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Publication Number: FHWA-HRT-12-051 Date: August 2012

Publication Number: FHWA-HRT-12-051
Date: August 2012

Sample Guide Specifications for Construction of Geosynthetic Reinforced Soil-Integrated Bridge System (GRS-IBS)

SECTION 4. CONTRACTOR QC

4.1. DESCRIPTION

The contractor shall provide a QC system to ensure that all materials and workmanship meet the required quality levels specified. The contractor shall provide qualified QC personnel and laboratory facilities and perform QC sampling, testing, inspection, data analysis, corrective action (when necessary), and documentation as outlined below.

4.2. CONTRACTOR QC PLAN

Before the start of the work, the contractor shall submit a written QC plan for approval by the agency. The QC plan is not intended to be a generic document, but rather, it must be project specific. The plan should sufficiently document the QC processes of all contractor parties (i.e., prime contractor, subcontractors, and producers) performing work required under this specification.

4.2.1. QC Plan Submittal Requirements

The contractor shall be prepared to discuss the QC plan at the pre-construction conference, including the proposed submittal date, QC organization, and sources of materials.

The contractor shall submit one hard copy and one electronic copy of the QC plan for agency approval no less than 45 days prior to the start of any work activities related to GRS-IBS construction, including excavation. The contractor shall not start work on the subject work items without an approved QC plan.

4.2.2. QC Plan Format and Contents

The QC plan shall be structured to follow the format and section headings outlined below. The pages of the QC plan shall be sequentially numbered. The plan shall address, in sufficient detail, the specific information requested under each section and subsection.

Cover Page

Table of Contents

Section 1. Scope and Applicable Specifications

Section 2. Quality Control Organization

2.1 QC Organizational Chart
2.2 QC Personnel and applicable Qualifications
2.3 QC Self-Checks by Production Personnel

Section 3. Quality Control Laboratories

3.1 QC Laboratory Accreditation or Agency Qualification

Section 4. Materials Control Procedures

4.1 Material Types and Source of Supply
4.2 QC of Project Produced Materials Offsite
4.3 QC of Standard Manufactured Items
4.4 On-site Material Storage and Handling

Section 5. QC Visual Inspection

5.1 QC Procedures for Equipment
5.2 Definition of Lots and Sublots (for Inspection)
5.3 Attributes Inspected for Project Produced Items
5.4 Attributes Inspected for Standard Manufactured Items
5.5 QC Inspection Report Forms
5.6 Evaluation of QC Inspection Results

Section 6. QC Sampling and Testing

6.1 Definition of Lots and Sublots
6.2 Random and Selective Sampling Procedures
6.3 Sample Identification, Storage, and Retention
6.4 Quality Characteristics Tested for QC
6.5 QC Sampling and Testing Report Forms
6.6 Evaluation of QC Testing Data

4.2.3. QC Plan Approval and Modifications

Approval of the QC plan will be based on the inclusion of the information required in section 4.2.2 of this guide. Revisions to the QC plan may be required for any part of the plan that is determined to be insufficient by the agency.
Approval of the QC plan does not imply any warranty by the agency that the QC plan will result in completed work that complies with the specifications. It remains the responsibility of the contractor to demonstrate such compliance.
The contractor may modify the QC plan as work progresses when circumstances necessitate changes in QC personnel, laboratories, or procedures. In such case, the contractor shall submit for agency approval an amended QC plan identifying changes at least 3 calendar days prior to the proposed changes being implemented.

4.3. QC PERSONNEL REQUIREMENTS

The contractor’s QC system and QC plan shall be administered by a qualified QC manager. The manager shall have full authority to institute any actions necessary for the successful implementation of the QC plan. Principal responsibilities of the QC manager shall include preparation and submittal of the QC plan, managing the activities of all QC personnel, communicating on quality issues, and ensuring that all requirements in the approved QC plan are met. The QC manager shall have relevant QC experience and qualifications acceptable to the agency.
All QC sampling, testing, and inspecting conducted at the construction site shall be performed by qualified field QC technicians (QCTs). A minimum of one field QCT shall be present during construction of the GRS-IBS. Work will not be accepted by the agency unless the field QCT is present at the site during construction operations and performs the required QC inspection, testing and documentation. All Field QCTs shall be qualified as required by the agency’s QA program.
Any QC testing that is performed at QC laboratories shall be performed by qualified laboratory QCTs. The contractor shall ensure a sufficient number of laboratory QCTs to adequately implement the minimum QC requirements contained in this specification and as outlined in the approved QC plan. All laboratory QCTs shall be qualified as required by the agency’s QA program.

4.4. QC LABORATORY FACILITY REQUIREMENTS

All QC testing shall be performed in laboratories qualified through the agency’s Laboratory Qualification program (LQP) or accredited through the AASHTO Accreditation program (AAP).
Laboratory facilities shall be kept clean, and all equipment shall be maintained in proper working condition. The QC manager shall have overall responsibility for ensuring that all laboratories utilized for QC are in compliance with the requirements of the LQP or AAP. This includes providing required AASHTO, ASTM, and agency reference documents and ensuring that all required testing equipment and tools are properly functioning and calibrated.
The agency shall be permitted unrestricted access to inspect and review the contractor’s QC laboratory facilities. The agency will advise the contractor in writing of any noted deficiencies concerning the laboratory facility, equipment, supplies, testing personnel, and procedures. Deficiencies shall be grounds for the agency to order an immediate stop to incorporating materials into the work until they are corrected.

4.5. QC OF STANDARD MANUFACTURED ITEMS

All manufacturers of standard manufactured items shall have a QC system in place that meets the requirements established in AASHTO R38-10.⁽¹⁷⁾ Each manufacturer shall maintain a Quality System Manual (QSM) that addresses the format and content of AASHTO R38-10.⁽¹⁷⁾ The manufacturer shall perform QC inspection and testing in accordance with their QSM.
All standard manufactured items delivered to the project site shall be accompanied by a manufacturer’s certificate of compliance (COC), which includes the QC inspection and testing results for the corresponding manufacturer’s lot.
- The contractor shall be responsible for reviewing the manufacturer’s COC and accompanying QC results for all standard manufactured items delivered to the project, including, but not limited to, the following:
- CMU blocks.
- Geosynthetic reinforcement.
- Flashing.
- Foam board.
- Reinforcing steel bar.
- Asphaltic coating.
The contractor shall provide copies of each manufacturer COC to the engineer. The contractor’s QC personnel will assist the agency in obtaining acceptance samples for any standard manufactured items, as required by the agency.
The contractor will perform QC inspection of all standard manufactured items upon delivery to the project site and during storage. Contractor QC personnel will also provide inspection of all standard manufactured items throughout field installation of the GRS-IBS system.

4.6. QC INSPECTION

The contractor shall perform QC inspection of all work items addressed under this specification. Inspection activities during production and placement may be performed by qualified production personnel (e.g., skilled laborers, foremen, and superintendents). However, the contractor’s QC personnel shall have overall responsibility for QC inspection.

QC inspection activities must address the following primary components: equipment, environmental conditions, materials, and workmanship. The minimum frequency of QC inspection activity shall be in accordance with the requirements below and as outlined in the approved QC plan.

4.6.1. QC Inspection of CMU Facing Element, Backfill, and Geosynthetics

The contractor’s personnel will perform QC inspection during installation of the CMU facing element, backfill material, and geosynthetics in accordance with the requirements of this specification. The minimum attributes to be inspected are outlined in table 2 and table 3. The contractor shall identify in the QC plan the specific inspection activities necessary to ensure the quality of the work, including any additional QC inspection attributes not specifically listed in table 2 and table 3.

**Table 2. Minimum QC inspection of CMU facing element.**
Inspection Component	Attributes Inspected	Minimum Inspection Frequency	Point of Inspection	Inspection Method
Equipment	As specified in QC plan	Per QC plan	Per QC pan	Per QC plan
Environmental conditions	Underlying surface soundness and moisture	Per QC plan	Underlying surface	Visual check
Environmental conditions	Temperature of air and underlying surface	One per day	At placement location	Check measurement
Materials	CMU blocks (correct type)	Per QC plan	Stockpile on site	Visual check and manufacturer COC
	CMU block dimensions	Per QC plan	Stockpile on site	Check measurement
	Reinforcing steel bar (correct type)	Per QC plan	Stockpile on site	Visual check and manufacturer COC
	Concrete wall fill (correct type)	Per QC plan	At placement location	Check concrete batch ticket
Workmanship	CMU block course (free of debris)	One per CMU course	Each CMU course	Visual check
	CMU block fit (free of gaps)	One per CMU course	Each CMU course	Check measurement or visual check
	CMU block horizontal alignment	One per CMU course	Each CMU course	Check measurement or visual check
	CMU block vertical alignment	One per two CMU courses	Each two CMU courses	Check measurement
	Reinforcing steel bar alignment/cover	One per top of wall or wall parapet	At placement location	Check measurement or visual check
	Concrete wall fill finishing/curing	One per top of wall or wall parapet	At placement location	Visual check
	Concrete coping wall fill finishing/curing	One per top of wall or wall parapet	At placement location	Visual check

**Table 3. Minimum QC inspection of backfill material and geosynthetic reinforcement.**
Inspection Component	Attributes Inspected	Minimum Inspection Frequency	Point of Inspection	Inspection Method
Equipment	As specified in QC plan	Per QC plan	Per QC plan	Per QC plan
Environmental Conditions	Underlying surface soundness and moisture	Per QC plan	Underlying surface	Visual check
Environmental Conditions	Temperature of air and underlying surface	One per day	At placement location	Check measurement
Materials	Abutment backfill (correct type and free of organics)	One per backfill layer	At placement location	Visual check
	RSF backfill (correct type and free of organics)	One per backfill layer	At placement location	Visual check
	Integrated approach backfill (correct type and free of organics)	One per backfill layer	At placement location	Visual check
	Geosynthetics (correct type and free of tears)	One per backfill layer	At placement location	Visual check and manufacturer COC
Workmanship	Abutment backfill (lift thickness)	One per backfill layer	Post-compaction of each lift	Check measurement
	RSF backfill (lift thickness)	One per backfill layer	Post-compaction of each lift	Check measurement
	Integrated approach backfill (lift thickness)	One per backfill layer	Post-compaction of each lift	Check measurement
	Level of backfill behind CMU facing block	One per backfill layer	Post-compaction of each lift	Visual check
	Geosynthetics (embedment area coverage = 100 percent)	One per backfill layer	Each geosynthetic layer	Visual check
	Geosynthetics (coverage of top surface of CMU blocks > 85 percent)	One per backfill layer	Each geosynthetic layer	Visual check
	Geosynthetics (no excessive construction damage)	One per backfill layer	Each geosynthetic layer	Visual check
	Geosynthetics (splice seams staggered)	Per reinforcement schedule	Each geosynthetic layer	Visual check

4.7. QC SAMPLING AND TESTING

The contractor’s QC personnel will perform QC sampling at the site of GRS field placement. QC testing will be performed at the field placement site or at the contractor’s QC laboratory depending on the quality characteristic being tested. The contractor shall furnish approved containers for all material samples. The engineer shall be provided the opportunity to monitor and witness all QC sampling and testing.

4.7.1. GRS Lot and Sublot Sizes

Each lot of GRS backfill material will represent material from the same source, be produced or obtained under the same controlled process, and will possess normally distributed specification properties. Each lot will be divided into sublots of equal size to assess the quality characteristics of the lot. The lot size and corresponding sublot size for each GRS backfill material item is listed in table 4.

**Table 4. GRS backfill material lot and sublot sizes.**
Backfill Item	Material Type(s)	Lot Size	Sublot Size
Abutment backfill	Well-graded aggregate	Total quantity (cubic yard) of backfill material type/same source/abutment	See table 5
Abutment backfill	Open-graded aggregate		See table 5
RSF backfill	Well-graded aggregate	Total quantity (cubic yard) of backfill material type/same source/RSF	See table 5
Integrated approach backfill	Well-graded aggregate	Total quantity (cubic yard) of backfill material type/same source/integrated approach	See table 5

4.7.2. Random QC Sampling

The contractor’s QC system shall utilize stratified random sampling of each lot produced and placed. The contractor’s qualified QC personnel shall obtain random QC samples at the minimum frequencies specified in table 5. In all cases, the QC sampling frequencies shall result in a minimum of one random sample per sublot.

Random sample locations shall be determined using the random number tables and procedures contained in ASTM D 3665-07 or an electronic random number generator.⁽¹⁸⁾ The determination of all random sample locations shall be documented on standard test report forms (TRFs). The contractor will provide the engineer with the random QC sampling locations for each sublot prior to production and placement of the relevant sublots.

4.7.3. Selective Sampling

The contractor’s QC system will also utilize selective sampling (i.e., non-random samples) as needed to provide supplemental information to assist in maintaining all production and placement processes in control. The contractor’s qualified QC personnel shall obtain selective QC samples from any sublot as determined necessary and in accordance with the guidelines established in the approved QC plan.

4.7.4. QC Sample Identification System

The contractor shall establish a reliable system for the identification of all QC samples obtained. All samples shall be correctly labeled with the following minimum information:

Contract number.
Date of sample.
Material type.
Lot and sublot number.
Sample number.
Sample type (i.e., random or selective).
Sample location (e.g., station and offset).

4.7.5. Retention of Split Samples

The contractor will retain split samples from each QC material sample and provide a split sample to the engineer if requested. All split samples shall be properly labeled and stored for a period of 30 days or until tested. These split samples will be utilized, if necessary, in the dispute resolution process. The retained split samples may be discarded prior to the required 30 days if mutually agreed on by the contractor and the agency.

4.7.6. QC Testing of GRS Lots

The contractor’s QC personnel will perform QC testing during production and field placement of the backfill material to ensure that the production and placement processes are providing work conforming to the contract requirements. All QC testing shall be in accordance with AASHTO, ASTM, or agency procedures specified in table 5. The engineer shall be provided the opportunity to monitor and witness all QC testing.

Laboratory testing shall follow section 9.3.1 of FHWA-HRT-11-026 at https://www.fhwa.dot.gov/publications/research/infrastructure/structures/11026/009.cfm#lab.⁽¹⁾
Field testing shall follow section 9.3.2 of FHWA-HRT-11-026 at https://www.fhwa.dot.gov/publications/research/infrastructure/structures/11026/009.cfm#field.⁽¹⁾
Testing shall also follow any supplements by XXX Department of Transportation.

**Table 5. Minimum QC sampling and testing of backfill material.**
Quality Characteristic	Test Method	Sublot Size	Minimum Test Frequency	Point of Sampling	Sampling Method
Gradation	AASHTO T 11-05(6) and AASHTO T 27-05(19)	—	One per lot	Source of material(before use)	Random; AASHTO T 2-91⁽²⁰⁾ and AASHTO T 248-11⁽²¹⁾
PI	AASHTO T 89-10(7) and AASHTO T 90-00(8)	—	One per lot	Source of material (before use)	Random; AASHTO T 2-91⁽²⁰⁾ and AASHTO T 248-11⁽²¹⁾
Maximum dry density and optimum moisture content	AASHTO T 99-10(16) (method C) and AASHTO T 180-10(22)(method D)	—	One per lot	Source of material(before use)	Random; AASHTO T 2-91⁽²⁰⁾ and AASHTO T 248-11⁽²¹⁾
In-place density and moisture content (per targets)*	AASHTO T 310-11(23) (method B) and other approved procedures	Minimum two per lift per day	One per sublot	In-place compacted backfill (before placing subsequent layer)	Random; AASHTO T 310-11⁽²³⁾
— Indicate that the there is no sublot size. *If density requirements cannot be achieved due to material incapable of being compacted or tested to maximum values as determined by AASHTO T 99-10, compact each layer a minimum of four passes using vibratory compactor until there is no visible evidence of further consolidation.⁽¹⁶⁾

4.8. QC Documentation and Data Evaluation

4.8.1. QC Inspection Documentation & Evaluation

The contractor shall document all QC inspection activity for each GRS lot produced and placed. All inspection results shall be recorded within 24 h of inspection on current standard inspection report forms (IRFs). The QC manager shall evaluate inspection results in a timely manner to confirm that production and placement processes are in control. The contractor shall submit hard copies of all IRFs to the engineer at the completion of each lot.

4.8.2. QC Sampling and Testing Documentation and Data Analysis

The contractor shall document all QC sampling and testing data for each GRS lot produced and placed. All sampling and testing data shall be recorded within 24 h of sampling and testing on current standard TRFs. The QC manager shall evaluate sampling and testing results in a timely manner to confirm that production and placement processes are in control. The contractor shall submit hard copies of all TRFs to the engineer at the completion of each lot.

4.9. QC RECORDS SYSTEM

4.9.1. QC Daily Diary

The QC manager should maintain a QC daily diary to document all major activities or actions related to the contractor’s QC system. The QC daily diary serves as a summary record of key actions taken by QC personnel each day. Recommended information that should be recorded in the QC daily diary includes the following:

The day’s weather or environmental conditions.
A summary of production or placement activities completed.
Any non-conforming material or workmanship identified.
Any corrective actions recommended or taken by QC personnel.
Discussions held with other contractor personnel or agency personnel.
Visitors to the production facility or field placement operation.

4.9.2. QC Record Books

The contractor shall maintain one or more ringed binders referred to as “QC record books” to store all required QC documents. Separate QC record books shall be kept at each GRS backfill material production facility and at the project field site. QC data for each pay item number shall be organized into separate sections by quality characteristic and by lot number. QC documents to be stored in the QC record book(s) include the following:

A signed copy of the current approved QC plan.
The original signed copies of all completed IRFs.
The original signed copies of all completed random sampling location forms.
The original signed copies of all completed TRFs.
A current copy or printout of all control charts.
A current copy or printout of all running QLA performed.
Current summaries of all individual QC test results to date (by lot and sublot).
Summary sheets of material quantities produced or placed (by lot and sublot).

Each required record shall be inserted into the corresponding QC record book within 24 h after the document has been completed. All QC record books shall be maintained in a suitable location. The engineer shall be provided access to all QC record books as part of the agency’s monitoring of contractor QC activity.

4.9.3. QC Records Retention

All contractor QC records identified above shall be retained for a minimum of 3 years. The records shall be protected from damage or alteration. When requested by any State or Federal agency for audit or similar purposes, the contractor shall provide complete access to all QC records.

Page Owner: Office of Research, Development, and Technology, Office of Infrastructure, RDT

Topics: research, infrastructure, structures
Keywords: research, infrastructure, structures
TRT Terms: research, infrastructure, Facilities, Structures
Scheduled Update: Archive - No Update needed

This page last modified on 01/31/2017