Construction Management Materials acceptance and quality assurance program (Qap)

Materials Acceptance & QAP Reference: LAPM Chapter 16.14 Caltrans QAP 2015

Quality Assurance Program Sampling and testing program that provides assurance that the materials and workmanship are in conformance with the contract specifications Main elements are acceptance testing and independent assurance sampling and testing

Quality Assurance Program Requirements for the type of QAP depends on the project. National Highway System (NHS) - Caltrans QAP Non-NHS - Local agency may adopt their own QAP, or adopt Caltrans QAP.

NHS Projects Local agencies must follow Caltrans QAP Independent Assurance Sampling and Testing (IAST) is performed by Caltrans Consultant testing firms will participate in approved Caltrans correlation testing program AMRL - AASHTO Materials Reference Laboratory CCRL - Cement and Concrete Reference Laboratory RSP - Caltrans Reference Samples Program

NHS Projects Methods for accepting material: Sampling and testing Source Inspection Certificate of compliance for manufactured products Products must not involve structural integrity or safety to the public

Non-NHS Projects Local agencies must adopt a QAP, may be Caltrans QAP. QAP must have as a minimum: Manufactured Materials Source Inspection Job site inspection Certificate of Compliance Acceptance Testing Regular testing of material to verify it complies with the contract IAST - procedures Verify that acceptance testing is performed correctly Must be approved by the Public Works Director. Non-registered PWDs must delegate to a City Engineer who is registered.

Sampling and Testing Preliminary Samples and Tests Used to determine the ability of material or product to meet specifications Indicate to contractor the extent of processing and control required Acceptance Sampling and Testing Should start on the first day material is delivered Indicate to contractor the extent of processing and control required Frequency tables are to be used as a guide.

Acceptance Testing (AT) Initial results should be sent to RE at the earliest possible time Maintain a testing log - identify re-testing of failed material Samples should be taken where specified in the special provisions. If none is identified, sample where indicated in frequency tables

Reporting Test Results Sieve Analysis, SE and CV - 24 hours after sampling at materials plant Compaction and Maximum Density - 24 hours after sampling at the job site Sieve Analysis, SE and CV - 72 hours after sampling at the job site R-Value and asphalt concrete extraction within 96 hours after sampling

Source Inspection Acceptance testing of manufactured and prefabricated materials at locations other than the job site for Tier 1 and 2 products If local agency cannot perform, and qualified consultants are not available, the agency may request METS to sample METS will only agree to the extent that their inspectors are available - Requires a cooperative agreement. SIQMP - Source Inspection Quality Management Plan from inspection firm.

Tier System

Tier System

Certificate of Compliance Acceptance of manufactured or prefabricated structural materials shall be based on either a Certificate of Compliance and/or source inspection. Contract documents should specify which materials require a Certificate of Compliance. Certified material lot number and project number shall be clearly identified on the certificate and on lot tags.

Independent Assurance Sampling and Testing Purpose of IAST is to: Verify the project sampling and testing is performed correctly; Ensure that equipment is properly calibrated.

IAST Required on all NHS Projects Caltrans will perform IAST RE shall schedule with IA engineer Samples are taken and split for Acceptance Tester and IA tester Results are compared between IA and acceptance tests IA tests are not to be used for acceptance tests

IAST - Non NHS Projects Local agency shall use the IAST procedures described in their approved QAP. Consultant IA testers shall be free of conflicts of interest if also performing other acceptance testing work.

Materials Acceptance Process Notice of Materials to Be Used CEM-3101 List all material to be incorporated into the project

Materials Acceptance Process Determine products to sample and test, source inspect, or accept by certificate of compliance Send CEM-3101 to source inspection firm for material to be source inspected. File copy in CAT 31. Determine if initial sampling and testing is necessary Schedule acceptance sampling and testing based on contractor’s schedule

Materials Acceptance Process Notify Contractor of required Certificates of Compliance Source inspector will send Notice of Inspection and Notice to furnish to suppliers/contractor, and report of inspection reports and material release to RE Remove release tags from material and verify with report of inspection

Materials Acceptance Process File release tags with Report of Inspection in CAT 41 File Certificates of Compliance with CEM-4102 in CAT 41 Material inspected at the project site - record on CEM- 4102 in CAT 41

Materials Acceptance Process File initial test results in CAT 29 File acceptance test results by item in CAT 37