CVE 4070 Construction Engineering Quality Control Value Engineering Prof. Ralph V. Locurcio, PE

Quality Control

Savings from quality

Quality control tools…

Pareto analysis…

Control chart analysis…

Preconstruction Conference… Conducted by owner’s representative Owner & user may attend Sets tone for the project General agenda items: Review contract docs, award & notice to proceed info Responsibilities of all parties Review schedule & payment; contingencies; damages Quality Control Plan & inspection procedure Submittals: shop drawings, samples, record drawings Changes, mods & claims procedures Site safety & operational considerations Labor & union procedures: EEO, Davis-Bacon wages Emergency procedures & work stoppage Project Closeout & Beneficial Occupancy

Quality Control & Assurance… Quality control vs. quality assurance Required on government contracts Inspection & Testing manual Policy matters that govern acceptance Inspection procedures Technical checklists List of testing for materials & equipment Work flow diagrams

Quality Control Process… Must have a Quality Control Plan or Manual An inspection" system” Special considerations: Timing of inspections; preclude delays Protection of work in place Most work is irreversible; i.e.. concrete, foundations Logistical sequencing Follow plans & specifications; changes not authorized Report and correct errors & deviations from spec; documents Three phased inspections… before each task Preparatory inspection Pre-inspection Final inspection QC Staff must be qualified, trained & dedicated

Inspection & Testing Manual… Detailed inspection procedures: Preparatory inspection: work flow, submittals, methods Initial inspection: workmanship & components Follow-up: results of work, tests, appearance Acceptance/rejection criteria… per specs Testing required & frequency… specs & sched Responsibilities for testing… specific names Outside labs & testing agencies… list or schedule Timing of inspections & work… WBS & sched Reports required, frequency & format… contract Documentation of test results… contract

Value Engineering

What is VE… really? VE is a “systematic” analysis of a project design to obtain the most value for every dollar of cost… The elimination of any part of the project that adds to cost without adding to functionality… Not only design & construction, but life cycle costs as well…

A second look at the design… Major cost items Materials cost & availability Construction methods Shipping costs Organizing & project admin But…

Most productive when… Contractor is involved Advantage of contractor’s expertise in purchasing, construction methods, organizing, techniques and quality control… Generally requires an incentive clause in the contract…

But there’s are risks… VE analyst may not fully understand the design basis… VE generates changes that could delay project completion… VE may not recognize field conditions that might outweigh cost savings… VE could result in lower quality components…

Role of the owner’s representative... Advocate for the owner & the project… Control the risks… Retain the overall value of the project

VE in the design phase… VE considers costs related to: Materials Labor Equipment Overhead & supervision

Costs related to materials… Transportation or shipping Testing cycles Complex inspections Tolerances Fabrication process

Costs related to labor… Quality of workmanship needed Excavation Forming or finishing Fitting Availability materials that reduce labor Construction timing

Costs related to equipment… Allow use of high production equipment Reduce need for special equipment Minimize haul distances Not force use of special equipment

Costs related to overhead… Special security requirements Limited site access or laydown areas Complex supervision or inspection

Cost saving design features… Duplicate members Use modular components Simplified structural components Eliminate special forming or finishing Siting to reduce excavation Specify local materials Use simple, clear or standard specs Use prebid conferences

VE in construction phase… Study physical features such as topography, geology, climate… Construction phasing to minimize use of high cost equipment or labor Modify construction methods to reduce forming or finishing Increase use of new or high production equipment Substitute materials or components that reduce cost

The VE process… Information or study Brainstorming Analysis Development of alternatives Presentation Follow-up

Brainstorming techniques Set time limits Record all ideas; quantity vs. quality Avoid judgment, detail or analysis Neutral controller Light free flowing atmosphere Non-competitive; all contribute Review and categorize at end

Presentation Describe the process & alternatives Pros & cons of alternatives Compare costs of original & VE Compare quality & functionality Present an implementation plan Show cost savings to owner

Contractor incentives… Generally 45% of any real savings Must share with sub-contractors Important to include in contract VE suggestions are proprietary

Role of the owner’s rep Be the advocate for the owner & the project… Control the risks… Keep the overall value of the project in perspective…

Cost Estimate HW

Cost Estimate-1

What are the elements?

What are the elements? Foundation – units? Floor slab – units? Floor covering - vinyl Exterior walls – vinyl siding Interior walls – wallboard Insulation – exterior walls Ceiling - wallboard Roof – slope is 4/12

Cost Estimate-2

Cost Estimate-3

Cost Estimate-4

Cost Estimate-5 r = 16 + 144 r = 160 r = 12.649 Roof Calculations… Roof slope given as 4 on 12 slope…. So… how much larger is the sloped roof than the flat roof? Roof slope factor = 12.649/12.000 = 1.054 So the sloped roof will be 1.054 x area of the flat roof r 4 12 r2 = 42 + 122 r = 16 + 144 r = 160 r = 12.649

HW #6 Due on Thursday Bring your solution to class We will correct your HW in class Also, study guide for Test 2 Test 2 is next week on Oct 27th

Questions?

Case Study A chemical facility was to be redesigned. A key requirement was that the new design should operate at a higher efficiency than the existing facility. The plant operator had completed conceptual engineering and simulation to finalize the process flow scheme. There was considerable skepticism that value engineering might improve the design. However, the client was open-minded and the engineering team persuasive and it was agreed that the exercise would proceed. The value engineering facilitator prepared functional flow diagrams. A representative of the operator and several contractor engineers from different disciplines met for 2 sessions, each of which lasted for 4 hours. During these well-planned and carefully facilitated sessions, 12 ideas were generated, of which 6 were deemed practical. The most significant idea that emerged from these focused brainstorming sessions was to change a column configuration from parallel to series, thereby saving significant condenser costs and improving the energy efficiency tremendously. The idea was refined and implemented. Overall, the capital cost saving was about $1 million (5% of total capital), with an operating cost saving of about $4 million/year.

Ethics Paper due Nov 27 NSPE Rules of Professional Conduct Read all of the rules Summarize each of the obligations in one paragraph Pick a case study: 1,7,58,58,60 Write a 2-page paper applying the NSPE rules to the situation in the case What errors were made How should the engineer behave in the case