BOS – Structures Maintenance

Fabrication Initiative

Richard Marz, PEChief, Structures MaintenanceWisDOT – Bureau of Structures

Richard Marz, PEChief, Structures MaintenanceWisDOT – Bureau of Structures

BOS – Structures MaintenanceFabrication Initiative

BOS Fabrication Improvement Process

• Define the Business Plan for the Shop Fabrication Unit

• Define unique needs for Mega Projects and Role of Shop Fabrications within

• Develop organization Chart for the Shop Fabrication Unit

• Develop clear Roles and Responsibilities of Unit Staff

Gather information :

• Interviews conducted with Steel Producers and fabricators

– CANAN/Structal – Tony Matutis

– High Steel, Lancaster PA• Ronald Medlock, Vice President

– ISC, Gary IN – Francisco Leal

– Veritias Steel, Wausau WI • Ray Isaelniks, QC Manger

Gather information :

• Contacted other Departments of Transportations

– Florida, Illinois, Indiana, Iowa

– Michigan, Minnesota, Ohio, Pennsylvania

– Tennessee, Texas

Gather information :

• Interviewed Bureau of Structures Staff

• Interviewed Regional WisDoT Staff

• Interviewed Consultants working on WisDot Mega Projects

Results of Interviews:

• WisDoT Procedures not well defined

• Communication concerns

• No consistency between projects

• Process differs from state to state

• Quality Assurance vs. Quality Control

Development of WisDot Process

• Focus on Quality Assurance

• Define Core components of WisDot

• Re – organize the Fabrication Unit

• Development of a Fabrication manual

Development of WisDot ProcessKey requirement

• The Fabricator/Detailer is required to provide a quality control review that includes AT A MINIMUM the items noted in Section 4 of NSBA G1.1. To verify that these checks were performed, the Fabricator/Detailer is required to submit the checklist of review items contained in G1.1 Section 4. The reviewer must initial and date each of the sections, 4.1 – 4.16 verifying that the items in that section were reviewed for accuracy as compared to the design drawings. The reviewer must be a licensed Professional Engineer and must stamp, sign, and date the submitted checklist. (Certificate of Shop Drawing Quality Control) In addition, there will be a location for the GC to sign and date.

Development of WisDot Process

• TWO LEVELS of SHOP DRAWING REVIEWS– LEVEL 1

• All Shop Drawings are required to have the submitted checklist (Certificate of Shop Drawing Quality Control) completed, signed and submitted by the Fabricator/GC.

– L EVEL 2• A percentage of structures will be reviewed based on NSBA

shop drawing review guidelines. Selection will be based on a number of factors, including complexity and size.

What is the anticipated timeline for the updated fabrication process?

Phase 1 • Anticipated to begin with the May 2015

Letting– All steel fabrication documents will need to be

submitted to the SFU utilizing SharePoint. (New)– A Fabricator Quality Management Plan (QMP) and

a General Contractor QMP will be required for each WisDOT project. (New)

• A Shipping Plan, Erection Plan, and Storage Plan will be outlined within the QMP . The intent is document the entire process. (New)

Phase 1 (Cont’d)

• Anticipated to begin with the May 2015 Letting

– Contractor’s submitted checklist (Certificate of Shop Drawing Quality Control) with GC signature will be required for each structure (PE Stamp not required until Phase 2) (New form)

– The fabricator will be required to submit regular (weekly) updates (Fabrication Project Status Record) listing deliverables and anticipated submission dates for the project.(Updated form)

Fabrication Project Status Record

• Form DT2172, the Fabrication Project Status Record, has been updated to include photos and require a signature by the fabricator QC representative. This form will need to be submitted on a regular (weekly) basis. (Draft)

Contractor’s Shop Drawing Checklist

Phase 2

• Phase 2, Beginning with August 11 2015 Let Projects– All phase 1 requirements, PLUS– Contractor’s Shop Drawing Checklist (Certificate

of Shop Drawing Quality Control) with PE stamp and GC signature will be required for each structure

– Shop drawings submitted with this certificate incomplete, lacking the PE stamp, or missing altogether will not be accepted.

How will fabrication documents be submitted to the SFU?

• SharePoint, a web application that is used for document and file management.

• You need no special software, just a login which will be assigned by Bureau of Structures staff.

• Training will be provided prior to the implementation of SharePoint.

Questions?

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