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Quality Assurance Program (QAP) Manual. Objectives. Define a Quality Assurance Program (QAP) Review common terminology Discuss the fundamentals of an acceptance program Discuss the fundamentals of an independent assurance program Develop a QAP for your local agency needs

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Quality assurance program qap manual

Quality Assurance Program (QAP) Manual


Objectives

Objectives

  • Define a Quality Assurance Program (QAP)

  • Review common terminology

  • Discuss the fundamentals of an acceptance program

  • Discuss the fundamentals of an independent assurance program

  • Develop a QAP for your local agency needs

  • Discuss lessons learned


Reference manuals

Reference Manuals

Caltrans Division of Local Assistance Publications

http://www.dot.ca.gov/hq/LocalPrograms/index.htm

Local Assistance Procedures Manual (LAPM) ( February 10, 2009)

Section 16.14:

Quality Assurance Program

Section 19:

Oversight and Process Review


Reference manuals1

Reference Manuals

Quality Assurance Program (QAP) Manual for Use

by Local Agencies (January 20, 2011)


What is a qap

What is a QAP?


23 cfr 637 205

23 CFR 637.205

The Code of Federal Regulations (Title 23, Section 637.05) states a state transportation department shall:

“…develop a quality assurance program which will assure that the materials and workmanship incorporated into each Federal-aid highway construction project…are in conformity with the requirements of the approved plans and specifications…”


Quality assurance program qap manual

LAPM

Local Assistance Procedures Manual

Chapter 16.14, “Quality Assurance Program”

“A sampling and testing program that will provide assurance that the materials and workmanship incorporated in each highway construction project are in conformance with the contract specifications.”


Qap manual requirements

QAP Manual Requirements

Quality Assurance Program (QAP) Manual for Use by Local Agencies (January 20, 2011)

  • Caltrans requires that local agencies receiving funds for a Federal-aid transportation project must have a QAP

  • Updated as needed, at least every 5 years

  • QAP shall be approved by the Public Works Director (Section 3.2)


Qap manual

QAP Manual

Quality Assurance Program (QAP) Manual for Use by Local Agencies

(January 20, 2011)

A QAP consists of:

  • Acceptance Program

  • Independent Assurance (IA) Program


Qap requirements on the shs

QAP Requirements on the SHS

  • The Caltrans Department of Transportation (Caltrans) Construction Manual

  • The Caltrans Independent Assurance Manual

  • Caltrans approved plans and specifications

  • Caltrans Test Methods

    (http://dot.ca.gov/hq/esc/ctms/index.html)

  • Caltrans Local Assistance IA staff provides IA services


Caltrans acceptance program

Caltrans Acceptance Program

  • CT Construction Manual, Chapter 6: “Sampling and Testing”

http://www.dot.ca.gov/hq/construc/manual2001/chapter6/


Caltrans ia program

Caltrans IA Program

  • Tester Qualification

  • Laboratory Accreditation

    • District IA Staff

    • Local Assistance IA Staff under METS

  • Reference Sample Program

http://dot.ca.gov/hq/esc/Translab/ormt/IA_reports/2005_IA_Maunal.pdf


Qap requirements on the nhs but off the shs

QAP Requirements on the NHS(but off the SHS)

  • Need a QAP

    • Acceptance Program/ IA program

  • Plans and Specifications based on a nationally recognized standard

    • Caltrans

    • Greenbook

  • Test Methods based on a national standard

    • Caltrans

    • American Society of Testing and Materials (ASTM)

    • American Association of State Highway and Transportation Officials (AASHTO)

  • Independent Assurance Program

    • Caltrans if CT test methods are used!


Qap requirements off the nhs

QAP Requirements off the NHS

  • There is flexibility, BUT

    • Still need a QAP!

      • Acceptance Program

      • Independent Assurance Program

  • And what if your agency has projects that are on the SHS, NHS and off the NHS?


Developing a qap

Developing a QAP


Definitions

Definitions


Acceptance program fundamentals

Acceptance Program Fundamentals


Types of testing

Types of Testing

  • Preliminary Sampling and Testing

    • Materials used on the job prior to award

    • Test for suitability for a project

  • Acceptance Testing

    • Testing of material entering the work

    • Ensure materials meet specification requirements

  • Source Inspection

    • Acceptance Testing of manufactured or prefabricated materials at locations other than the job site

  • Independent Assurance and Sampling and Testing

    • Dependent upon the Independent Assurance (IA) program used by the agency


Acceptance testing

Acceptance Testing


Quality assurance program qap manual

Lot size: 4500 tons

Sublot:

750 tons


Caltrans construction manual

Caltrans Construction Manual


Ct method of test for evaluation of aggregate for lean concrete base lcb

CT Method of Test for Evaluation of Aggregate for Lean Concrete Base (LCB)


Quality assurance program qap manual

From QAP Appendix D: Sampling and Testing FrequenciesPortland Cement Concrete (or Hydraulic Cement Concrete)

Sampling: Testing:

*Test every 500 cubic yards of concrete. For paving, test for flexural strength once every 500 cubic yards of concrete. For structural concrete, test two cylinders for compressive strength for every 500 cubic yards of concrete.


Quality assurance program qap manual

Websites for Additional Testing Standards

· American Society for Testing and Materials (ASTM)

http://www.astm.org/

· American Association of State Highway and Transportation Officials (AASHTO)

https://www.transportation.org/

· National Institute of Standards and Technology (NIST)

http://www.nist.gov/

· California Test (CT) Methods

http://www.dot.ca.gov/hq/esc/ctms


Reporting of testing results

Reporting of Testing Results

  • Timely reporting of results to the Resident Engineer

  • Typical tests and times:

    • Sieve analysis – 24 hours

    • Sand Equivalent – 24 hours

    • Cleanness value – 24 hours

    • R-value – 3 days

  • Some tests take time!

  • Testing frequencies and lot sizes can require a great deal of testing


Testing alternatives

Testing Alternatives


Certificate of compliance coc

Certificate of Compliance (COC)

  • Alternative method of acceptance testing

  • Method to accept prefabricated or manufactured items brought to job site

  • Certificate by the manufacturer

    • Specific to project

    • Includes lot number

    • Statement of specification compliance (applicable section)

    • Signed by manufacturer


Quality assurance program qap manual

Example of a Vendor’s

Certificate of Compliance

This is to certify that the Portland Cement

Supplied by ABC Cement Company complies with all requirements for Type II Portland Cement when tested in accordance with ASTM C - 494.

Local Agency Project No. Albert Howakowa HP21L – 5055 – 111 Quality Assurance Engineer ABC Cement Company

Date:08/20/14


Quality assurance program qap manual

Construction Materials Accepted by a Certificate of Compliance

Structural Metal Plate Pipe Arches and Pipe ArchesPerforated Steel PipePolyvinyl Chloride Pipe and Polyethylene TubingSteel Entrance Tapers, Pipe Downdrains, Reducers, Coupling Bands and Slip JointsAluminum Pipe (Entrance Tapers, Arches, Pipe Downdrains, Reducers, Coupling Bands and Slip Joints)Metal Target PlatesPaint (Traffic Stripe)ConductorsPainting of Electrical EquipmentElectrical ComponentsEngineering FabricsPortland Cement, Mineral Admixtures and Chemical AdmixturesConcrete Coarse Aggregate (Cleanness Value)Concrete Fine Aggregate (Sand Equivalent)PCC AdmixturesMinor Concrete Liquid AsphaltAsphaltic EmulsionsEpoxyHot Mix Asphalt (Quantities Less Than 10 Tons)


Independent assurance ia fundamentals

Independent Assurance (IA) Fundamentals


Quality assurance program qap manual

An Independent Assurance Program ensures the sampling and testing is performed correctly and the testing equipment used in the program is operating correctly and remains calibrated. It involves a separate and distinct schedule of sampling, testing and observation.

http://www.fhwa.dot.gov/pavement/materials/hif12001.pdf


Ia main components

IA Main components

  • Qualification of Personnel

  • Laboratory Accreditation

  • Equipment Calibration

  • Proficiency Testing

  • Corroboration Testing

  • Dispute Resolution


Types of ia programs

Types of IA Programs

  • Project Based

    • 10% of acceptance frequency

    • Independent Assurance Sampler and Tester performs IAST test independent of acceptance tester on a project by project basis

  • System Based

    • 90% of testers once or twice a year

    • Personnel qualifications are evaluated through written examinations, witness tests and corroboration testing

    • Annual report requirements


Quality assurance program qap manual

Project Based


Examples and frequencies of witness testing

Examples and Frequencies of “Witness Testing”


Ia program alternatives

IA Program Alternatives

  • Require independent lab accreditation

  • Hire an outside qualified consultant to perform IA services

    • Cannot perform acceptance testing

  • Use a qualified employee from within the local agency to perform IA services

  • If using CT test methods, Local Assistance IA personnel is available


Quality assurance program qap manual

AASHTO Certificate of Accreditation


Quality assurance program qap manual

  • AASHTO

  • Accreditation

  • Details

  • Look for:

  • Location

  • Test Methods

  • Expiration date 2 years after accredited.


Quality assurance program qap manual

  • Army Corps of Engineers

  • Look for:

  • Location

  • Test Methods

  • Expiration date


Qap section 5 0

QAP Section 5.0

If the local agency has an in-house IA Program

  • IA person should have familiarity with materials testing

  • IA staff must remain INDEPENDENT from acceptance testing

    • Main function is to “test the acceptance tester”

  • Certify personnel within organization

  • Not valid for project outside IA’s agency jurisdiction

  • IA person should be first certified in the test method used in certification; e.g. if ASTMs are used, IA person must be certified in ASTMs by recognized entity.

  • Participate in a proficiency testing program


Aashto materials reference laboratory

AASHTO MaterialsReference Laboratory

http://amrl.net


Cement and concrete reference laboratory

Cement and ConcreteReference Laboratory

http://www.ccrl.us/


Qap and lessons learned

QAP and Lessons Learned


Qap appendix y

QAP – Appendix Y

Sample of QAP that

has been used

by most if not all.

First lesson learned:

One size does NOT fit all!


Objectives1

Objectives

  • Define a Quality Assurance Program (QAP)

  • Review common terminology

  • Discuss the fundamentals of an acceptance program

  • Discuss the fundamentals of an independent assurance program

  • Develop a QAP for your local agency needs

  • Discuss lessons learned


Caltrans l a i a engineer

Caltrans L.A.I.A. Engineer

Bomasur Banzon, Lead IA Eng (HQ)

(916) 227-7234

Ignocencio Herrera, Dist. 1, 2, &3

(916) 227-7192

David Small, Dist. 4, 5, & 6 (northern)

(916) 247-7923

Seree Yenjai, Dist. 6 (southern), 7, 8, &9

(916) 247-1911

Afsaneh Ostovar, Dist. 11 & 12

(916) 247-6311


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