Design Quality Plan Ohio River Bridges Downtown Crossing

Design Quality Plan Ohio River Bridges – Downtown Crossing Presented By: Photo credit: kyinbridges. com Vinay K. Polepalli, PE, MBA, PMP Richard Sutherland, PE

Presentation outline 1 • Introduction 2 • Stages of plan submittals 3 • Steps/description of the QC/QA Process 4 • Examples 5 • Benefits of QC/QA process 6 • Questions & Answers

INTRODUCTION Current QA/QC process: • QA is the responsibility of the design consultants • QC is the responsibility of KYTC

INTRODUCTION Drawbacks with the current QC/QA process Drawbacks Puts burden on the client to perform extensive QC which consumes a lot of time in resolving issues Often results in schedule slippages

INTRODUCTION ORB-DTC introduced new QC/QA approach… • Design team to perform extensive QC per DQP QA – Quality Assurance • Independent QA by a PE who is not involved in the production process QC – Quality Control DQP = Design Quality Plan • Documents submitted to the client for their review and comment Review and Comment

INTRODUCTION KEY PROJECT STATS Design and Construction Cost $860 M 27 Office Locations Lead Design Firm Offices – Jacobs Engineering 10 No. of Design Firms 13 8300 No. of Drawings No. of Buildable Units 217 Total No. of Design Packages 517 Plans Reports As-Built Plans 217 116 184

Design Quality Plan implemented at various stages of plan submittals Design submittals: 1 • Conceptual(30%) 2 • Interim(60%) 3 • Pre – RFC(100%) 4 • RFC 5 • RFC Revisions 6 • As-built plans

Steps in the Design Quality Process The design quality program consisted of several steps: Planning the work Preparing design documents Checking and reviewing the documents Releasing documents for construction Auditing and Certifying Making revisions As-built drawings

Project. Wise Controlled access Organization Coordination Collaboration Single platform Document Control

Document Control Project. Wise Folders

TWO STEP QC/QA PROCESS QC by design team QUALITY ACCOMPLISHED Independent QA

QC/QA Process Quality Checking (QC) Designing Checking Correcting Verifying Quality Assurance (QA) Enforcing Communicating Verifying Certifying

QC PROCESS Color Code Key Error Verified Correct Comment or instruction

QC PROCESS Roles during Checking – at least 2 sets of eyes Originator: Prepares documents Checker: Checks for errors Backchecker: Checks the checker Corrector: Corrects the documents Verifier: been made Verifies that the corrections have

QC PROCESS Checking Process Example #1 Example #2 Example #3

QC PROCESS Check Print Stamp Ø Checker, Backchecker, Corrector and Verifier initial the check print stamp

QC PROCESS Checking Process Inter-Discipline Design Checking (IDC) Designate appropriate reviewers Section Technical Manager (STM) YES Coordination and Verification Constructability, Environmental and A&E Compliance and utility coordination comments from Walsh Section Technical Manager (STM) NO Noted on the Review Print Stamp

QC PROCESS IDC Review Print Stamp Ø IDC stamp is initialed by all the discipline leads who reviewed the plans

QA PROCESS Document Requirements for various submittals 1. 2. 3. 4. DQA Form, completed by DQM to document audit. Plan Sheets and Special Provisions are signed and sealed for RFC in accordance with DQP Field Design changes During Construction, do not require QA audits if design documents are not re-released. However, if these documents need to be re-released (RFC’d) then audit procedures need to be followed. The STM determines the need for supporting calculations and internal reviews based on the significance/magnitude of the change. KYTC reserves the right to request and review supporting calculations

QA PROCESS Certification DQA (Design Quality Audit Checklist) Form was used to perform, record, and certify the audit. Nonconformance Package sent back to EOR Submits package for certification EOR addresses QA comments

QA PROCESS Certification Conformance Certification Submit to R&C

QA PROCESS DQA Certification

Design Review and Comment KYTC’s review team performs a design review Documents comments on Review Comment Summary Resolution (RCSR) form Comment Resolution DB team and Review team discuss and agree QC/QA cycle continues

QC/QA PROCESS – RCSR Form Package Description / Section: BR_A 008 Pre-RFC - Section 1 Submittal Date: Reviewer: (Name /Initials /Title /Organization) Comme Sheet nts No. * No. By Initial s: Review Comment Due Date: Initi al Co de ** Response Respo Fin KYTC Correct nse al Conc ion By: Co ur. Verified de Y/N - By: *** By: Code: A=Accept Comment; B=Review and Discuss Comment; C=Comment Not Implemented; D=Comment Beyond Scope or Beyond Design Phase; E=Agreement Reached in Resolution Meeting (SEE INSTRUCTIONS TAB for clarification of Codes, Responses and Verification) Note: * Indicates Sheet No. , Page No. and Line No. or "G" for General Comment; ** Filled out by Design; *** Agreed Resolution (code "B" is not acceptable)

Last Step - As-built drawings • After the BUs are constructed Final step in the process Plans changed in CADD • Per as-built instructions • QC/QA process is enforced Similar QC/QA process

QC calculations QC plans Auditor comments Examples

EXAMPLES Sample QC Plan with RYG colors

EXAMPLES Sample QC Calculations with RYG colors

EXAMPLES Audit comments • On PDF page 4 of 53 in Check Print set, for TYPICAL SECTION (SPAN 1) DETAIL, for the “left shoulder” the text “VARIES” was struck out. However, on PDF page 4 of 56 on Clean Plan set, this text appears. Please look into this and fix it accordingly. • Corrected. • On PDF page 27 of 53 of Check Print, for “TYPICAL SECTION AT IEB 1 SB” detail on the top left hand corner, the markup show “ 5 -5 S 14 e and 5 S 16 e @” However, on clean Plan Set, on PDF page 27 of 56, the label shows only “ 5 – 5 S 16 e”. Please look into this and address it accordingly. 1. Also, for the same detail, a markup on Check Print shows “@ 12” = 3’ – 2 ½” “. However, on the clean plan set, the text shows up as “ @ 12” = 4’ – 0” “ Please look into this and correct accordingly. • Corrected. • For the same detail, near the “BEAM LINE 12” the markup shows “STET” however, the correction was made on the clean plan set on PDF page 34 of 56. Please look into these and address them accordingly. • Corrected.

Benefits of Independent QA QA performed by a P. E. not involved with plan development Enforcement of DQP by independent third party Quality accomplished

Benefits of formal QC/QA Higher reliability and accuracy of information provided to the Contractor Higher quality project with reduced change orders Reduced risk for the designers Benefits of formal QC/QA

Benefits to design team Reduced conflict with the Contractor Reduced chance of plan issues Benefits to design team

Benefits to contractor Less field corrections due to plan issues Saves time and money Benefits to contractor

Benefits to the KYTC Reduced conflict in the field with the Contractor Increased likelihood of a high quality product Less time in review Benefits to KYTC

Are there any downsides? Yes…. . • Cost • Time DOWNSIDES: but…. • Higher quality is a bargain

3 Steps to creating a formal QC/QA Program Implement • Train staff and consultants • Develop a comprehensive DQP Develop • Hire an independent QA consultant • Develop policies and guidelines • Require consultants to implement the formal QC process Vinay K. Polepalli, PE, MBA, PMP – 502 -296 -2534 Richard Sutherland, PE – 859 -422 -3000 Enforce

Questions & Answers