BOS – Structures Maintenance Fabrication Initiative Richard Marz, PE Chief, Structures Maintenance WisDOT – Bureau of Structures

Richard Marz, PE Chief, Structures Maintenance WisDOT – Bureau of Structures BOS – Structures Maintenance Fabrication Initiative

BOS Fabrication Improvement Process Define the Business Plan for the Shop Fabrication Unit Define unique needs for Mega Projects and Role of Shop Fabrications within Develop organization Chart for the Shop Fabrication Unit Develop clear Roles and Responsibilities of Unit Staff

Gather information : Interviews conducted with Steel Producers and fabricators – CANAN/Structal – Tony Matutis – High Steel, Lancaster PA Ronald Medlock, Vice President – ISC, Gary IN – Francisco Leal – Veritias Steel, Wausau WI Ray Isaelniks, QC Manger

Gather information : Contacted other Departments of Transportations – Florida, Illinois, Indiana, Iowa – Michigan, Minnesota, Ohio, Pennsylvania – Tennessee, Texas

Gather information : Interviewed Bureau of Structures Staff Interviewed Regional WisDoT Staff Interviewed Consultants working on WisDot Mega Projects

Results of Interviews: WisDoT Procedures not well defined Communication concerns No consistency between projects Process differs from state to state Quality Assurance vs. Quality Control

Development of WisDot Process Focus on Quality Assurance Define Core components of WisDot Re – organize the Fabrication Unit Development of a Fabrication manual

Development of WisDot Process Key requirement The Fabricator/Detailer is required to provide a quality control review that includes AT A MINIMUM the items noted in Section 4 of NSBA G1.1. To verify that these checks were performed, the Fabricator/Detailer is required to submit the checklist of review items contained in G1.1 Section 4. The reviewer must initial and date each of the sections, 4.1 – 4.16 verifying that the items in that section were reviewed for accuracy as compared to the design drawings. The reviewer must be a licensed Professional Engineer and must stamp, sign, and date the submitted checklist. (Certificate of Shop Drawing Quality Control) In addition, there will be a location for the GC to sign and date.

Development of WisDot Process TWO LEVELS of SHOP DRAWING REVIEWS – LEVEL 1 All Shop Drawings are required to have the submitted checklist ( Certificate of Shop Drawing Quality Control) completed, signed and submitted by the Fabricator/GC. – LEVEL 2 A percentage of structures will be reviewed based on NSBA shop drawing review guidelines. Selection will be based on a number of factors, including complexity and size.

What is the anticipated timeline for the updated fabrication process?

Phase 1 Anticipated to begin with the May 2015 Letting – All steel fabrication documents will need to be submitted to the SFU utilizing SharePoint. (New) – A Fabricator Quality Management Plan (QMP) and a General Contractor QMP will be required for each WisDOT project. (New) A Shipping Plan, Erection Plan, and Storage Plan will be outlined within the QMP. The intent is document the entire process. (New)

Phase 1 (Cont’d) Anticipated to begin with the May 2015 Letting – Contractor’s submitted checklist (Certificate of Shop Drawing Quality Control) with GC signature will be required for each structure (PE Stamp not required until Phase 2) (New form) – The fabricator will be required to submit regular (weekly) updates (Fabrication Project Status Record) listing deliverables and anticipated submission dates for the project.(Updated form)

Fabrication Project Status Record Form DT2172, the Fabrication Project Status Record, has been updated to include photos and require a signature by the fabricator QC representative. This form will need to be submitted on a regular (weekly) basis. (Draft)

Contractor’s Shop Drawing Checklist

Phase 2 Phase 2, Beginning with August Let Projects – All phase 1 requirements, PLUS – Contractor’s Shop Drawing Checklist (Certificate of Shop Drawing Quality Control) with PE stamp and GC signature will be required for each structure – Shop drawings submitted with this certificate incomplete, lacking the PE stamp, or missing altogether will not be accepted.

How will fabrication documents be submitted to the SFU? SharePoint, a web application that is used for document and file management. You need no special software, just a login which will be assigned by Bureau of Structures staff. Training will be provided prior to the implementation of SharePoint.

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