QPL vs Specification requirements.

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Critical Construction IssuesBy Rafiq Darji

• QPL v/s Specification requirements.
• Steel Girder Erection issues.
• Picket Railing on Bridges.
• Concrete Field Technician Level II
  requirements.

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QPL v/s Specification Requirements

• Selecting a product from the QPL does not by
  itself constitute final acceptance of that
  product.
• Final acceptance of a product is granted only
  when it is in full compliance with applicable
  specifications, which may require that the
  product be manufactured by a producer who is
  qualified by the Department and is on the State
  Materials Office (SMO) list of Producers with
  Acceptable QC Programs .
• The list can be obtained at the following
  website
• http//www.dot.state.fl.us/statematerialsoffice/qu
  ality/programs/qualitycontrol/materialslistings/po
  stjuly2002.htm

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• Currently SMO website has 15 lists depending on
  the category of product. The following is a
  summary of those items on the QPL by category
  that are required to be on an approved producer
  list of the SMO website.
• Precast Temporary Barrier Wall (Specification
  521), Sound Barrier Panels (Specification 534),
  Retaining Wall Panels (Specification 548) and
  Concrete Strain Poles (Specification 641) SMO
  List Concrete Sources Precast Incidental,
  Drainage and Pipe
• Galvanizers for Guardrail (Specification 536)
  Roadway Sign Supports (Specification 700-2.3) and
  Light Poles (992-2.1) SMO List Coatings
  Sources
• Steel Strain Poles, Steel Mast Arms and Monotube
  Assemblies (Specification 649) and Steel and
  Aluminum Light Poles (992-2) SMO List - Metal
  Fabricators
• Aluminum Pedestrian-Bicycle Railing (Index 860)
  and Aluminum Pipe Guiderail (870) SMO List
  Metal Fabricators

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• If the component is not manufactured by a
  producer on the SMO list then even if it appears
  on the QPL, it may not be accepted for use on a
  Department project.
•  
• Where required, the product must be stamped by
  the producer which signifies that the product has
  been manufactured in full compliance with the
  producer's QC Plan and the applicable
  specifications and the required certifications.

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• Here is an example of typical specification
  requirements.
• For Prestressed Concrete Poles, the Section 641-1
  says, Obtain precast, prestressed concrete
  poles from a manufacturing plant that is
  currently on the Departments list of qualified
  precast, prestressed concrete plants and listed
  on the Departments Qualified Products List
  (QPL).
• Look out for a DCE memo that will be issued very
  shortly emphasizing this issue.

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Steel Girder Erection Issues

• There has been more than one incident where beams
  did not fit between the end bents or beam seats
  after they were fabricated and erected. Hence,
  the beam ends had to be cut in the field and
  jacking was performed to accommodate the as-built
  conditions.
• Do your homework prior to erecting the girders
  Verify the as-built locations of the piers and
  beam seats with respect to the plans
  dimensions. If there are any differences, fix
  them in the shop prior to shipping or on the
  ground prior to erecting. Any repair work done
  after the erection will be difficult, costly,
  risky and unsafe.
• Verify backwall plumbness. Out of plumbness of
  the backwall combined with geometry and
  temperature effects on the girder will pose
  serious fitting issues.

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• If any jacking is required to correct the miss
  alignment after the erection, place jacks at the
  plans specified locations. Placing jacks at
  different locations may damage the pier caps
  and/or girders. Communication between the
  Contractor and CEI is very critical in achieving
  the success. Have a meeting prior to jacking
  operations.
• Erection during hot weather conditions may pose
  more challenges especially for those girders
  where high skew, steep superelevations and tight
  horizontal curvatures exist. Watch out for
  length variations due to temperature rise/fall.
• If possible, erect girders at fix bearing first.
  Adjustments and fit up at the expansion bearing
  can easily be accommodated due to the presence
  of slotted holes, sliding surfaces, etc.

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• Do not apply lateral or longitudinal forces on
  to the girder system without releasing all the
  restrains. Otherwise, you may introduce torsional
  moments into the girder system.
• Do not force the girders to fit in to the anchor
  bolt holes. Otherwise, this may introduce
  locked-in forces into the girder system.
• Verify that the anchor bolt block-out locations
  are in compliance with the plan details prior to
  concrete placement.
• Make sure that the anchor bolt block-out formwork
  is secured and stable during concrete placement
  operations. if it is displaced, new holes needs
  to be cored into the cap, which may damage the
  existing cap steel and may affect the design. An
  Engineers approval will be required prior to any
  coring.

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Aluminum Pedestrian /Bicycle Picket Railing on
Bridges

• Due to some recent failures in the welded
  connections of picket railings, the Department
  has modified the Standard Index No. 860 (2008
  version) to allow non-welded connection at the
  top.
• Previous Index details require welding at both
  top and bottom picket connections.
• Now, on Bridges only, the index requires
  non-welded connection between the picket and top
  rail and welding connection between the picket
  and bottom rail.
• Non welded connection is optional for other
  locations such as for roadway applications.

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Here are some photographs of failed picket rails

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I encourage incorporating this detail in all
ongoing bridge projects, If this is possible.

Index 860 Non welded Picket and Top Rail
Connection Detail
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Concrete Field Technician Level II requirements

• The Specification Section 105-5.7.2 requires a
  level II technician must be present on the
  jobsite during all concrete placements on major
  bridge projects. Prior to the placement of
  concrete, the technician will inspect the element
  to be cast to ensure compliance with Contract
  Documents.
• The following questions have been raised many
  times on the above requirements,
• Is this indented to apply only to placements that
  are structural elements of the major bridge as
  opposed to all placements of structural concrete
  anywhere on a project that includes major bridge,
  e.g. inlet tops, etc.?
• Is the reference to inspection prior to casting
  intended to require that only a level II
  inspector is qualified to do a pre-placement
  inspection or that a level II technician
  supervise the process as with testing plastic
  properties?

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• Here are clarifications to those questions
• The level II requirement applies only to placing
  components of a major bridge and not to all
  placements on a project which includes a major
  bridge. The Specification 105-5.7.2, is intend to
  apply to structural components of major bridges
  including decks, caps, footings, columns, crash
  walls, abutments, barrier walls etc.   The type
  of structures that are considered to be MAJOR are
  defined in Specification
• 5-1.4.1(e).
• The Level II Technician must personally inspect
  form work (bracing, alignment, dimensions, etc.),
  rebar placement (positioning, size and quantity),
  screed operation, preparation for curing and
  inclement weather and evaporation rate monitoring
  to name some of the items to be checked, prior to
  the actual placement of concrete.
• During the actual concrete placement process
  (delivery, sampling, testing, record keeping,
  concrete placement, vibration, screeding,
  finishing, evaporation monitoring, curing, etc.)
  the Level II Technician should be present at the
  site of work in progress.

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Having said that, one may ask, why is level II
technician not required for minor bridges? Is
this because the quality on minor bridges is not
as important as on major bridges ? There is no
doubt, quality on minor bridges is as important
as on major bridges. But, due to the scarcity of
Level II Technicians, the Contractors would have
a very hard time to find and supply Level II
Technicians for all bridge projects. Hence, the
Department in conjunction with the Contractors
had decided to have this requirement only for
major bridges.

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Departments Future Direction on the Level II
Requirements
In order to be a Level II qualified, the
Construction Training and Qualification Manual
(CTQM) requires an ACI CTCI certification. This
course is difficult and covers topics other than
bridges, which has been a problem for
Contractors. In order to address this issue, at
present, the ACI is at the final stage of
developing a new course concentrating on roads
and bridges. After the course is finalized and
accepted by the Department (i.e. TRT), the course
will be offered to the public. Once this is
done, a year after this date, the Department will
require Level II technicians for Contractors in
all bridge projects regardless of it being a
minor or a major bridge project. The one year
time is allowed so that the Contractors have
sufficient time to train their personnel and take
the required course.

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REMINDER

• Due to variety of quality problems on Category 2
  (C2) construction projects, few years ago, a memo
  (No.17-05) was issued to clarify the role of
  State Construction Structures Engineer (SCSE) on
  C2 bridge construction projects .
• Require notification and consultation with the
  SCSE by the CEI staff on technical matters such
  as any proposed deviation from the plans and
  specifications Contractor means and methods that
  might adversely impact the performance or
  durability of the finished bridge and Contractor
  proposed corrections of damaged or defective
  structural components.

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