Division of Engineering Services – Materials Engineering and Testing Services (METS)

Presented by Keith Hoffman, Maged Armanuse, and Nina Choy

METS STATEWIDE CONTRACTS

OVERVIEWROLE OF METS/ PROJECT

DELIVERY

FUNCTION OF THE METS CONSULTANT

PERSONNEL AND PERFORMANCE REQUIREMENTS

A&E CONTRACTS

OVERVIEW

WHY WE DO QA?ROLE OF METS/ PROJECT DELIVERY

Code of Federal Regulations Title 23 - Highways

ROLE OF METS / PROJECT DELIVERY

ORGNAIZATIONAL CHARTROLE OF METS/ PROJECT DELIVERY ROLE OF METS / PROJECT DELIVERY

Proj

ect D

eliv

ery

Construction

Design

Engineering Services

Administration

Structure Design

Structure Construction

METS

Office of Roadway Materials Testing

Office of Structural MaterialsGeotechnical

Services

PPM & OE

Structure Policy & Innovation

Environmental Analysis

Project Management

Right of Way & Surveys

METS OFFICES AND BRANCHES ROLE OF METS/ PROJECT DELIVERY ROLE OF METS / PROJECT DELIVERY

METS

Office of Roadway Materials Testing

Asphalt Binder & Hot Mix Asphalt

Branch

Independent Assurance and

Reference Sample Program

Electrical Testing Branch

Chemical Testing Branch

Joint Training & Certification

Program

Instrumentation Testing Branch

Structural Materials Testing & Corrosion

Branch

Concrete Material Testing Branch

Quality Assessment and Management

Branch

Office of Structural Materials

Quality Assurance & Source Inspection

Sacramento Branch

Quality Assurance & Source Inspection

LA Branch

Quality Assurance & Source Inspection Bay Area Branch

The Office of Structural Materials (OSM) ROLE OF METS/ PROJECT DELIVERY ROLE OF METS / PROJECT DELIVERY

Quality Assessment and Management Branch (QAM) • Fabricator facility audits and programmatic assessments• Data management, J2, DIME, Forms, and Quality Manuals

The Structural Materials Testing/ Corrosion Branch (SMTL)• A2LA accredited lab • structural products: reinforcing and pre-stressing steel, bearing pads,

steel plates and rebar coupling systemsQuality Assurance and Source Inspection Branch (QASI)

• Source inspection at fabrication facilities• Works with contractors, fabricators and stakeholders to provide

material engineering supportConcrete Material Testing Branch

• Aggregate, Cement, and Concrete Laboratories conduct acceptance and prequalification testing of concrete materials for projects throughout the State

Office of Roadway Materials Testing (ORMT)ROLE OF METS/ PROJECT DELIVERY ROLE OF METS / PROJECT DELIVERY

Chemical Testing Branch• Field bridge paint inspections• AASHTO accredited lab for cement testing

IA/RSP/ Skid Testing Branch

• Reference Sample Program Management

Electrical Testing Branch• Testing of traffic control, traveler information and monitoring, lighting, and power

distribution

Instrumentation Services• Structural instrumentation, equipment repair, and electronic design

Asphalt Binder and Hot Mix Asphalt Lab• AASHTO and ASTM accredited lab on polymer modified, rubber modified and air

refined asphalt binders• Testing for research projects, forensic pavement evaluations, and long-life

pavement design and performance

METS QUALITY MANAGEMENTROLE OF METS/ PROJECT DELIVERY ROLE OF METS / PROJECT DELIVERY

ISO IMPLEMENTATION

LEVELS OF INSPECTIONROLE OF METS/ PROJECT DELIVERY ROLE OF METS / PROJECT DELIVERY

METS QA Award, Advertise, Administered by Caltrans

METS OVERSIGHTAward, Advertise, Administered by Local Agency

METS IQAAlternate Delivery / Design Build Contract

Quality Assurance and Source Inspection (QASI) Branches

ROLE OF METS/ PROJECT DELIVERY ROLE OF METS / PROJECT DELIVERY

VallejoSacramento

Los Angeles

ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Technician Support

METS Representative (METS Rep) formerly SMR

Metallurgical, Welding and Corrosion Engineering

Non-Destructive Testing (NDT) Services

Coating Experience

Fabricator Audits

QA Audits

Function of the METSROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

A&E staff are integrated into METS / Caltrans staffProvide inspection and engineering services for:• Capital Projects and Oversight of Local Agency Projects• Maintenance Contracts and Permit Jobs• Specialty Services (metallurgy, welding engineering,

paint, timber, etc.)

Quality Assurance and Source Inspection (QASI) Branch

ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Quality management activities for all materials:• Conducts risk assessment and coordinates inspection, sampling,

and release of a wide variety of fabricated and manufactured products with industry and fabricators

• Verify the structural materials for the CalTrans contracts are in compliance with the project requirements

• Fabrication inspection at the source (statewide and international)• Perform audits of design builders QC/QA efforts• May also observe field welding at job sites and review quality

submittals• Develop specifications with Design

Complex Testing Critical to Success …ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

NON-DESTRUCTING TESTING• Critical in evaluation of material• Requires highly trained and certified staff • Verifies that weld will perform as designed

Complex Testing Critical to Success …ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Ultrasonic Testing

Complex Testing Critical to Success …ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

RadiographicTesting

Complex Testing Critical to Success …ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

MagneticParticle Testing

Complex Testing Critical to Success …ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Liquid Penetrant Testing

PRECAST CONCRETEROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

• PCI Level II or Level III• Experience stressed bridge girders / deck slabs• ABC Construction

INSPECTOR EXPECTATIONSROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

• Perform testing and sampling• Stay current in specification changes and industry

practices• Inspect to verify that the fabricator’s approved Quality

Control plans are implemented effectively• Ability to navigate and interpret codes and

specifications• Identify non-conformance issues – clearly

communicate to METS Rep • Communicate with project team members• Conforms to ASNT TC-1A Written Practice

TYPICAL INSPECTIONROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

• Dynamic in nature. OSM is not always aware of fabrication schedule until the fabricator notifies OSM.

• Inspection is coordinated upon notification• Inspector is dispatched to review contract

documents, set up travel, execute inspection, then document the inspection.

• May have multiple projects inspected at one time, at various stages of production

• Inspection staff may be put on long term assignment depending on fabrication schedule.

The Materials Representative (METS Rep)ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

• Effective communication acting as the Single Point of Contact between OSM and: • Construction• District Materials Engineers (DMEs)• Other Caltrans functional units (Design, Maintenance, etc.)• Local Agencies

• Manages the quality methodology of materials for each project, including shop drawing and control plan submittals

• Understands various fabrication practices and provides technical recommendations to Construction in a timely manner

• Ability to perform research and analyze material data in order to determine engineering solutions and provide engineering recommendations to METS customers.

SUBJECT MATTER EXPERTISEROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Expert recommendations• Welding Engineering (AWS D1.1, D1.5)• Metallurgical Engineering• Corrosion Engineering• Failure Analysis• Structural Concrete Engineering

SNAPSHOT OF CT PROCJECTSROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Districts 1, 2, & 3215 Active, Approx. 15-20 new per month

Districts 6 & 10249 Active, Approx. 5-10 new per month

Districts 4 & 5 421 Active, Approx. 15-20 new per month

Districts 7, 8, 9, 11, & 12592 Active, Approx. 20-25 new per month

Total 1,477 Active ContractsDoes not include all permit jobs, minor contracts, or

cooperative agreement contracts

TYPICAL PROJECT (EXAMPLE)ROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

• 194 Bid Items, 26 of which OSM would typically inspect and release at the source of fabrication

• Other OSM-related items released via programmatic inspection or by the RE at the jobsite

TYPICAL PROJECT (EXAMPLE) - MATERIALS

R O L E O F M E T S / P R O J E C T D E L I V E RY FUNCTION OF THE METS CONSULTANT

• Furnish Steel piling (2.4m) – XKT Engineering, Mare Island (CWI + UT or RT)• Furnish Steel piling (760mm) – Trinity Products, St. Charles, MO (CWI+UT or

RT)• Furnish Steel piling (Class 625) – Unknown• Drive Steel piling – Field welding (CWI + UT inspection)• PTFE Bearings – (Sp. Training for Engineer or Inspector)• Prestressing (CIP) strand – Unknown (typically Sumiden Wire Products,

Stockton)• Prestressing (CIP) anchorages – Unknown (Could be Avar in Campbell, CA

or SDI, or other as proposed by Contractor• Joint Seal Assembly – Unknown (Could be Watson Bowman in Buffalo or

D.S. Brown in Ohio)• Rebar Couplers – Unknown• Signal and Lighting Poles (Unknown, Omaha, Canton, Tulsa typ.)

INSPECTIONROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Multiple inspection locations require flexibility

INSPECTION EXAMPLEROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Consider the Signal and Lighting Source Inspection …

Signal and Lighting Poles

1 inspector per shipmentExample:

•3 contracts District 7•2 contracts District 3•4 contracts District 4

Personnel And Performance RequirementsROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

Consultant Contract Manager • 5 years of responsible experience for similar service contracts. • Shall be a licensed PE in the State of California.

Consultant Task Order Manager • Primary contact for assigned task order and available as needed

METS Representatives • Qualifications equivalent to Caltrans Transportation (Civil), Range D.• Valid Registered Civil Engineering License in the State of California.

Welding Inspectors • Certified as Certified Welding Inspector (CWI) in accordance with AWS QC-1. Fracture Critical (3 years bridge experience)

NDT Level III Inspector

• ASNT Level III certificate holder in UT, PT, MT and RT• ASNT TC-1A Written Practice• Provide Level III Program to insure consultant’s Level II inspectors

are trained and qualified

NDT Inspector • Level II per SNT TC-1A in at least two of the disciplines: UT, RT, MT and PT

Pre-cast Concrete Inspector • PCI Level II or III CertificationPaint and Coating Inspector • NACE Certified Coating Inspector- Level III

Technical Experts • Metallurgical, Welding, Corrosion, Failure Analysis, Structural Concrete Engineering

CONSULTANT ROLEROLE OF METS/ PROJECT DELIVERY FUNCTION OF THE METS CONSULTANT

• Provide flexibility for Construction support• Provide efficiency to work on multiple contracts • Maintain consistency!

Keeps projects moving forward!

1. Caltrans AAA (excluding Gerald Desmond, Maintenance and SFOBB)

ROLE OF METS/ PROJECT DELIVERY A&E CONTRACTS

Quality Assurance (QA) services for projects statewide with Caltrans AAA method of

procurement for Materials Engineering and Testing

Services subdivision.

3 Years $32 Million

59CONTMETA18

2. Caltrans Oversight and Maintenance ROLE OF METS/ PROJECT DELIVERY A&E CONTRACTS

Independent Quality Assurance (IQA) Services for Statewide

projects where Caltrans has an Oversight role over Local

Agencies, and Quality Assurance (QA) of Maintenance projects

statewide.

3 Years$6 Million

59CONTMETB18

MAINTENANCE PROJECTSROLE OF METS/ PROJECT DELIVERY A&E CONTRACTS

HM-1 PAVEMENTThe HM-1 (Pavement) program funds Highway Maintenance (HM) contracts for work related to Pavement Preservation projects. These contracts should primarily focus on preservation projects to maintain existing pavement in good condition. Pavement maintenance activities are generally grouped into Preventative (122 – State Funded and 124 – Federal Funded Programs) or Corrective (Base Programs).

HM-3 BRIDGESThe HM-3 (Bridge Preservation – Major Maintenance) program funds contracts for routine structure preservation projects that meet the program’s guidelines. The typical nature of the work funded by this program is in response to repair recommendations identified in Bridge Inspection Reports that are prepared by Area Bridge Maintenance Engineers. This program focuses on preserving the bridge infrastructure so that future rehabilitation needs are minimized.

3. Alternative Project Delivery (excluding GDB)

ROLE OF METS/ PROJECT DELIVERY A&E CONTRACTS

Quality Assurance Services for State-wide projects with alternative method

of procurement including:

• Public Private Partnership (P3)• Design Build• Construction Manager/General

Contractor (CMGC) [AB 2498]

QA and IQA5 years

$7.5 Million59CONTALT17

CONCLUSIONROLE OF METS/ PROJECT DELIVERY METS STATEWIDE CONTRACTS

Provide flexibility for Construction support.Maintain consistency!

Thank you for your assistance.

Making Conservation a California Way of Life.