Student Manual

Lesson 6- QC Manager Role & Responsibilities

Lesson 6

THE QC MANAGER S MANAGERS ROLE & RESPONSIBILITIES

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Lesson 6- QC Manager Role & Responsibilities

Learning Outcomes

Describe QC Managers role & responsibilities Describe the QC Managers duties Describe the QC Managers reporting requirements

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Upon completion of this lesson, you will be capable of performing these Learning Outcomes.

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Lesson 6- QC Manager Role & Responsibilities

QC Manager Role Overview

Plan QC Needs Est. QC Manpower Qualified Subs Establish Rework Goals Administer QC Plan Monitor QC Activities Provide Monthly Certification Maintain Records Evaluate Performance DDM/EAR LIMS

Pre-Bid Pre-Bid
Prepare QC Plan Qualified QC Staff Qualified Labs Producers QC Plan Verification

Pre-Construction Pre-Construction

Construction Construction
Sampling/Testing Records Material Certifications LIMS EARs Closed/DDM Warrantee Items
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Post-Construction Post-Construction

Shown above are the major phases for the QC Managers 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. Which tasks are assigned will be determined by the upper level managers of the Prime Contractor. During the pre-bid phase, they 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, which lead to developing the QC Plan. 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 for ensuring 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. As the old saying goes, it isnt 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.
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Lesson 6- QC Manager Role & Responsibilities

Integrity

XYZ

QC

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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 Departments 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.

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Lesson 6- QC Manager Role & Responsibilities

QC Manager Role
Serve as Contractors Quality Representative Prepare QC Plan Administer and Monitor QC Compliance Coordinate Resolution of Conflicts Administer and Monitor QC inspection, sampling, testing and reporting Provide monthly Certification
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Listed above are some of the functions of the QC Manager, which will be covered in detail in this lesson.

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QC Manager Authority
Who should the QC Manager report to?

Do they have any authority over the Production staff?

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QC Manager Authority
Should the Inspectors report to the QC Manager?

Do the Inspectors have any authority to stop work?

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Pre-Bid Activities
Review Contract Documents

Plan QC Program Identify QC inspection, sampling & testing requirements Identify potential Inspectors/Technicians Identify potential QC problem areas

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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 a rough QC Plan 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.

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Pre-Bid Activities
Prepare QC Budget

Estimate QC inspection, sampling & testing manpower, per phase Estimate QC Costs, per phase Provide the bid Estimators the QC Costs

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-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). - Will there be multiple concrete placement sites, concurrently. If so, 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.

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Pre-Bid Activities
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

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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. Regardless if they have the best price for Estimating, if they cant meet QC requirements, it doesnt do Estimating any good. Therefore, you need answers to the following questions: -Do anticipated suppliers/producers meet the QC requirements for the project? If not, others should be sought. Also, give thought to having back-up subcontractors/suppliers, should problems arise with a particular subcontractor/supplier. -Does the QC Inspection staff have all of the required CTQP qualifications? Is some CTQP training needed to meet the needs of the project? -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, as the Prime, you are responsible for their actions. You want subcontractors that are as concerned about quality as is the Prime Contractor. Last but not least, you need to communicate with Estimating as some of the quotes they are getting may be coming from firms who do not meet QC requirements. They need to know this and arrange to get quotes from others.

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Lesson 6- QC Manager Role & Responsibilities

Pre-Bid Activities
Establish Rework Goals Estimate rework potential, per phase Establish reasonable rework goals

Original Activity

Rework Duration Standby Rework Gear up

Continuation of Original Activity

Rework ID
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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 dont 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 a manhour. 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.

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Rework Cause Classification

Human Resources Capability
Unclear Instructions To Workers Excessive Overtime Insufficient Skills levels Ineffective Mgmnt of Project team

Leadership & Communications

Lack of Safety & QA/QC commitment Poor Communications

Inadequate supervision & Job Planning Late Design Changes Poor Document Control Scope Changes Errors and Omissions Constructability Problems

Lack of Operations (End User) Perceives Buy-in Late Design Input Unrealistic Schedules Untimely Deliveries

Contribute To Re-work
Prefab & material not to Project Requirements

Non-compliance With specifications

Engineering & Reviews

Insufficient Turnover & Commissioning Resourcing

Materials not in right place when needed

Construction Planning & Scheduling

Material & Equipment Supply

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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 projects 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.

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Lesson 6- QC Manager Role & Responsibilities

Pre-Bid Activities
Establish Rework Goals

Past Job Cost Experience level of personnel (Management & Craft) Suppliers past problems Subcontractor past problems

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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 todays market this must be considered, because you dont 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 re-work 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.

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Lesson 6- QC Manager Role & Responsibilities

Pre-Bid Activities
Establish Rework Goals

Past Owner relations issues Equipment availability problems Quality of Contract Plans

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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 dont 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 interstate and your asphalt paver in not the best one you have in the fleet you may anticipate removing a few areas because of using older equipment). Quality of Contract Plans The condition of the contract plans often breeds rework on the job. Today's project sizes and complexities often produce multiple EORs 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 estimate phase by the senior management.

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Pre-Construction Activities
We got the jobDo that QC thing you do

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Lesson 6- QC Manager Role & Responsibilities

Pre-Construction Activities
QC Plan Preparation Finalize Project QC requirements Prepare & Submit QC Plan Prepare QC Administrative Tools Prepare Earthwork Record System Prepare LOT numbers Setup LIMS access
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So, your firm was low-bid and now you have the Project. You now need to finalize many of those tasks you performed in the pre-bid phase. Sharpening the pencil will probably be one. 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 4. 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 cant just sit back and wait. Remember, you basically cannot start construction 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 the project 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). If required, it is important for you to obtain from the Contractor, a letter stating you are acting as their agent and empowered to stop or control operations. Make sure it is signed by an officer of the company, authorized to do so. This aides in establishing the authority you have and demonstrates the Contractors commitment to Quality.

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Lesson 6- QC Manager Role & Responsibilities

LOT Numbering
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

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The identification of where material was placed on the job for recording purposes is extremely important. The system used by the QC manager can make it easy or difficult for others on the project and for themselves. Remember, you dont want to miss any required sampling or testing. The definitions of LOT sizes, by material, is defined by the specifications, and each of the primary materials, Asphalt, Concrete and Earthwork are different. Within these materials are various subsections, such as classes of concrete, embankment materials, etc. Each has its own LOT Index, the system where the results for a LOT are recorded. There currently is no official procedure for numbering LOTs, as this is left up to the Contractor, it is their responsibility. 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.

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LOT Numbering
Concrete LOT numbers by Class of Concrete Per Contract Number Type II Bridge Deck (50 CY or 1 days production) Asphalt LOT numbers by tons per specifications Per Contract Number

Asphalt

LOT 76

LOT 32
Sta 325+00

Sta 100+00

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The following described methods for numbering LOTs is a system developed and used by existing, very experienced, and very successful, QC Managers, who have found this to be the easiest, not only for others, but for them. As was reviewed earlier, we know that in general, LOTs for concrete are typically 50 CY or a days production, whichever is less. This is fairly straight forward, it then just becomes a matter of the stationing and class of concrete. Therefore, if you set up your LOTs by Concrete Class, and naturally Station Number, it makes it extremely easy to locate where a specific LOT of concrete is located. Asphalt is similarly easy, as the specifications set forth LOTs by tons, therefore, in addition to station numbers, asphalt LOT numbers come from the tons placed.

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LOT Numbering
Page____ of _____

xx

Page 1 computer-plotted graph only occurs once under Embankment in the QC Earthwork Record System

LOT 3 LOT 2 LOT 1

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The numbering of LOTs for the Earthwork operations is not as simple and causes the most difficulties. The manner in which these are numbered ranges all over the place, making it extremely difficult to figure out where LOTs are located. Part of this is because there are so many construction types in earthwork and the requirement that the Earthwork Record System (ERS) be maintained as one book, pages sequentially numbered by construction type. By procedure, every computer-plotted graph page produced is to be consecutively numbered from 1 to whatever. This includes embankment, structures/ pipe, subgrade, base, etc. For instance, the Embankment Section pages may take up Pages 1-123, structures 124-189, etc. Because the sheets of the ERS are by construction type, why not the LOT numbering the same. Therefore, each construction type would have its own set of LOT numbers and LOT Index sheet, which is part of the required ERS. So the first section sheet in Embankment (Section 120 SSRBC) would have LOT 1 thru whatever. The first sheet in Structures and Pipe will have LOT 1 thru whatever, and so on. Another system uses the page numbers of the ERS. Remember, each page, by construction type appears only once in the ERS and therefore each page could have their own LOT numbers. In the illustration above, if this was the first Embankment Sheet, Page 1, then as shown, the first LOT is #1 and so on. This makes it extremely easy for the earthwork Inspectors for their sampling and testing and makes it easy to locate a specific LOT if needed.

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Lesson 6- QC Manager Role & Responsibilities

LOT Numbering
Page ____ 21 of _____ XX

LOT 1
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Lesson 6- QC Manager Role & Responsibilities

LOT Numbering
In summary; Put some thought into this If needed, seek help from successful QCMs or FDOT Be consistent Educate others

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In summary, how you number the LOTs has an impact on you and others. Put some thought into it.

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Lesson 6- QC Manager Role & Responsibilities

Pre-Construction Activities
QC Awareness

Conduct pre-construction QC meeting Champion QC effort Provide QC Tools Review QC Process/Recording/Reporting

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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 doesnt 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. 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 LIMS access at the appropriate levels for project personnel.

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Lesson 6- QC Manager Role & Responsibilities

Construction Activities
Were burning daylightWe better get To work

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Lesson 6- QC Manager Role & Responsibilities

Construction Activities
Administer QC Plan

Perform QC Plan Revisions as necessary Provide interpretation of contract documents Assist in Internal Work Plan preparation Review QC Process/Recording/Reporting Results

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Part of administering the QC Plan 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 concrete mix designs, personnel changes, etc. are causes for revisions to the QC Plan. Some Contractors have the 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 performance, 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 Manager. The work plan is also reviewed with the crew weekly 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.

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Construction Activities

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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: www.dot.state.fl.us/statematerialsoffice/quality/programs/ qualitycontrol/guidelines/contractor/cqcforms.xls For example: If you need to access Form 700-050-66, you would click on the link, unzip the file to the directory/folder of your choice and then you would run the Excel program. You would go through this process for each form you needed.

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Construction Activities

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When unzipped and opened, you would be at this screen for the tabulation of quantities. Upon completing your entries, you you could select Go to Main Sheet, which brings up the Contractor Certification Sheet. Shown below and full-size following, is the Monthly Contractor certification to be completed, which carried over the information you entered in the previous screen

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Lesson 6- QC Manager Role & Responsibilities

Construction Activities
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

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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 develop a matrix or spread sheet of these qualifications. This lets all know who is qualified for what and avoids unqualified personnel performing inspection, sampling or testing tasks. You also need to ensure that the proper manpower resources are available for the QC tasks required per phase, and the schedule. Based upon the QC staff, some internal or external training may be needed and as QC Manager, you will probably be responsible for arranging any required training and ensuring that qualifications are maintained.

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Lesson 6- QC Manager Role & Responsibilities

Construction Activities
Administer Inspection Program

Ensure adherence to required specifications, procedures and methods for personnel & equipment Coordinate Verification and Resolution testing activity Ensure adherence to QC Plan elements by Inspection staff Conduct/Attend internal and external project meetings Conduct/Attend pre-operations meetings

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As the QC Manager, you are responsible for the administration, management and evaluation of the QC efforts. 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. Although IA may be coming around, you need to take some active participation and ensure that the proper procedures and requirements of the QC Plan are being followed. A plan is great but if no one follows it, it is useless. You may need to get involved in QC vs Verification issues or problems, or need to coordinate 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. 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 plan 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.

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Lesson 6- QC Manager Role & Responsibilities

Construction Activities
Evaluate QC Performance Monitor, Evaluate & Report QC performance Coordinate DDMs & EARs Record QC lapses & provide preventive solutions Track rework goals Evaluate current practices and recommend improvements Attend Project Progress meetings
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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 it in place, you may be responsible for initiating the Engineering Analysis Report (EAR) in an effort to have the Department accept the material based upon an Engineering Report. 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, that fixes the problem. 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.

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Construction Activities
Track Re-work Costs Spreadsheet Tracking Prepare summaries of re-work events Focus on improving processes to minimize re-work
COST TO DATE / GOAL 100,000 75,000 50,000 25,000
7 May 05 7 Nov 05 7 Dec 05 7 Aug 05 7 Feb 06 7 Mar 05 7 Feb 05 7 Mar 06

Re-Work Costs Verses Goal Graph

Re-work Goal Dollars Used To Date

7 Jun 05 7 Jan 06 7 Apr 05 7 Oct 05 7 Jul 05 7 Spt 05 7 Apr 06

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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 see if your program is effective or if you need to improve on a certain area. Another good practice is to put together a summary of the rework 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 youre 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.

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Lesson 6- QC Manager Role & Responsibilities

Control Charts

Identify Process problems Identify QC problems Assist in meeting/improving processes

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As discussed in Lesson 3, 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.

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PCC-Control Charts
Sample #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Strength
7840.0 7340.0 7260.0 7150.0 6610.0 6470.0 6540.0 6620.0 6700.0 7890.0 7610.0 7840.0 7970.0 7780.0 6650.0 6740.0 6870.0

Avg of 15 Strength

Test Results Air % 3.10 2.90 7.30 3.60 2.80 3.80 2.40 2.80 4.00 3.90 3.30 3.10 4.20 3.90 3.00 3.60 4.00 Slump 2.25 2.75 2.75 3.00 4.00 3.50 4.00 4.50 4.50 2.50 2.75 2.25 2.50 2.75 4.25 4.25 4.25 Temp. 77 80 72 77 70 80 85 78 78 80 87 84 84 85 85 87 83 W/C 0.36 0.37 0.37 0.37 0.37 0.37 0.37 0.30 0.31 0.36 0.36 0.37 0.35 0.29 0.36 0.36 0.38 6-32

7218.0 7144.7 7113.3

For this example, the above Test Results are the Compressive Strength Test Results from concrete cylinders on a project. Shown below is the project Quality Characteristics we are monitoring and their respective Upper and Lower Limits. The next page shows the Control Chart Plot of these results.

Control Chart QC Data- Class IV, 5500 PSI PCC

Limits Target Upper Lower Concrete Strength 9000 5500 Concrete Strength 9000 5500 Concrete Air % 3.5 6.0 1.0 Concrete Slump 3.0 4.5 1.5 Concrete Temp. 95 70 Concrete W/C 0.41

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PCC-Control Charts
What are the charts showing? High Slump Lower Slump

Strength Loss Strength Gain

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Earthwork -Control Charts

48 million CY of earthwork Specified Moisture Content of not less than 2% of Optimum Incentives for density higher than 95%

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On this non-Florida project involving 48 Million CY of embankment, there was a moisture specification for compaction that was required. The specification required that no less than 2 % of optimum moisture to have passing density of 95 % of a T-180, at a minimum and had an incentive for higher compaction than 95%. The first month there was a learning curve to go through on the project. Once the Contractor had an understanding of what they had to do with this material they did very well. The exception was one month where a new crew and foreman were brought on site, who had the learning curve issue to deal with. This is a good example of use of control charts to produce higher quality and make more money as the Contractor received 98% of available incentive on the operations by using control charts on a daily, weekly and monthly basis to control the operation. Information provided by Peter Kiewitt Sons, Inc.

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Earthwork -Control Charts

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This Control Chart is the plot of QC data comparing Density/Moisture Relationship for 121 Proctors. By using these charts, the Contractor , as discussed on the previous page, was able to meet and exceed requirements and earn extra money.

Information provided by Peter Kiewitt Sons, Inc.

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Disposition of Defective Material

Engineering Analysis Report (EAR)

Initiated by Contractor Submitted to Project Administrator Follow FDOT EAR Guidelines

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There are instances where material may not meet the project requirements but based upon analysis by an Engineer, may be left in place, though generally at a reduced payment. As the QC Manager, it may be your responsibility to initiate the EAR process. The Department has published guidelines for the development of an EAR, so you should take advantage of this document and ensure the Engineer utilized is aware of and follows these guidelines. A copy of the guideline follows. Note- as there is no partial pay or acceptance of earthwork not meeting the requirements, this process would not be applicable in most cases.

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Disposition of Defective Material

Disposition of Defective Material

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This is the form used by the Department in cases of Defective Material not meeting specifications or project requirements, which the Contractor desires to leave in place. 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. As you can see, the EAR goes thru a formal process for acceptance. A full size of this form follows.

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Construction Activities
Record Management

Oversee LIMS data entry Verify QC record completeness and submittal Verify completion & submittal of Certifications Consult on Final Estimate issues

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It isnt over until the paperwork is done. A truism in todays construction industry, especially as it relates to QC. The Department uses the Laboratory Information Management System (LIMS) for the storage of all sampling and testing information, except for earthwork densities, which are maintained in a Contract Earthwork Record System. The QC sampling and testing data must be entered into this system. You need to ensure that personnel assigned to LIMS entry, have the appropriate access and training to use the system. Untrained, inexperienced and careless personnel will only create problems in the LIMS data entry, which are problems for you. Choose carefully. Each month you will be responsible for submitting the Contractor Monthly Certification(s), Forms 700-020-02 & 700-020-03, certifying as to the accuracy and completeness of the sampling, testing and reporting performed.

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Certificate of Compliance
105-2 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. This notarized certification will also be required as a final Certification summarizing all QC exceptions before final payment will be made in Accordance with 9-9.
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SECTION 105 CONTRACTOR QUALITY CONTROL GENERAL REQUIREMENTS 105-1 General. Certain operations require personnel with specific qualifications. Certain materials require production under an approved QC Plan to ensure that these materials, whether manufactured or processed, or procured from suppliers or subcontractors, meet the requirements of the Contract. Applicable materials are identified in 6-8. For all applicable materials included in the Contract, submit a QC Plan prepared in accordance with the requirements of this Section to the Engineer. Do not incorporate any of these materials into the project prior to the Engineers approval of the QC Plan. 105-2 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. This notarized certification will also be required as a final certification summarizing all QC exceptions before final payment will be made in accordance with 9-9. This form, 700-020-02, is available from the FDOT website.

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QC Manager Requirements
Construction Compliance with Specification and Plans

QC Manager is responsible for signing the form monthly.

This form, 700-020-02, is available from the FDOT website. A full size of this page follows.

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Certificate of Compliance
What is the intent of this form?

What is an Exception?

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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.

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Certification Form Exceptions

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 (EAR) performed, Disposition of Defective Material (DDM) 3. Any failed QC samples. 4. Any QC samples that do not have results entered into LIMS. 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.
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Instruction Page- 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 (EAR) performed, Disposition of Defective Material (DDM) 3. Any failed QC samples. 4. Any QC samples that do not have results entered into LIMS. 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. MEMORANDUM NO. 32-03 states: This new form is effective for all applicable contracts starting January 1, 2004. Exceptions: Same as above. NOT Exceptions: 1. QC samples that have been tested but not verified. 2. QC samples that have been tested and had verification tests results that did not compare.

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QC Manager Requirements
Who signs this form?

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Quality Control Manager: Signature of the Quality Control Manager signing the certification. By: Type or print the name represented by the signature in Quality Control Manager:" section. Title: Type or print the title of the person signing the certification.

Contractor: To be signed by an officer or director of the Contractor with an authority to bind the Contractor. By: Type or print the name represented by the signature in the Contractor signature block. Title: Type or print the title of the person signing the certification.

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QC Manager Requirements
What does signing this form mean to you?

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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 Contractors Certificate of Qualification being suspended.

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Certification of QC Inspection

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This form, which may or may not be required depending upon project requirements, is executed monthly certifying that all QC Inspections were performed in general accordance with project and specification requirements. It has the same implication as the previous certification.

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Certification of QC Inspection

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In executing this form, you are certifying that all QC inspection, sampling and testing was performed in accordance with project and State policies, requirements and procedures. If you sign this form, knowing that it is not true, you can be held liable and prosecuted under State and Federal laws.

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Disciplinary Actions
Can your QC Manager Qualification be suspended? Can a QC Manager be disqualified?

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7.5 Suspension of a Quality Control (QC) Manager 7.5.1 Background The Department began training and qualifying QC Managers in November, 2001. Construction Training and Qualification Program (CTQP) qualified QC Managers were required on FDOT construction projects that include Contractor Quality Control (CQC) Specifications let after July 1, 2002. Through the Construction Project Administration Manual (CPAM), Chapter 13.1, the Project Administrator has the ability to initiate a Deficiency Letter (DL) as a direct result of deficient project quality control plan (Specification 105). While a DL may document deficient Prime Contractor quality control plan, it does not have an effect on the QC Managers CTQP qualification. This procedure details how the Department can document and (if necessary) disqualify a QC Manager that is not correctly performing required duties.

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Contractors Past Performance Rating

CPAM, Chapter 13.1

PA issues Warning Deficiency Letter (WDL) to Contractor OR Resident Engineer issues Deficiency Letter (DL) to Contractor Contractor has 10 days to file appeal with RE Appeal is meeting with District Construction Engineer If appeal is successful, DCE issues letter rescinding the DL
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7.5 Suspension of a Quality Control (QC) Manager 7.5.2 Causes for Letters of Warning The Prime Contractor has responsibility for quality control under Contractor Quality Control (CQC) contract specifications. Although the Department has a contractual relationship with the Prime Contractor, the Department also has a responsibility to ensure CTQP qualified technicians are correctly performing their duties. While quality control is a contractual responsibility of the Prime Contractor, it is the direct responsibility of the QC Manager to ensure compliance with Specification 105. The Project Administrator has a mechanism to document Prime Contractor deficient performance (see CPAM Manual, Chapter 13.1). When the Resident Engineer sends a DL that is directly related to a deficient quality control plan due to the QC Managers failure to properly apply the specifications and Quality Control procedures, a letter of warning (or suspension) must also be sent to the QC Manager. CPAM, Chapter 13.1 (2) Warning Deficiency Letter (WDL): The Project Administrator will issue the WDL letter (Refer to the Guidance Documents for this section), under normal circumstances, to notify the Contractor of shortcomings/non-compliances with the contract. Prior to issuing a WDL, the Project Administrator should discuss the performance concerns with the Resident Engineer. A single WDL can be used to address concerns in more than one performance category. However, blatant violations or non-compliances may result in a Deficiency Letter being issued without a warning. The WDL may be sent certified mail or delivered to the Project Superintendent with the Project Superintendent signing to acknowledge receiving the WDL. (3) Deficiency Letter (DL): The Resident Engineer will issue a DL to the Contractor for the sole purpose of addressing continual performance concerns and issues that were previously documented by a WDL or blatant violations or non-compliances.

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QC Manager Suspension
Qualification Suspension by a 3 letter system

Letter of warning issued by the State Construction Training Administrator (SCTA) 2nd Letter of warning issued by SCTA within one year of first 3rd letter suspends qualification Suspension is for one year Decision may be appealed to the Director, Office of Construction
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7.5.3 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 (see Attachment 2). 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 Managers 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. The suspension shall be for one calendar year (365 days). This decision may be appealed to the State Construction Engineer. The State Construction Engineer's decision is final. Prior to having the qualification reinstated, the technician must meet all initial QC Manager qualification requirements including passing the QC Managers 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.
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Lesson 6- QC Manager Role & Responsibilities

Post-Construction Activities
Asphalt Amounts/Certifications/Reports LIMS/Sampling & Testing Material Certifications Earthwork Record System Disposition of Defective Materials Shop Drawings As-builds
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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. The FDOT website contains some of the the forms needed at this time. www.dot.state.fl.us/proceduraldocuments

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Lesson 6- QC Manager Role & Responsibilities

Learning Outcomes

Review the Learning Outcomes achieved during this lesson.

Describe QC Managers role & responsibilities Describe the QC Managers duties Describe the QC Managers reporting requirements

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Questions?

ANY QUESTIONS ?

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Do you have any questions.

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