Construction Management/Construction Inspection (CM/CI) Rapid Bridge Replacement Project Magnitude, Challenges & Technology Date: March 28, 2018
www.trcsolutions.com | Pittsburgh Section Presenters
Scott Gallaher, PG SVP Infrastructure, CEI/CIM Practice Lead [email protected]
Richard Shoemaker VP – Principle Manager – CEI, Construction Engineering Group [email protected]
Colby Dressler, PE Project Manager/Construction Engineer [email protected]
Robert Horwhat, PE Director Structural Materials Inspection [email protected]
www.trcsolutions.com 2 Agenda
TRC PA Rapid Bridge Project Relevant Projects Polyester Polymer Concrete P3 Materials Inspections Conclusions (Takeaways)
www.trcsolutions.com 3 Company Fact Sheet About TRC A pioneer in groundbreaking scientific and engineering developments since the 1960s, TRC is a national engineering, environmental consulting and construction management firm providing integrated services to the power, oil and gas, environmental and infrastructure markets. From more than 120 offices throughout the U.S., our 4,100 employees serve a broad range of commercial, industrial and government clients, implementing complex projects from initial concept to operations. Employees 4,100 Headquarters Lowell, Massachusetts Locations 120 U.S. Office; U.K Office, China (Shanghai) Office, Canada Office ENR Top 500 Design Firm Rank 23
Businesses While we work in a broad range of industries our focus is on the Environmental, Power/Utility, Oil and Gas and Transportation sectors. Services span categories including:
Power Oil & Gas Environment al 4 Infrastructure www.trcsolutions.com TRC Offices
. 4100+ employees . 120+ U.S. offices; London and Shanghai office
www.trcsolutions.com 5 Infrastructure
Highways and Roadways | Bridges | Utilities, Sewers and Water Lines | Railroads | Building Structures
. Roadway and Bridge Engineering Design . Building Condition Assessments . Construction Management, Engineering . Site and Civil Engineering and Inspection . Traffic Engineering . Geotechnical Engineering, Inspection and . Metallurgical Engineering Testing (field and lab) . Structural Steel Fabrication Shop Inspection . Geotechnical Test Borings . Precast/Prestressed Concrete Plant . Bridge Safety Inspection Inspection . Public Relations
www.trcsolutions.co m 6 Pittsburgh Section 7 PURPOSE of project
PA taking advantage of Act 88 to address the roughly 4500 structurally deficient (SD) bridges. With this Public Private Partnership (3P) approach, 558 SD bridges will be replaced more quickly; help achieve significant savings for taxpayers; and minimize the impact on the traveling public. The P3 (PWKP) will finance, design, construct and maintain the bridges for 28-year term. Construction was to be completed for all 558 bridges within 36 months. PennDOT will maintain ownership of the bridges throughout the contract. Roughly 20 % of Pennsylvania’s bridges are structurally deficient, (4506 of 22000) while the national average is 9.1 percent(2016). Unless replaced, these bridges will ultimately have to be closed, jeopardizing public safety and harming the state’s ability to grow economically and create jobs. A SD bridge is not unsafe. The designation means that one or more of its major components is deteriorating.
www.trcsolutions.com 8 PADOT Rapid Bridge Replacement Project (PARBRP)
558 bridges in ~ 2 & 1/2 years 411 single Span Bridges 27 Multiple Span Bridges 120 are Culverts
Prestressed, Culverts, Steel Average Structure is about 60’ in length 62 will be more than 100’ long 417 bridges will be constructed using 2,291 pre-stressed concrete beams The beams will use 6.1 million linear feet of steel strand or 1,155 miles
Construct as per revised PADOT 408 Change #7
Construct as per specifications as if this were a standard design bid build
9 Role of the CQAF Construction Quality Acceptance Firm :CQAF Construction Quality Acceptance Managers: CQAM
Construction Quality Acceptance Staff
A quality acceptance inspection and material sampling/testing staff shall be employed by the CQAF and shall, under the direction of the CQAM, perform inspection and material sampling/testing of all Work performed and materials incorporated into the Project by any member of Development Entity’s group.
The services of the CQAF shall be part of the Development Entity’s Quality Management System. perform independent quality acceptance material testing and inspection; perform quality acceptance inspection; perform audits addressing compliance with QMP; certify that the Work meets Development Entity’s acceptance criteria;
10 Role of the CQAF TRC Engineers is contracted to the By the Technical Provisions, CQAF Development Entity, Plenary Walsh worked with Development Entity Keystone Partners, LLC (PWKP) to produce the acceptance scope; The owner did review contract TRC Engineers by contract has joint and Throughout development of equal reporting responsibilities to both Inspection and Test Plans (ITP’s), PWKP, and PADOT. issues arose where the Owner TRC is the only entity contractually tied to preferred more involvement from both the owner (DOT) and the developer. the CQAF Even without disagreements to extended scope, because contract terms were set out up front, this still created contractual/financial challenges
Dual Reporting presents challenges for the CQAF
11 Role of the CQAF Inspection process for CQAF in 2015 and 2016 was designed Inspection process for CQAF in 2017 was converted to 100% as a “HOLD POINTS” inspection relative to items that are Full Time CQAF along with removal of most Contractor QC defined as an acceptance test, or activity that required full staff. time witness: CQAF is “full time” with exception of activities that Foundations do not require inspection in an effort to conserve Test piles resources and provide for quality of life Production piles Rebar tying Concrete placement Job site Clean up Acceptance breaks Etc. Hold points that were required in past years, still Backfill required Bituminous Paving
In addition to the field inspection element TRC Engineers, is also responsible for: Full time inspection in fabrication facilities for prestressed, precast, structural steel elements 30 facilities to date in multiple states. Project documentation review- Source of Supply, certifications, QC plans, etc.
12 Role of the CQAM The CQAM shall review, approve, authorize, examine, and confirm any methods or procedures requiring the “Engineers’ review, approval, authorization, examination, confirmation, etc.” which are contained in Publication 408. (Ex Dot: Structures control Engineer) is part of the three part dispute resolution team consisting of TRC, PADOT, HDR Issue Recommendation Letter for substantial completion Issue Recommendation letter for final acceptance.
13 Structure of CQAF Developed a structure in CQAF, Construction Managers, Area Field Managers and Field staff, Auditors. Parallel Unit for fabrication shop inspection. This structure is loosely matched on the QC side with WGCJV 3 regions across state typical pyramid structure Created a matrix of communication in quality management units and PADOT Intent is to push down decisions making levels, and establish escalation processes if needed. Final say goes to dispute resolution team
14 Challenges
15 Challenges Understanding the differences in roles between CQAF, Quality control, Quality assurance Qualified Inspectors Same certifications as standard delivery Available resources Different approach to acceptance with CQAF Hold Point inspection Substantial on-boarding effort Extensive winter school Fully integrated sub consultants
16 Challenges Matching manpower to Contractors schedule General schedule is on a continuous two day look ahead Real schedule is hourly
Work force fatigue High stress job everyone is watching Extensive travel – 4,672,643 miles driven thru Feb 2018 OT hours, routinely OT running at the equivalent of 19 FTE’s/ month Contractor delays
Paperless project
17 P3 Multi Asset Challenges In many cases, design-build projects nearing $1 billion are usually single assets or localized to a general area. The project team is located in/around the project.
With 558 assets, resolving project and technical issues becomes exponentially more difficult; for example: You can’t “look out your window” and see your project Many of the assets chosen for replacement are small, single-span bridges in remote areas Lack of cell service
THE HUMAN FACTOR== At any point in time, there is always two entities involved in a project issues- CQAF and Lead Contractor. Many times, the statements of the exact problem do not match.
Must utilize common tools to truly resolve- conference calls, FaceTime/Skype, real time pictures, etc.
18 “The Learning Experience” Some fundamental changes in normal requirements Experienced “fit up” issues with precast culverts- this subsequently led to requiring fabricators to “fit up” adjoining pieces Contract required CQAF to work with labs that were AMRL accredited- upon searching it was found that no labs existed in the state which led to accreditations being received Fundamental changes in how prestress strand is tested/accepted- now takes into account failures due to testing operation, grip, etc. Clarified some items for ease of construction Use of aluminum instead of Masonite when setting culverts Use of a protective asphaltic board in place of an asphalt mix for culvert protection Clarification of grouting requirements for culverts (50 psi)
19 Paperless Project
No Field Offices Paperless Project
Paperless project Shared systems 24 hour turn around on reports Field report written Supervisor approved Placed in SharePoint Fully computerized field and audit staff Dell venues, with wifi and 4g Use of smart forms Cross checks for all source of supply with audit staff
21 Paperless Project - Mobile Internet Service
22 Paperless Project
Dell Venue 11 Pro with External Keyboard
23 Paperless Project Reasons for using the Venue Windows Based (familiar to most people) Full-sized keyboard provides a laptop-like experience Compatibility with Adobe Smart Forms Compatibility with Industry Time and Expense Software Embedded 4G LTE card Full size USB3.0
Lessons Learned Standard Car Chargers do not work Don’t trust internet service maps, worse than what they advertise Need Dedicated IT support for “How To Questions”
24 Pittsburgh Section 25 PennDOT Rapid Bridge Replacement P3 Statewide Pennsylvania
TRC is under contract to the project’s P3 consortium to perform a variety of services for this massive $900 million project which represents the state’s first use of P3 legislation to replace 558 aging bridges across the state in just three years. It also represents the first P3 in the U.S. to bundle multiple bridges into a single procurement.
• Construction Quality Assurance Firm (CQAF) responsible for performing construction QA inspection for all 558 bridges being replaced. • Geotechnical test borings for over 200 bridges across the Commonwealth. • Precast/prestressed concrete plant inspection. • Steel fabrication shop inspection.
www.trcsolutions.com 26 LaGuardia Airport Redevelopment Queens, New York
TRC is serving as a subconsultant to the project’s design-builder, Skanska-Walsh Joint Venture, during the massive redevelopment effort underway at LGA. Planned in two phases, Phase One will cost $4 billion and is considered the largest Public-Private Partnership involving infrastructure work in the United States. Work will consist of replacing the Central Terminal Building (Terminal B) with a new 1.3 million square-foot building having 35 gates. Phase Two will involve redeveloping and connecting the Delta-operated terminals (C and D) to the airport.
. QA/QC inspection and NDT of structural materials: • precast member fabrication (2,729 members) • structural steel fabrication (40,000 tons of steel) • bridge steel fabrication (20 total bridges) • curtain wall fabrication • welded steel pipe foundations (7,040 piles) . Inspection and testing of utilities (water, sewer, force mains, storm drains) and other airside work (runway lighting and runway pavement). . QA/QC inspections of building renovations. . Advisory role to Skanska-Walsh for resolution of QA/QC issues with the PANYNJ MEU (Materials Engineering Unit).
www.trcsolutions. com 27 Queensferry Bridge Replacement P3 Project Edinburg, Scotland; China, England, Spain and Poland This new prestigious cable-stayed bridge opened in 2017 and replaces the Forth Road Bridge which was one of the world’s most significant long-span suspension bridges. TRC served as the Independent Inspection Authority (IIA) to the project consortium during the fabrication of 32,000 metric tons of steel. At £1.2 billion (approximately $1.7 billion USD), the Queensferry Crossing is the largest public works project in the history of Scotland and is considered the single most important transportation project in the United Kingdom and possibly all of Europe.
. Off-site steel fabrication inspection: pier boxes and box girders / orthotropic deck structure / tower anchor boxes / bridge bearings |/temporary tower structures / erection devices / tower jump forms / launch approaches / tower caissons / cofferdams . On-site steel construction consultation . Non-destructive testing (NDT)
www.trcsolutions.com 28 US 35 Public-Private Partnership Project Putnam and Mason Counties, West Virginia Representing the second Public-Private Partnership project to be undertaken in the state of West Virginia and one of the largest construction contracts ever let by the state, this project represents a new $175 million four-lane section of U.S. Route 35 that represents the last stretch of the 412-mile U.S. Route 35 corridor from Indiana to WV to be widened to four lanes.
• Overall responsibility for the design of the project: • roadway alignment design • drainage design • hydraulic analysis • NPDES permitting • bridge structure design • geotechnical design and geotechnical borings • Re-evaluation of the project’s NEPA study • QC management and inspection during construction
www.trcsolutions.com 29 San Francisco-Oakland Bay Bridge SAS Oakland, California; China, Japan, Korea, and England The San Francisco-Oakland Self-Anchored Suspension Bridge (SAS) was California’s largest public works project under construction to-date with a price tag of $1.4 billion. It is the world’s largest single tower self-anchored suspension bridge with a design life of 150 years. With a staff of 75 engineers, inspectors, technicians, administrators and managers working around the clock in five countries, TRC was the major consultant to Caltrans during the construction of this unique and highly complex project. • Quality Assurance • structural steel members • concrete • coatings • Source inspection • Material engineering • Construction engineering • Safety • Submittal review • Confined space work www.trcsolutions.com 30 Scudder Falls Bridge Replacement Bucks County, Pennsylvania Broken into three (3) contracts, the $396 million Scudder Falls Bridge Replacement Project includes replacement of the existing I-95 bridge over the Delaware River with new northbound and southbound structures, along with 4.4 miles of approach roadway and interchange improvements in Pennsylvania and New Jersey.
• Construction inspection for all work under Contract CI- 671A: • Reconstruction of both the NB and SB lanes on I-95 from the I-95/PA Route 332 Interchange in PA to the south approach slabs of the Scudder Falls Bridge. • Reconstruction of the Taylorsville Road/I-95 Interchange and both the Taylorsville Road Bridge and the Delaware Canal Bridge. • All Electronic Toll (AET) gantry, toll equipment and the Bridge Monitor/All Electronic Toll (BM/AET) building. • Pedestrian/bike path and wetlands mitigation work.
www.trcsolutions.com 31 Susquehanna River Bridge Replacement Columbia County, Pennsylvania This $49.9 million PennDOT District 3-0 project entailed the reconstruction/rehabilitation of approximately 2 miles of I-80 EB and WB in northeast Pennsylvania. The work entailed significant structures-related work, highlighted by the construction of a new 17-span structure carrying I-80 WB over the Susquehanna River.
• TRC was retained to provide a 13-member inspection staff at peak periods for this 5-year project. • Contractor work activities inspected by TRC staff included: • drainage • earthwork (excavation, embankment, E&S controls) • bituminous paving • complete new bridge structure construction • structure rehabilitation (parapet, beam and deck removal; retrofit of existing piers; placement of new concrete beams, deck and parapets) • bridge structure widening • new overhead sign structures
www.trcsolutions.com 32 Questions on Rapid Bridge Project? Scott T Gallaher, PG Dick Shoemaker P: 724.325.7483 | E: [email protected] P: 717.798.4627 | E: [email protected]
www.trcsolutions.com Pittsburgh Section 34 Polyester Polymer Concrete (PPC)
www.trcsolutions.com 35 Pennsylvania Rapid Bridge Replacement Project Project Specification 9000-7001 ¾ Inch Polyester Polymer Concrete Overlay
Description – This work consists of furnishing and placing a ¾ inch thick Polyester Polymer Concrete (PPC) overlay system with a High Molecular Weight Methacrylate (HMWM) resin primer on concrete surfaces. The surface of the concrete substrate shall be prepared and the PPC overlay system shall be applied in accordance with these specifications in conformity with the lines, grades, thickness, and typical cross-sections shown on the plans.
www.trcsolutions.com 36 Materials:
• Polyester Resin Binder • Unsaturated isophthalic polyester-styrene co-polymer • Accelerators or inhibitors • Aggregate • High Molecular Weight Methacrylate (HMWM) Primer • Wax-free low odor, high molecular weight methacrylate primer • Resin • Initiator (metal drier and peroxide) • Promoter • Sand for abrasive finish • Commercial-quality blast sand
www.trcsolutions.com 37 Submittals:
• Placement QC Plan that includes: • Staging plan description overlay placement sequence • Description of equipment • Method for protecting and finishing around drains and parapets • Method for controlling, measuring and maintaining thickness and profile • Cure time • Storage and handling • Disposal • Cleanup • Chain of command • Environmental BMP’s required
www.trcsolutions.com 38 Safety:
• Safety Data Sheets: • PPC – 1121EC (Polyester Polymer Resin) • KBP Z-Cure (Resin Activator) • Cumyl Hydroperoxide (Organic Peroxide) • Methyl Ethyl Ketone Peroxide (Organic Peroxide) • KBP Pro-Prime (High Molecular Weight Methacrylate Primer)
• PPE • Face shield/Goggles/Safety glasses • Ear plugs/ear muffs • Respirator • Gloves • Toe/Foot protection
www.trcsolutions.com 39 Equipment:
• Portable mechanical mixer • Calibrated continuous automated mixer truck • Or motor mixer
• Paving/finish machine • Self-propelled slip-form finish paving machine • Or vibratory screed riding on preset forms or rails
www.trcsolutions.com 40 Construction:
• Pre-paving meeting
• Pretest patch on concrete slab measuring a minimum of 10ft x 6ft
• Bridge deck shall cure a minimum of 28 days and attain the required design compressive strength prior to start of surface prep
www.trcsolutions.com 41 Construction:
• Surface Preparation • Areas to receive overlay shall be cleaned by shot blasting or abrasive sandblasting • To occur a maximum of 48 hours before PPC
• Goal of surface prep: • Remove all weak or loose surface mortar • Expose course aggregate within the concrete • Open concrete pores (entrained air voids) • Produce visible color change
www.trcsolutions.com 42 www.trcsolutions.com 43 Shot Blasted Not shot blasted www.trcsolutions.com 44 Area Good Missed
Over shot blasted
www.trcsolutions.com 45 Over shot blasted Good
www.trcsolutions.com 46 Construction:
• Primer • Surface must be free of any standing water or surface darkening that would indicate locations of previously standing water • Entire concrete surface must appear to be uniformly light in color and show no further lightening when drying • All cracks must be dry • Concrete surface temperature between 40° and 100°F • Ambient temperature shall be 40°F or higher • Immediately before placing primer all exposed surfaces shall be blown clean with compressed air
www.trcsolutions.com 47 Construction:
• Primer • Primer placed within 5 mins of mixing • Primer applied a minimum of 15 mins and max of 2 hours before placing PPC • Shall be applied by flooding and uniformly spread to completely cover surface • Primer to be reapplied to areas that appear dry
**Primer acts as the “root” system soaking into concrete pores and helping PPC adhere to concrete surface
www.trcsolutions.com 48 Just started primer
www.trcsolutions.com 49 Uniform application
www.trcsolutions.com 50 Construction:
• Polyester Concrete – Mixing/Placement • If portable mechanical mixer used – polyester concrete to be mixed a minimum of 2 minutes prior to placing • Shall have a set time of at least 30 mins and at most 90 mins – considered set when cannot be deformed by pressing with a finger • If not set by 90 min – Remove and Replace • Consolidate with screed, additional hand finishing may be necessary
www.trcsolutions.com 51 www.trcsolutions.com 52 www.trcsolutions.com 53 www.trcsolutions.com 54 www.trcsolutions.com 55 www.trcsolutions.com 56 Construction:
• Polyester Concrete - Tining • Immediately after finishing broadcast surface friction sand finish on the glossy surface • Sand can be placed either before or after tine texturing • Tining either transverse or longitudinally • Tining grooves shall be neat in appearance and uniform in depth and applied by spring steel tines as outlined in Pub408 Section 501.3(k)4 • No texture shall be added to overlay surface within 12”-18” of parapet
www.trcsolutions.com 57 www.trcsolutions.com 58 www.trcsolutions.com 59 www.trcsolutions.com 60 Construction:
• Polyester Concrete - Curing • The overlay shall be considered cured to a traffic ready state when: • After 2 hours following final finishing, at a minimum of every 10LF a minimum reading of 3,000 psi on a Schmidt Hammer is achieved for all readings.
www.trcsolutions.com 61 Construction:
• Polyester Concrete - Curing • Schmidt Hammer
www.trcsolutions.com 62 www.trcsolutions.com 63 Testing:
• Polyester Concrete – Acceptance Testing • Acceptance of the PPC will be determined based on vertical axis bond tests (Pull Test) • Pull test shall be performed after a minimum of 24 hours • One pull test shall be performed on each bridge per days placement – located using PTM 1 • Additional testing as directed • Smoothness quality testing must satisfy the requirements of Pub408 Section 501.3(o) • Transverse and longitudinal - ¼” in 10 feet
www.trcsolutions.com 64 Testing:
• Polyester Concrete – Acceptance Testing • Test cores shall be drilled a minimum of 0.50” below bond line • Minimum bond strength of PPC on normal weight concrete shall be 250psi. • An acceptable test will demonstrate the overlay bond strength is sufficient by producing a concrete substrate failure area greater than 50% of test surface area.
www.trcsolutions.com 65 www.trcsolutions.com 66 www.trcsolutions.com 67 www.trcsolutions.com 68 -PPC/Concrete line at 7/8” -Shows concrete substrate failure
www.trcsolutions.com 69 Rapid Bridge Replacement Project
PPC Overlay Inspection Report
www.trcsolutions.com 70 www.trcsolutions.com 71 www.trcsolutions.com 72 Questions on PPC?
Colby Dressler, PE P: 717.645.7543 | E: [email protected]
www.trcsolutions.com
www.trcsolutions.com 74 Pittsburgh Section P3 Materials-Testing-Inspection – Challenges and Solutions
www.trcsolutions.com 75 Presentation Summary
• Precast-Prestressed Concrete Fabrication overview • Requirements • Documentation – Requirements > Identified issues • In Process - Findings from projects • Mechanical Reinforcement Couplers • Supplier approval • Epoxy coating • Prestressing Strand testing • Material variability – test specification allowance • Re-test confirmation • Prefab – Installation: Culverts • Solutions • Communication! • Material qualification • Policy and procedure revisions www.trcsolutions.com 76 Materials-Inspection-Testing: Challenges and Solutions - P3
www.trcsolutions.com 77 Precast and Prestressed Concrete Fabrication
Prestressed Concrete Beams: Set up – reinforcement placement
www.trcsolutions.com 78 Box Culverts
www.trcsolutions.com 79 Concrete Testing
www.trcsolutions.com 80 Concrete Placement
www.trcsolutions.com 81 Finishing - Curing
www.trcsolutions.com 82 Concrete Acceptance – F’c
83 Why did/do we sample, test and inspect?
www.trcsolutions.com 84 To ensure specification compliance for owners/FHWA - safety, avoid future costs …….
www.trcsolutions.com 85 Process –CQAF and Inspection – It’s the LAW • Federal Regulation CFR 23 -Quality Assurance Program • Contract Scope of Work • Specification Compliance • Public confidence?
www.trcsolutions.com 86 Requirements - Documentation • Construction or Inspection can’t begin without a contract • Typically these involve a VERY detailed ‘Scope of Work’ for the services • The more detailed the better to protect both the owner and the firms providing services - …otherwise ‘out of scope’ services usually result in previously unanticipated claims and cost
• P3 required TRC to follow PennDOT specifications • Independent of all other projects • Stand alone inspection – material sampling and testing! • 3rd party Laboratory Testing – AASHTO – ARML/CCRL - Separate reporting requirements - Separate conflict resolution requirements www.trcsolutions.com 87 Value: Several Findings from CQAF P3 Inspection – Mechanical Couplers • Couplers - P3 project required sampling and testing of all couplers • 3 assembled • 1 unassembled – rules out individual materials
www.trcsolutions.com 88 Mechanical Couplers • Inspection revealed • Coupler mfgr – approved?: Yes….but • Epoxy coating – powder: Not approved • Epoxy coating applicator: Not approved • PennDOT prequalifies all materials and applicators for reinforcement • Applies to couplers • Isolated incident • No! • Investigation • Multiple suppliers were found to have fabricators, coatings and coaters that were not approved • Why • Systematic process Find/Fix
www.trcsolutions.com 89 Standard Gel – Long Gel – Short Gel
www.trcsolutions.com 90 ..Another issue to deal with
May 11, 2016
Approved Epoxy Powder Manufacturers in Bulletin 15
Re: Long Gel (or other) Versions of Epoxy Powders Request for Internal and Independent Testing per ASTM A775 Bulletin 15 – Qualified Products List for Construction Section 709.1(c) Epoxy Powder and Patching Material Manufacturers Dear Business Partner:
We recently discovered that all epoxy powder material manufacturers approved in Bulletin 15, Section 709.1(c) supply both a standard gel and long gel version to epoxy coating facilities. And at least one manufacturer has a ‘fast’ gel variant of their standard powder as well. We understand the necessity for coaters to use non-standard versions for coating wire mesh, couplers, and other specialized steel components where faster or shorter curing periods are required.
While these various gel versions are being used, our records indicate that only the standard gel version was evaluated and tested during our Bulletin 15 approval process. rd party test data to Therefore, PennDOT is requesting both internal and independent 3 confirm that any ‘non-standard’ versions you wish to have approved and listed in Bulletin 15 meet the requirements of ASTM A775.
In the short term, PennDOT is requesting any internal performance and compositional test results already performed for ASTM A775 including an infrared spectroscopy/thermal analysis fingerprint for all non-standard gel versions you wish to supply to Bulletin 15 approved epoxy powder coaters. All reports must indicate the product designation (LG, long gel, SG, spray grade, etc.). By May 31, 2016, please submit these internal test results to the following email or postal address: www.trcsolutions.com 91 Triggered: Coupler Letter to resolve broad based issue
- Fabricator, if system - Coating/coater - Grout - Original listing
www.trcsolutions.com 92 What was reviewed - Project(s) resolution
• Verification of other State DOT acceptance • Manufacturer testing – independent test results • Previous use • Risk • Rejection/Acceptance • Mechanical – OK • Coating/Coater – Only ‘at risk’ issue
www.trcsolutions.com 93 Prestressing Strand • Strand • Critical Element to structure • Non routine sampling and testing
www.trcsolutions.com 94 3rd Party Testing- Elongation failure • Initial Strand Failure • Elongation • Specification and failure analysis • 3rd party testing review • Lot identification • Additional testing Minimum elongation at Ft, Inc 1 • Revised testing policy…..
….In reviewing ASTM A416 we noted an inconsistency within the applicable test method from our testing and we will be modifying for our future strand testing accordingly. Three sample increments will be sampled. If the first sample passes we will release the sample as passing. If it fails, the second two will be tested. In the past we sampled and tested all three increments requiring all to pass which we believe is a carry-over before a specification revision to this test method was made sometime in the past. Pls advise TUV accordingly.
www.trcsolutions.com 95 Box Culverts Issues
• Construction - Alignment-fit up - Post tensioning/grouting
www.trcsolutions.com 96 Box Culverts • Represents > 75% of all bridge Structures replaced in P3 • > 90 % precast by 6 manufacturers – mostly ‘in-state’ • Alignment and geometry Issues from past – • P3 no exception – Escalated the need to fix the problems with: • Overall Geometry • PT duct locations • Joint alignment • Design – 10 psi - Joint material- C5 stiffness • Affects joint compression/sealing
www.trcsolutions.com 97 Take Aways..at a glance
• Process Leads to issue I dentification and resolution! • Learn – Observe – Listen – Report/Document o Learn Learning begins at birth Learning never ends o Observe Be observant Question the norm o Report Document what you do, what you see…
……all of these issues were resolved because someone took the time to ask questions, escalate issues and ask for answers
98 Questions on P3 Material Testing Inspections?
Robert D. Horwhat, PE P: 717.567.7878 | E: [email protected]
www.trcsolutions.com Conclusions (Takeaways) . TRC – Top Ranked Company!
.Values – Committed to!
.Opportunity – Take it!
.Success – Celebrate it!
.Satisfaction – Yours for the creating!
www.trcsolutions.com 100 Questions?
Scott T Gallaher, PG Richard Shoemaker Colby Dressler, PE Robert Horwhat, PE www.trcsolutions.com