2021 Materials Training - Deb Bischoff Quality Management Program Engineer

2021 Materials Training

          Deb Bischoff
Quality Management Program Engineer
          2021 Materials Training

                April 2021

Materials
               Standard Spec 106: Control of Materials
• All materials must be approved before they are
  incorporated into the work.
   Materials approved when conformance is
    demonstrated
   Conformance based primarily on testing
        Manufacturer
        Department
        Contractor

Quality Management Program (QMP)

Quality Management Program (QMP)
• QMP is a method of department acceptance
• Under QMP specifications, the department bases
  approval on:
   Contractor quality control (QC) testing
   Department quality verification (QV) testing
   Inspections of material production, storage and handling,
    and construction processes
   Documentation and reporting

Contractor
                 QC

 Dispute                     Department
Resolution                      QV

              QMP
Independent                    Personnel
 Assurance                    Certification

               Qualified
              Laboratories

                                              5

• Our 3 big materials: Base Aggregate, Concrete, and HMA
• Pavement Ride Quality
• Density Testing
     HMA Pavement Nuclear Density & HMA Pavement PWL
     Base Aggregate Compaction
     MSE Wall, Mill & Relay, Pulverize & Relay, CIR

• Material or work that is not accepted by QMP or by
  certification/APL, are accepted based on department
  testing.
• That testing falls under our larger ‘Quality Assurance’
  umbrella

Non-Conformance & Non-Performance
• NonConformance (NC): pertains to the physical material or work
  not meeting specifications as determined by testing, inspection, or
  other approval activities.

• NonPerformance of QMP (NP): pertains to insufficient actions
  executed under the requirements of QMP specifications.

NonConformance
• Materials must conform to various properties or an AASHTO/ASTM material standards
• When material fails to meet any of the specified properties, it is NonConforming
• NonConforming or non-approved materials should not be incorporated into the work.

NonConformance Examples for QMP and Non-QMP Materials
QMP Materials                                     Non-QMP Materials
• Base Aggregate                                  • Backfill
     NC gradation
     Low fractured faces
                                                       NC gradation
     High plasticity or liquid Limit                  High plasticity or liquid limit
• Concrete                                        • Geosynthetics—Geotextile Fabrics or Geogrids
       High/Low air
       High/low slump
                                                       Low grab tensile strength, low puncture strength, etc.
       Low strength                              • Document indicates wrong ASTM/AASHTO standard
       NC gradation
                                                       PMCs should detect this and not allow the material
• HMA                                                   to be incorporated into the work
       High/low Air Voids
       Low VMA                                   • Product not on a required department-approved list
       Low TSR                                        PMCs should detect this and not allow the material
       NC Asphalt binder                               to be incorporated into the work
       Low Density (or high for SMA pavements)

Importance of Project Materials Coordinators

• Immediately bring material issues and concerns to light.

• Prevent material problems from compromising the quality and
  acceptability of the work.

PMCs and Their Role in NonConformance

• Material approval prior to use
    Review documentation
    Review pre-placement test results
• PMCs notify other party immediately of NC material
    Act on the information

NonConforming Material

• The disposition of NonConforming materials is the engineer’s decision.
• NC materials allowed to remain in place are subject to a pay reduction.
• Some of the department’s specifications include pay reduction amounts or ranges for different levels of
  NonConformance. For those that don’t, refer to CMM 810 for guidance.
• The engineer must consult with the regional materials engineer for all NonConformance pay reductions.
• Document all NonConformance issues and resultant pay reductions in the DT1310.

NonPerformance Examples
• Missed Sample(s) / Test(s)
• Wrong sample or test location (non-random)
• Improper documentation and/or reporting
• Insufficient WisDOT notification
• Non-certified sampler / tester
• Unqualified laboratory or equipment
• Improper sampling or testing method

PMCs’ Roles in Reducing or Eliminating NonPerformance

• Work together
    Forecast upcoming work & corresponding requirements
    Communicate with all parties to ensure nothing gets missed
• Proactive Communication is key to success

Nonperformance of QMP Trend
               Total Nonperformance Reported Occurrences Statewide per Year
400
                                                            368
350

300

250                                252
         233
200
                                                                                 178
150

100

50

 0
      2016                      2017                     2018                 2019

Nonperformance of QMP

• Project Staff must run NonPerformance disincentives
  through the regional materials engineer.
• Ensure fairness and consistency throughout the region.
• Document all QC and QV NonPerformance Issues in the
  DT1310, Certification of Materials Report

                                                           17

Questions?

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