assuring quality in a fast-paced world · automation failure / tampering scale inaccuracy /...
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Assuring Quality in a Fast-Paced World
Donald A. Streeter, P.E.
NYSDOT – Materials Bureau
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130 billion vehicle miles annually
485 public and private aviation facilities
12 major public and private ports
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New York State’s Transportation System is a vast and expansive network
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Need for rapid repairs / replacement
Drivers First
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Need for rapid repairs / replacement Emergency response
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Our “Fast Paced” World
R u Imp8ent ??? Trained for Instant
Gratification
“Faster is better” mentality
Is “faster” really better?
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Minimizing Risk –Maximizing reward
Managing a Balancing Act between: Reasonable quality for service
What is reasonable – 25 yrs, 50 yrs, more?
Quality Assuance – adherence to specs?
Drivers First Minimize impact on traveling public
Cost Completing work within or below budget
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FHWA’s ABC EDC Initiative
Accelerated Bridge Construction: Precast construction
Accelerated PCC mixtures
UHPC Slide-in technology SPMT
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“Faster” and “Sustainable”Keys:
Do it right the first time
Don’t rush faster than you need to
Don’t push materials beyond their capabilities
Use the right materials for the job
Use responsible engineering judgment
Consider alternatives
Don’t use “Super, High, or Ultra” in the name
Goals:
Achieve Sustainability
Provide Quality Assurance
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Design
Select the right acceleration means Is “acceleration” even necessary?
Nights and weekend closures / temporary detours
vs.
Alternate traffic patterns
w/ long term detours
Consider alternativesand cost
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Faster Materials / Methods
Precast Components systems w/ Traditional PCC closures
Accelerated PCC closures
UHPC closures
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Fastest Materials / Methods
Pre-constructed components Slide in units
Temporary structures
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Rocket Science Requires attention to
details
Back-up systems
Extra oversight
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Quality Assurance - Materials
Approved / Qualified Products list
Trial batches for design mixtures Strength – ultimate and rate
F/T durability
Permeability / resistivity
Placement characteristics
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Quality Assurance - Materials
Pre-evaluation Time consuming
Requires lead time
Doesn’t assure quality Minimizes risks
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Quality assurance - Construction
Trial placements Use mock-ups
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Construction
Once started… have to complete May need temporary placements / conditions
to open back to traffic
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Remember Murphy’s Law
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Murphy…
Weekend – 8pm Friday to noon Sunday Saturday 5 PM, On Schedule Started Pouring Joints Sat @ 10 PM on
Schedule, Scheduled to Finish Midnight Concrete Flash Setting Problems in the
Next 5 Hours…..5 Rejected Concrete Loads
Finished Pouring at 7 AM!!!! Left 9 hours - Curing, Temp. Barriers,
Paving, Striping and taking down TCP
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Minimizing Risk –Maximizing reward
The Balancing Act between: Reasonable quality for service Drivers First Completing work within or below budget
Assuring Performance and Quality?
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Performance / QualityCurrent prescriptive process: Automation / recordation Scale check / lab Mix designs Inspection – production
Gradation / moisture / friction
Project sampling Air / slump / cylinders
All DOT actions ergo all DOT Risk
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Performance / QualityPrescriptive Risks: Automation failure / tampering Scale inaccuracy / tampering Mix / materials variability Inspection – Expertise of TCI’s
Testing proficiency Awareness of plant operations
Project sampling Testing proficiency / Sample handling
End performance remains DOT’s Risk
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Performance based specsFor PCC production: Delegate responsibility Re-assign risk Improved economics Improved product Evaluation tools
New and existing tools – verify quality
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Performance process Automation / recordation required
Current system requirements remain certified by producer
Scale Checks / Lab facilities Current system requirements remain
certified by producer
Verified by DOT – payment measure
Truck inspection Current system requirements remain
certified by producer
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Performance process QC Plan
Producers to define QC process
DOT audits – assure effort / compliance Review of:
Agg gradation / moisture / friction
Cement / pozzolan sampling
Scale accuracy
Batch records
Truck conditions
Etc…
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Performance process Mix designs
Performance criteria for mixtures Strength
Resistivity (assures low permeability)
Indirectly controls w/c, pozzolan use,
aggregate gradation
Air content
Friction
ASR resistance
F/T resistance (flatwork)
JMF’s established
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Performance process Mix designs
We don’t care about: Min / max cement content
w/c ratio
Aggregate gradation
Slump
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Performance process Mix designs – benefits:
Mix economy Improved gradations
Strength w/ less cement
Improved mix characteristics Resistivity (assures low permeability)
Indirectly controls w/c, pozzolan use,
aggregate gradation
Varied strength designs
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Performance process Mix designs – issues:
Some prescriptive req Internal curing
DOT approved materials
Pay factors Strength / Air / Resistivity
Pass / fail vs pay factors?
Friction / safety
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Performance process Project sampling – Quality Control
Air F/T durability control Every 50 CY minimum
Slump Verify consistency Every 50 CY minimum
Cylinders (producers actions) As desired for own records Contractor data / statistical analysis?
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Performance based specsQuality Achieved / Acceptance Air meter / Super Air Meter (SAM) Surface resistivity Meter Wash samples Compressive strength
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Performance based specsQuality Achieved / Acceptance Air meter / Super Air Meter (SAM)
Measures: air content quality of bubble structure
Repeated pressure test 15 minute test
Verify convenence equip
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Performance based specsQuality Achieved / Acceptance Surface Resistivity Meter
Measures resistivity(inverse of permeability)
Indirectly controls:
Water content
Pozzolan use in mixtures
Mixture design
Cement content
Aggregate gradation
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Performance based specsQuality Achieved / Acceptance Wash samples
Friction ASR (?)
Compressive strength
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Performance process Field testing – risks:
Acceptance verification day of placement Correct materials used
Proper air content
Acceptance determined later date Strength
Resistivity
Results subject to proper QA Good sampling / testing
Cylinders handled properly
No impact on placement operations
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Q1: What types of closure materials are currently used with precast concrete components?
– Traditional PCC closures
– Accelerated PCC closures
– UHPC closures
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Q2: What are some of FHWA’s ABC initiatives?
– Precast construction
– Slide-in technology
– SPMT
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Q3: What are some of the potential benefits when using performance based PCC specifications?
- Delegated responsibility / authority- Improved economics- Improved product performance
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Q4: What are some of the performance criteria that determine quality of PCC mixtures? - Strength
- Resistivity (assures low permeability)
- Air content
- Friction
- ASR resistance
- F/T resistance (flatwork)
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Q5: What is SAM and what does it do?
- Super Air Meter- Measure air content and air bubble quality
(determines spacing factor, size, and specific surface of air in concrete)
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Q5: What does a Surface Resistivity Meter measure?
- Resistivity (permeability of concrete)- Indirectly controls quality of mixture including
Water content Pozzolan use in mixtures Mixture design
Cement content Aggregate gradation
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Thank you