Quality Assurance Program (QAP) Manual

1. Quality Assurance Program (QAP) Manual

2. 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

3. 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

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

6. What is a QAP?

7. 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…”

8. 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.”

9. 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)

10. 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

11. 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

12. Caltrans Acceptance Program • CT Construction Manual, Chapter 6: “Sampling and Testing” http://www.dot.ca.gov/hq/construc/manual2001/chapter6/

13. 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

14. 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!

15. 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?

16. Developing a QAP

17. Definitions

34. Acceptance Program Fundamentals

37. 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

38. Acceptance Testing

39. Lot size: 4500 tons Sublot: 750 tons

41. Caltrans Construction Manual

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

43. 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.

44. 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

45. 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

46. Testing Alternatives

47. 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

48. 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

49. 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)