Several DOTs conduct tests for otheragencies, standard testing rates areestablished and costs are typically charged tothe project§ Main challenge is costs associated withinspection and on-site testing24

Regionalized QA Process Recommendations1. Three Categories: PSE, Structural PCE, NonStructural PCE2. Plant Certification and Producer TestingRequirements3. Agency Inspection4. Logistics25

1. Recommendation Layout (Categories)§ Prestressed Elements (PSE)– Examples:§ NHDOT Item 528, RIDOT Item 809, MEDOT Item 535§ Structural Precast Elements (precast piles,precast concrete superstructure etc.)– Examples:§ NHDOT Item 594, RIDOT Item 804, MEDOT Item 534§ Non-structural Precast Elements (catch basins,storm drains etc.)– Examples§ NHDOT Item 603, RIDOT Item 702, MEDOT Item 60326

2. Plant CertificationItemQC Plan (QSM) and PlantRequirementsElementPCI/NPCARequirementPSEPCI MNL-116Structural PCENon-Structural PCEAdditionalRecommendationsPCI MNL-137 forPCI MNL-116/NPCA repair works andAASHTO M-157 forReady MixNPCA27

2. Producer Testing Recommendations (modifications to NPCA/PCI)ItemCasting BedJ-Ring or L-Box(AASHTO T345 or ASTM lRecommendationsElementPCI/NPCA RequirementPSEStructural PCE-Non-Structural PCE-PSE-Structural PCE-Non-Structural PCE--PSEMinimum of 4 Cylinders perelementAdditional 4cylinders for destressing strengthStructural PCEProfile andAlignment checkFor each SCCdesign and at thestart of eachelement type4 Cylinders;PCI: Daily for each individual Min. once per eachconcrete mix, or every 75 CY day's production orevery 150 CYNPCA: Every 150 CY per mixor once per weekMin. once per each4 Cylinders, every 150 CY perday's production orNon-Structural PCEmix or once per weekevery 150 CY28

2. Fabricator QC TechnicianRequirements§ PSE– Minimum of PCI level 2 or higher qualification (ornew NETTCP PS level 1 certification)§ PCE– Minimum of ACI level 2 or PCI level 1 (or NETTCPPS level 1 certification)– ACI level 1 is also acceptable for non-structuralPCE29

3. Agency Inspection: Pre Pour§ Minimal differencesbetween agency practices.§ Maine and New Hampshirecheck-lists are the mostcomprehensive and userfriendly§ A combined version ofthese is proposed to beused30

3. Agency Testing RecommendationsInspection CriteriaElementPSETemperatureStructural PCENon-Structural sStructural PCETest FrequencyAt least once per element and every100 CYOnce per continuous pourAt least once per element and every100 CYNon-Structural PCEOnce per continuous pourPSEOnce per element or every 100 CY;Number: Total 6 cylinders forpermeability and strength testingStructural PCENon-Structural PCEOnce per continuous pour; Number:Total 4 cylinders for strength testing31

3. Agency Inspector Qualification§ PSE– Minimum of PCI level 2 or higher qualification (orNETTCP PS level 1 certification)§ PCE– Minimum of ACI level 2 or PCI level 1 (or NETTCPPS level 1 certification)– ACI level 1 is also acceptable for non-structuralPCE32

5. Curing Requirements§ Accelerated curing is the current state of the practice§ PSE and Structural PCE:– Controlling temperatures shall be those actuallyachieved within the concrete elements– Accelerated curing should started after concrete hasattained initial set– Concrete temperature may be increased during thepreset period at a rate of 10 F per hour or less– Total temperature gain during the preset period shouldbe less than 40 F higher than the placementtemperature or 104 F (lower of two)– A heat gain should not exceed 36 F per hour,measured in the concrete, provided the concrete hasattained initial set33

6. Logistics of Regionalized QA Process§ Need central entity to manage QAI pool– Central managing entity might be the solution (NETC orNETTCP like model)– ShiftPlanning or similar system (currently used by Vtrans)could be used to manage the pool and for purposes ofscheduling§ Initial trials could be conducted using only consultantinspectors– Current range of rates are established and can be used forplanning purposes– Focus initial trials for pre-stressed elements (simpler to unifyQA process requirements)§ Technology could really help streamline the process– RFID tags cloud-based storage§ Currently being explored by various agencies§ Could serve as vehicle for real time data transfer34

Thank you for your attentionContact:eshan.dave@unh.eduPhone: 603-862-526835

PSE PCI MNL-116 PCI MNL-137 for repair works and AASHTO M-157 for Ready Mix Structural PCE PCI MNL-116/NPCA Non-Structural PCE NPCA. 28 2. Producer Testing Recommendations (modifications toNPCA/PCI) Item Element PCI/NPCA Requirement Additio