Construction Quality Assurance/Quality Control Program

Transcription

1 Construction Quality Assurance/Quality Control Program CUIRE/UCT Trenchless Technology Engineering and Inspection School January 28 & 29, 2007 Hilton Americas, Houston, Texas Gerhard (Gerry) P. Muenchmeyer, P.E.

2 EPA Estimates Need According to the EPA, $388 billion is required for sewer rehabilitation and $274 billion for water renovation over the next 20 years in this country. That equates to over a $33 billion a year need 2002 EPA Clean Water Needs Survey (CWNS)

3 Projections Underground Construction magazine estimates that water & sewer rehabilitation spending in 2007 will exceed 4.1 billion. 8 th Annual Municipal Sewer & Water Survey

4 Potential For Manhole Rehabilitation Over 20 million existing manholes in the US 4 million are over 50 years old Over 5 million are years old Current expenditures are at $100 million/year Projected annual expenditures estimated at $500 million 2003 Wade & Assoc.

5 Potential Lateral Sewer Rehabilitation Over 72 million existing sewer laterals in US Over 48 million laterals will need replacement over the next 20 years At a cost of $2000 each = $72 billion $4.8 billion annually Estimate 20% trenchless = $1 billion/year

6 Potential Near Future Market Trends Future market for Trenchless Pipeline Renovation could be in excess of $5 billion per year Expanding Opportunities in the US Water & Sewer Pipe Renovation Industry Grant Whittle

7 Why The Increasing Demand For Pipeline Rehabilitation? Increased public awareness of the aging and deteriorating underground pipeline infrastructure Elimination of Combined Sewer Overflows (CSO s) Elimination of Sanitary Sewer Overflows (SSO s) Frequent emergency pipe failures NPDES permit requirements EPA consent decrees requiring pipeline renovation GASB 34 CMOM

8 Why Trenchless vs Excavation? Easier-faster Cleaner-safer Typically lower in cost Minimal or no utility impact Minimal environmental impact Typically no surprises/change orders 50 year design life when properly installed Significant social & political benefits

9 Technology Choices

10 Quality Assurance/Quality Control (QA/QC) Testing and Inspection Its All About Raising The Industry s s Quality Level

11 Background Trenchless technologies have improved significantly over the last 30 years (evolution) Industry standards have been developed over those years (trial and error) Many sources available for obtaining technology (products are now commodity items) But technologies, in some cases, do not perform as expected (wrong tool or wrong specifications) Occasionally customers suffer the inconvenience of accepting inferior products or have the expense of subsequent replacement (customer satisfaction has not been achieved?)

12 Why Are Some Technologies Not Performing As Expected or Failing? Wrong technology selected for the project Poor installation or application by untrained applicator Incomplete or vague project specifications Poorly enforced specifications Minimal or no project QA/QC Weak or no testing requirements Lack of technology training for inspection personnel

13 What is a Failure? The Technical Council on Forensic Engineering of the American Society of Civil Engineers (ASCE) defines failure as:.an un-acceptable difference between expected and observed performance

14 Project specific grouting pressures and procedures included in the Quality Assurance plan could have prevented this pipe collapse. Is this installation a candidate for repair or replacement?

15 Is the lift in the bottom of the liner repairable or is total replacement required?

16 Quality controls for existing pipe measurement and liner fabrication may have prevented folds in the cured pipe. Is this a candidate for repair or replacement?

17 Specified employee qualification requirements would have prevented this.

18 Project Problems Commonly Encountered Project requirements, in many cases, are based on specific manufacturers technical requirements and recommendations Standards are specified but not adequately enforced Low bids are received based on poorly written specifications resulting in poor quality work and extra work orders Trenchless technology inspection requirements, during construction, are not fully understood or enforced. Inspectors are untrained without the necessary tools to assure the quality of a project Poor quality installations are accepted by the Customer after completion of the project.

19 Some Common Technology Issues Customer expectations are not met. Customer relaxes specifications and accepts inferior products. Qualified inspection is not provided or enforced. Remedies for poor performance are not clearly defined in the specifications. Poor project results are directly related to the quality of the specification and the price paid. You Get What You Pay For

20 Quality Product Prerequisite: Good, consistent, quality products meet specification requirements and satisfy the expectations of the Customer Product & technology selection Well written, detailed specification Documented contractor/installer qualifications Quality assurance requirements clearly defined in the specifications Quality control requirements during construction with specified testing program and written documentation Qualified & trained inspector Warranty inspections

21 Correct Product & Technology Selection Product/technology matched to project requirements Minimum qualification (i.e. lineal feet in the ground, square feet applied, quantity & size installed, etc.). References with projects of similar size & application completed. Documented manufacturer s quality control program for the products selected. Longevity or history of material for similar applications. Verified third party testing of the material in a similar environment. Demonstration projects, for new unproven technologies, to verify acceptability for the project application.

22 Correct Specification Prescriptive (Design) Specifications Applicable to custom projects. Detailed installation procedures & requirements are typically defined. Performance Specifications Applicable to commodity type technologies. Leaves the means & methods of construction up to the contractor with defined verification procedures. Combination of Prescriptive & Performance Used for custom designs but with commodity product installation.

23 Performance Specifications Performance based type specifications result in a higher level of performance resulting in a high quality product. Performance specifications are a statement of the project requirements in terms of anticipated results. They define the functional requirements of the product. Have very specific criteria for verifying compliance.

24 Contractor /Installer Experience Must be licensed, certified, trained, etc. in the technology Must have installation history of technology for similar. project size and applications (typically 2-3 years) Superintendent experience (typically 2-3 years) Forman and crew experience

25 Quality Assurance Clearly Defined in the Specifications Must be technology specific. Quality Control Plan submittal required by the Contractor. Raw material & finished product sampling and testing by the customer to verify required product quality. Manufacturer certification requirements. Defined Quality Control implementation procedures during technology installation and completion. Clearly defined repair/replacement criteria for the technology in the event of defects.

26 Quality Control During Construction Verification of the specified QA requirements. Contractor s responsibility for general quality control during project execution. Quality control inspections by inspector fully documented in writing. Becomes part of the project records. Inspector follows documentation guidelines outlined in the specifications. Inspector ensures chain of custody of all materials to be tested. Trained inspectors verify proper installation.

27 Quality Assurance/Quality Control SAMPLE FORM Contract Name: CIPP Lining Contract No: Contractor/Installer: Construction Observer/Inspector: Report No. Weather: Structure Temp: Ambient Surface Other Work in Progress: _ByPass Pumping, Cleaning, Point Repairs, Traffic Control, CCTV Inspection Performance Acceptable Results No. Quality Assurance Standard Quality Quality Control Pass/Fail Comments Tube meets type, size, length, thickness and quality as specified. Measure the size (dia) length and thickness of Submit for third-party testing as ASTM F1216, material supplied for the project. Obtain tube 1 required. F % samples for third-party testing. Record testing lab used. 2 Resin meets type and quality as specified and approved. Submit materials for testing as specified. ASTM D5813, F1216, F % Obtain resin and catalyst samples and submit to lab for testing. Record testing lab used. 3 Wet-out - Quantities of resin used to impregnate tube. Wet-out procedure to ensure no dry spots. Industry Standard % Record resin quantity for tube size and length. 4 Installation rate not to exceed 10 fpm Curing and cool down at manufacturer's recommended rate. Release pressure only after recommended temperatures 5 have been achieved. ASTM F1216, F % ASTM F1216, F % Verify cleanliness of pipe installation rate not to exceed 10 fpm. Record minimum and maximum curing temperatures. Record cool down method, time and pressure readings for the installation. 6 Finished pipeliner shall be continuous, defect free and fit tight within the host pipe. ASTM F1216, F % Verify liner from end to end. Review final video and record defects. Check liner fit at service connections and at pipe ends. Owners Representative: Name Signature Date Contractor/Installer Representative: Name Signature Date All QA/QC as per specific manufacturer's recommendations.

28 Qualified & Trained Inspector The project inspector is key to the successful trenchless rehabilitation project Is trained and knowledgeable in the project technology. Is knowledgeable in quality controls, testing and documentation of product being installed including instrumentation and equipment to be used. Is ability to recognize key elements of product success or failure during installation.

29 Warranty Inspections Detailed visual or CCTV inspection of the project upon completion before final acceptance. Inspections, during warranty period, based on specific product requirements. Specific warranty inspection work defined. Parties participating in inspection. Written documentation of inspection and results. Contractor affects repairs based on acceptable remedies clearly defined in the specifications

30 Expected Project Results Project meets or exceeds product manufacturer s advertised claims. Project meets or exceeds specification requirements. Product performs for the life expected. Customer s expectations are met

31 Conclusion The key to successful Trenchless construction projects includes: Selection of the correct technology. Complete performance based specifications. Qualified contractor/installer. Quality assurances clearly defined in the specifications. Quality controls implemented during construction. Product testing with a verified chain of custody. Knowledgeable and trained inspection personnel. Clearly defined warranty inspections. Raising The Industry s Quality Level

32 The solution is not cheaper technologies. The solution is better engineered technologies at a lower cost

33 Any Questions Gerhard Gerry P. Muenchmeyer, P.E Director of Engineering & Operations Reline America, Inc. Web Site

34 References/Credits Photo s and schematics by: Underground Construction Aries Industries LMK Liners Permaliner Industries TT Technologies John Jurgens TRI International