Formal Design Qaqc Training

ICC CONTRACT B MD 200 EAST OF MD 97 to WEST OF US 29

Design Quality Training June 2009

1

Let’s Get Started

￭ Please Sign the Attendance Form and pick up one copy of each handout ￭ Cell Phones on Vibrate or Off ￭ Safety Message ￭ The class is interactive, ask questions at any point ￭ This Training Is Mandatory ￭ Written Test at the End

Agenda ￭ Introductions ￭ Course Objectives ￭ Important Considerations ￭ ICC-B Project Quality ￭ Design Quality Documents Organization ￭ Design Checking and Review Processes ￭ Use of “Centric Project” ￭ Control of Nonconformances ￭ Document Retention Policy ￭ Q&A

Course Objectives ￭ Make all Project personnel aware of the ICC-B Quality Management Program ￭ Learn how to locate the Quality Procedure(s) that relate to the issues at hand ￭ Understand the use of Yellow highlight, Red-line, Green check, Blue circle, and Green circle in the QC checking process ￭ Reduce the stress of the whole Quality Process by knowing whom to turn to for assistance

Important Considerations

￭ What is Quality? ƒ The degree to which a set of inherent characteristics fulfill requirements

￭ What is Quality Control? ƒ A part of Quality Management, focused on fulfilling quality requirements

￭ What is Quality Assurance? ƒ A part of Quality Management, focused on providing confidence that quality requirements are fulfilled

Important Considerations (Continued)

￭ Why is Quality important? ƒ MD200 Constructors’ commitment to satisfying quality requirements ƒ The need to produce the correct design on-time and the goal to do it right the first time ƒ A design that meets the target construction cost

￭ The Measurement of Quality is the Cost of Nonconformance ƒ Nonconformances are to be corrected and financed by MD200 Constructors ƒ Expensive construction due to design affects profitability

ICC-B Project Quality ￭

Highest-tier document: DesignBuild Quality Plan (DBQP), which includes: ƒ Design-Build Quality Manual ƒ Design-Build Quality Procedures ƒ Design-Build Quality Forms

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Second-tier documents: Design Quality Plan (DQP) and Construction Quality Plan (CQP), each consists of their respective: ƒ Quality Manual ƒ Quality Procedures ƒ Quality Forms

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Second-tier document: Environmental Compliance Plan, consists of 15 individual plans covering activities in Design & Construction phases.

Design Quality Documents

￭ The Design Quality Plan (including the Manual, Procedures, and Forms) must be considered in conjunction with relevant portions of the DesignBuild Quality Plan ￭ Adherence to Procedures will help ensure that project deliverables conform to Contract requirements ￭ The DQP is a living document and changes will be issued, as the program requires refinement or adaptation to more effectively manage quality

Design Quality Plan

￭ The DQP addresses processes that are specific to design quality ONLY ￭ The Design Quality Manual specifies the Project’s: ƒ Design Quality Organization ƒ Design Quality Management System ƒ Management Responsibility ƒ Design Control ƒ Design Documentation

Design Quality Organization ￭ Establish and implement the Project QA/QC Program ￭ Verify and certify that Design QC complies with Procedures ￭ Identify project activities that require new procedures ￭ Design Quality staff are independent of, but work with, Design Management ￭ Identify and report designrelated nonconformances ￭ Provide periodic reports to Administration on performed reviews, nonconformances, and status of submittals

Design Quality Procedures # D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 D17 D18 D19

Title Preparation and Maintenance of Design Project Management Plan Checking of Calculations Checking of Calculations Utilizing the Independent Analysis Method Checking of Drawings Checking of Specifications, Studies and Report-Type Documents Quality Control and Validation of Computer Software Checking of Input to Computer Programs Review of Plans, Studies and Report-Type Documents Inter-Discipline Review of Submittals Constructability Review of Documents Environmental Compliance Review of Documents Documentation and Transmission of Design Directives and Revisions Preparation of As-Built Drawings Design QC Review Working Plan Review Control of Design Nonconformances Response to ICC Team-Issued Nonconformances Review of Design Prepared by Third Party Control of CAD-Produced Documents

Design-Build Quality Procedures #

Title

#

Title

DB1 DB2 DB3

Control of QMS Documents Scope of QMS Replacement of Key Personnel

DB18

Consultant, Subcontractor and Supplier Quality

DB19

Stop Work Order

DB4

Organizational and Technical Interfaces Control of Contract Documents Contract Modifications Development and Approval of Quality Procedures Control of Quality Records Control of Nonconformance Corrective and Preventive Action Internal Quality Audits

DB20

Control of Customer Supplied Product

DB21

Environmental Quality

DB22 DB23 DB24 DB25 DB26 DB27 DB28 DB29 DB30 DB31

Project Closeout and Turnover Design-Build Task Forces Issue for Construction Request for Information Field Design Changes Notice of Design Changes Shop Drawing and Submittal Review Procurement and Purchasing At-Risk Construction Design and Construction Survey

DB5 DB6 DB7 DB8 DB9 DB10 DB11 DB12 DB13 DB14

Executive Management Reporting and Reviews Project Quality Council Quality Training

DB15

Response to ICC Team-Issued Nonconformance

DB16 DB17

Non-Technical Contract Submittals Correspondence and Transmittals

Construction Quality Procedures # C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17

Title Construction Work Plans Pre-Activity Meetings Initial Inspections Quality Only Meetings SOE and Falsework Policy Inspection and Test Plans Inspector and Technician Qualifications Quality Check Points Source of Supply Receiving and Acceptance of Materials Offsite Inspection, Sampling and Testing for Material Acceptance Permanent Materials Receiving, Storage and Protection Foreman’s Toolbox Meetings Calibration of Inspection and Test Equipment Construction Quality Records Punch List Revision of Erosion and Sediment Control Measures

Quality Control Resources ￭ The Design Quality Plan, including Manual, Procedures, and Forms, is available on the ICC-B Project network drive and Sharepoint site: ƒ On Project network: à P:\ICC-B\300_Proj_Procedures\Design Quality Plan

ƒ On Parsons’ Sharepoint site: à https://projects.parsons.com/sites/iccb/default.aspx à Go to “Shared Documents” à Go to “ICC-B Design Quality Plan”

Design Checking and Review Process

Design Checking and Review Process ￭ Checking and review process of design begins within each individual discipline: ƒ Create check prints for all documents ƒ Create a review print for the review by the originating discipline (Discipline Lead’s or other senior engineer’s review) ƒ For Definitive Designs ONLY, a discipline-specific Standards Compliance Form must be completed (Form DC-1 for Landscaping, Form DC-2 for Drainage, Form DC-3 for Geotechnical, etc.)

Design Checking and Review Process (Cont’d) ￭ Design moves to Designer’s Internal Environmental, InterDiscipline, Constructability, Environmental Compliance, and Independent MDE reviews ￭ Forward check and review prints to Design QC for review and certification ￭ Certification of Conformance or Nonconformance Report issued, and Corrective Action taken, as needed ￭ Certified design forwarded to SHA and MDE for comment ￭ At any time, corrections/comments are resolved with additional checking and reviews, as required

Checking of Calculations ￭ Use Procedure D2, Checking of Calculations for all calculations except as defined in Procedure D3 ￭ Use Procedure D3, Checking of Calculations Utilizing The Independent Analysis Method for calculations for:

ƒ permanent components ƒ major temporary components, and ƒ effects of temporary components on permanent components, including construction sequences that affect the permanent components

What is a Check Print? ￭ A Check Print is a legal document, required by our contract to be maintained for 7 years after the Project is Completed. ￭ The Check Print color scheme must be followed to provide reproducible evidence that QC was done ￭ People signing a Check Print are certifying they performed the QC task ￭ A check print is initiated after the design development is completed ƒ DO NOT include design development iterations as Check Prints ƒ Check Prints that have no red marks (everything highlighted in yellow) are OK

Check Print Roles ￭ Originator ƒ The originator of the document ￭ Checker (must not be the Originator) ƒ A “peer” of the Originator ￭ Backchecker (must not be the Checker) ƒ Determines if the changes / corrections identified by the Checker should be incorporated ￭ Corrector ƒ CADD operator or other person who updates the document ￭ Verifier (must not be the Corrector) ƒ Person who verifies that all approved changes have been incorporated into the new document

Use of Colors on Check Prints ￭ Yellow: Used by the Checker to indicate agreement; all lines, dimensions, and written text. ￭ Red: Used by the Checker to indicate corrections & additions ￭ Green √ (check mark) or line & text: Used by the Backchecker to indicate approval, modification, or rejection of checker's changes ￭ Blue Circle: Used by the Corrector to indicate the change has been made to the updated document ￭ Green Circle: Used by the Verifier to verify that the change is indeed incorporated into the Document

Procedure D2: Checking of Calculations ￭ Applies to all calculations created by hand or by basic text or spreadsheet software ￭ Designer (Originator) presents calculations in a neat and logical manner conducive to checking ￭ Checker thoroughly checks calculations including assumptions, mandated parameters, references, given values and formulas, omissions, and correctness of arithmetic

Procedure D4: Checking of Drawings ￭

Originator of work is responsible for accuracy and should not rely upon checking system to complete drawing

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Checker checks for accuracy and conformance to all applicable standards, design criteria, and specified project design directives

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For changes on a checked drawing, only those portions that changed are marked up as appropriate on a new check print

Check Print Stamp ￭

Check Print Stamp used with Design Quality Procedures: ƒ ƒ ƒ ƒ

D2: Checking of Calculations D3: Checking of Calculations Using Independent Analysis Method D4: Checking of Drawings D5: Checking of Specifications, Studies and Report-Type Documents

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D6: Quality Control and Validation of Computer Software D7: Checking of Input to Computer Programs

Review Print Stamp ￭ Review Print Stamp used with Design Quality Procedure D8, Review of Plans, Studies and Report-Type Documents ￭ Typically used for internal reviews by the originating discipline and Designer’s independent MDE reviews.

Review Comment Resolution

￭ The Reviewer documents comments on a review print, and signs and dates the Review Print stamp ƒ Comments may be recorded by hand on hard copy or electronically (using “Track Changes” or similar) ƒ If no comments were recorded, the Reviewer notes “NO COMMENT” on the stamp

￭ The Responsible Engineer determines disposition for each comment and documents it on the same review print (“Accept,” “Dismiss,” “Clarify,” or “Resolve”)

Review Comment Resolution (Cont’d)

￭ The agreed-upon changes are transferred onto a new check print by the Responsible Engineer or designee (acting as a Checker) ￭ The changes are then backchecked, corrected, and verified ￭ In case of disagreement between the Reviewer and the Responsible Engineer, consult the Segment Manager ￭ When all review comments are addressed and corrections are made, the Responsible Engineer verifies the changes made and signs off on the Review Print stamp

“ICE” Review Print Stamp ￭ “ICE” Review Print Stamp used with Design Quality Procedures: ƒ D9: Inter-Discipline Review of Submittals ƒ D10: Constructability Review of Documents ƒ D11: Environmental Compliance Review of Documents

“ICE” Review Comment Resolution ￭ The process is very similar to that described above: ƒ Comments are documented on a copy of the document stamped with ICE Review Print stamp ƒ If no comments were recorded, the Reviewer notes “NO COMMENT” on the stamp ƒ The Responsible Engineer determines disposition for each comment and documents it on the same review print ƒ When all review comments are addressed and corrections are made, the Reviewer verifies the changes made and signs the ICE Review Print stamp at the bottom (“All Review Comments Addressed”)

Design QC Manager’s Review ￭ Received all contents required for submittal? ￭ Check prints properly and fully documented for each Discipline in submittal? ￭ Calculations properly Documented? ￭ Originating discipline, Designer’s internal environmental review, and Independent MDE Reviewer’s comments addressed and reviewer satisfied? ￭ Inter-Discipline, Constructability & Environmental Compliance review comments addressed and reviewers satisfied? ￭ All ICC Team nonconformances & value added comments addressed & discussed? ￭ Partial check prints performed on all changes? ￭ Does the final package “look – good” with no obvious errors / undocumented changes?

Use of Centric Project

￭ Web-based application used for logging, storing, distributing documents for review, and tracking status of submittals ￭ After checking and review by originating discipline have been completed, a Technical Submittal is initiated in Centric (a copy of the document is uploaded, in PDF format) ￭ Target completion dates assigned, Reviewers notified ￭ A reviewer can provide comments in hard copy (or attach a scanned hard copy in Centric) or record them directly in Centric

Use of Centric Project (Cont’d)

￭ If Reviewer provided comments on hard copy, the Responsible Engineer must record responses on the same hard copy ￭ If Reviewer provided comment directly in Centric, the Responsible Engineer must recorded responses in Centric ￭ The submittal proceeds to the next “step” in Centric when all reviewers from the previous “step” approve the submittal

Document Retention Policy

￭ Most official correspondence and submissions must be retained for 7 years from Contract closeout ￭ Check prints and review prints must be retained for those 7 years ￭ Unofficial documents, working documents and the like should be destroyed when the next version of the documents is available

Control of Design Nonconformances

￭ Nonconformance is any condition in equipment, materials, or processes which does not comply with required plans, specifications, codes, standards, documentation, records, procedures, or Contract requirements, which cause equipment, materials, or processes to be unacceptable or indeterminate ￭ Nonconforming design products are prevented from unintended use or installation on the Project ￭ Design quality control processes allow for re-work of design products until they meet the specified requirements

Control of Design Nonconformances (Cont’d) ￭ Any Project staff member, subconsultant, subcontractor, or supplier has the authority and responsibility to identify and report a nonconforming condition ￭ Early identified nonconforming elements (during iterative design working process) are corrected through updates to draft submittal and do not require issuance of a Nonconformance Report (NCR) ￭ Nonconforming conditions identified during Design QC Manager’s review may require issuance of NCR ￭ See Procedure D16, Control of Design Nonconformances, for more information

Discussion and Q&A

￭ Questions? ƒ You can always stop by later and ask (VERY GOOD!) or contact us at: [email protected] (301) 755 2330 [email protected] (301) 755 2331 [email protected] (301) 755 2319

ƒ Or you can ask now (EVEN BETTER!)

Written Test

￭ Open Book, Open Notes ￭ Write your name and today’s date at the top ￭ Don’t ask those sitting next to you – they may not know any better than you do