South Carolina Department of Transportation Short Course Quality Control and Quality
Assurance Technician Certifications for Contractors and SCDoT Personnel
Coarse Aggregate Portland
Cement Concrete Resident Engineer
Coarse Aggregate Technician Certifications
Statement of the Problem and Scope of Report
In 1998, a research project was initiated by SCDOT to explore the Development of
a QC Program for Aggregates in South Carolina. The primary goal of this project
was to develop a program of supplier self-testing and control. This type of program
shifts a larger amount of testing onto the supplier and subsequently increases the
level of monitoring for the SCDOT. With limited personnel, however, the SCDOT is
unable to provide the same level of coverage as its neighboring states. Therefore
it is essential that the suppliers’ QC/QA personnel is highly qualified and
certified in standard aggregate testing. Variances in specifications and test procedures,
coupled with personnel turnover, result in potentially variable material quality
control. A successful certification program aims to minimize the impact of these
problems on material quality.
In 2000, the principal investigators completed a research project on Technology
Transfer Programs for Aggregate and Concrete QC/QA Certification of Contractors
and SCDOT Personnel, Phase I: Planning. The outcome of this Phase I study was the
plan for a certification program based on SCDOT needs and a review of existing state
programs. All technicians involved in the testing of aggregate for SCDOT projects,
including SCDOT personnel, are required to attend a course and pass a series of
examinations. With this program in its initial stages, no state-to-state reciprocity
of aggregate technician certification is permitted. As this program continues to
develop, and states move towards more standardized certification measures, reciprocity
may be considered within the SCDOT program.
This report describes the pilot program and implementation phase for certification
of aggregate technicians. It is important to note that the certification program
is not intended to function as a training school. Attendees should have prior experience
with aggregate testing before attempting certification through this program. The
goal is to provide a pool of technicians who are familiar with SCDOT specifications,
familiar with the newly adopted Policy for Approval of Coarse Aggregate Sources
(Aggregate QC/QA Program), and are certifiably competent in the necessary aggregate
test procedures. To achieve this goal, the examinations must include a hands-on
demonstration of each test procedure by each technician. This hands-on testing requires
time and resources, but is considered essential for verifying technician competence
in each test being performed.
This program consists of two levels of certification. Level I: Sampling and Grading
is intended for all participants and provides a strong background in issues affecting
QC/QA for aggregate suppliers. Level II: Testing is aimed at suppliers’ QC/QA
technicians and appropriate SCDOT personnel who are required to perform and regulate
necessary aggregate QC/QA tests. The Level I course serves as the primary certification
required of all QC technicians and focuses on field sampling, sample reduction and
grading.
During this course, technicians must be certified for proficiency in Sampling of
Aggregates (AASHTO T 2), Reducing Samples of Aggregate to Testing Size (AASHTO T
248), and Sieve Analysis of Fine and Coarse Aggregates (AASHTO T 27).
The Level II course is an advanced course that focuses on physical property testing.
Technicians at this level are certified for proficiency in Specific Gravity and
Absorption of Coarse Aggregate (AASHTO T 85), Resistance to Degradation of Small-Size
Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine (AASHTO T 96),
Plastic Fines in Graded Aggregate and Soils by Use of the Sand Equivalent Test (AASHTO
T 176), and Method for Determining Flat and Elongated Particles in Coarse Aggregate
(SC T 77).
Course instruction is provided through modular presentations on course topics and
hands-on demonstrations of standard test procedures. Course manuals consist of printed
versions of each modular presentation developed in Microsoft PowerPoint. For each
required test, a module describes the test significance, equipment, major steps
required to perform the test correctly, and common errors associated with the test.
For both certification levels, instruction is covered in one day and the examination
is conducted during the next day. To be certified, technicians must pass a one-hour,
open-book written examination and demonstrate individual proficiency in each of
the required tests. During the pilot programs, 17 Level I technicians and 11 Level
II technicians were certified. Changes to both the course content and the examination
procedures were adopted based on the Aggregate Technician Certification Task Force
evaluation of pilot programs at each level.
To fully implement this program, a total of 10 certification courses were offered
during the year 2000. 76 Level I technicians and 24 Level II technicians were certified.
The certification rate for Level I was significantly higher than for Level II. The
certification rate for all Level I courses offered in 2000 is 89%, but the certification
rate for all Level II courses is only 57%. The majority of all attendees were not
familiar with major steps of the standard procedures prior to the certification
program. The following list indicates some of these observed problems during Level
I:
· Lack of awareness on minimum field sample and test sample sizes
· Lack of understanding standard drying of aggregate (“constant mass”)
· Lack of awareness of minimum and maximum shaking time for aggregate gradation
· Difficulty in calculating and reporting percent passing correctly
· Lack of awareness of minimum percent loss requirement for aggregate gradation
The instructors now spend more time on these problematic areas. However, the impact
this program can have on the technicians’ state of knowledge is limited. One
of the major challenges of the Level II program is that most technicians do not
normally perform all four required tests as part of their job responsibilities.
Therefore, many attendees are not properly prepared for this level of certification,
resulting in the low certification rate.
This program is intended to certify suppliers’ technicians and SCDOT personnel
and not to train them. It is therefore essential that technicians registering for
this program arrive well prepared on the required standard procedures. To ensure
continued success of this program, communication of this intention to certify, not
train, is vital. The program directors have established a list of aggregate supplier
contacts and continue to communicate the necessity of having all participants prepared
for the certification course. This program aims to be self-sustaining, offering
courses continuously, as necessary, to certify currently employed technicians yet
to be certified, newly hired technicians, and eventually re-certify technicians
when the five-year term expires.
Portland Cement Concrete Technician Certifications
Statement of the Problem and Scope of Report
The South Carolina Department of Transportation (SCDOT) is in the process of developing
and initiating contractor Quality Control and Quality Assurance (QC/QA) programs
for several of its construction-related processes. In the early 1990's, a research
project was initiated to explore the feasibility of establishing a contractor QC/QA
program for asphalt work. Subsequent research projects developed the process and
SCDoT is now in the implementation phase with pilot projects being conducted and
full implementation expected in 2000. Certifying SCDOT and contractors' personnel
has been an integral part of the process.
In 1998, SCDOT initiated a research contract with Transtec Consultants (Austin,
TX) to develop a Quality Assurance Program for Portland Cement Concrete in South
Carolina. In late 2000, Transtec delivered their draft report entitled Development
of a Quality Assurance Program for Portland Cement Concrete in South Carolina. This
document included the Quality Assurance specification and supporting documentation.
A significant component of the proposed specification is technician certification.
An April 2001 revised draft copy of the SCDOT specification Structural Concrete
Quality Assurance is included in Appendix A- Concrete QC/QA Certification of Contractors
and SCDOT Personnel - Module D - SCDOT Supplemental Material. Appendix A represents
the “course notes” for the pilot offering of the certification program.
The Department of Civil and Environmental Engineering (CEE) of the University of
South Carolina (USC) undertook to develop a comprehensive certification program
for Portland cement concrete contractors and SCDOT technical personnel. This program
is aimed at providing certification for SCDOT technicians and inspectors and contractors'
personnel pursuant to the adopted SCDOT Specification for Structural Concrete Quality
Assurance.
The objectives of this program were to undertake the necessary planning, develop
instructional materials, conduct a pilot program, and to put in place the infrastructure
necessary to fully implement a concrete QC/QA certification program. The concrete
QC/QA certification program complements a similar program developed by the investigators
for aggregate suppliers.
American Concrete Institute (ACI) certification programs were adopted as the basis
for SCDOT certification. Additional supplemental material, relevant to SCDOT practice
was appended to the existing ACI certification program. A detailed description of
this supplemental material and an overview of ACI certification is provided in this
report.
ACI certification was selected as the basis because it is most cost efficient, complete,
up-to-date and nationally recognized.
A pilot offering of the SCDOT certification program was offered June 19-21, 2001.
Eighteen participants were selected. Eleven of these have received SCDOT certification.
Success rates are believed to be typical of what should be expected in the future.
Considerable feedback was solicited from the pilot program offering and appropriate
changes were made to the content and presentation.
It is believed that the experience of the pilot offering will be representative
of future offerings in terms of operation, content and participant performance.
It is further believed that the program described in this report satisfies the requirements
set out in the SCDOT specification Structural Concrete Quality Assurance.
SCDOT Resident Engineer Academy
The Resident Construction Engineer (RCE) and the Resident Maintenance Engineer (RME)
play important roles in the South Carolina Department of Transportation (SCDoT).
The engineers in these positions are responsible for SCDoT projects from pre-construction
activities through final plans and maintenance activities. To keep these engineers
up-to-date in the varied activities related to their positions, a technology transfer
program was organized for the following topics (modules):
- Office Administration
- Environmental
- Materials
- Construction Management
- Intelligent Transportation Systems (ITS)
- Safety
It was determined that the SCDoT would establish the module Safety in-house due
to the number of related programs that they have already developed. The other modules
were developed and piloted at the University of South Carolina (USC).
Modules will be offered twice per year. Please see schedules for presently scheduled
dates.
Cost for each module is $400. Substitutions can be arranged in advance with our
office; however, cancellations without notice of at least 3 business days and no-shows
will not result in a refund of the module fee.
All modules begin at 8:00 a.m. on the beginning day, unless otherwise specified
on the class agenda, and will be held in the Faculty Lounge of the Swearingen Engineering
Center, 301 Main Street. Signs will be posted directing attendees to the classroom,
and attendees are expected to come early to pick up a parking permit. Download map
and directions for parking and building locations.
I: Administrative:
The module consists of 1.5 days of presentations followed by a short examination.
The agenda items are:
- Project Initiation Prior to Pre-Construction
- Project Initiation During Construction
- Project Initiation Ending Construction
- Miscellaneous Reports
- Maintenance
- DBE/EEO
- Public Relations
- Website Presentation (SiteManager)
- Purchasing/Procurement
- STARS Payroll
- Review and Examination
The manual consists of handouts for all items except Public Relations and Examination.
II: Environmental:
The module consists of 1.5 days of presentations followed by a short test. It regularly
follows the Administrative module (after a lunch break) on Day 2 to ease travel
requirements for the participants. The agenda items are:
- Federal and State Laws, Regulations & Guidances: Overview
- 404 Permit (33 USC 1344)(33 CFR Part 330) Highway & Site Management: Hazardous
Materials, Razing Structures, Debris Disposal, Waste Management
- OCRM Permit, Wetlands, Endangered Species, Archeological Sites
- Inspections & Audits: DHEC & EPA, Self-Auditing(Compliance Mgmt), Reporting/Records
(Haz Waste & Generation)
- USTs, Spills, Non-haz Materials/Wastes, Housekeeping
- SPCC Plans
- Introduction to ISO 14000
- Roadside Vegetative Management
- Stormwater Quality Management: Intro., Federal & State Requirements, Permitting,
Management & Planning, MS-4, SWP-3
Examination
The manual includes sections with handouts for all items except Examination.
III: Materials:
The module consists of 1.5 days of presentations and discussion followed by a short
test and then a subsequent 3-day laboratory section in small groups conducted by
SCDoT lab personnel at the SCDoT Materials Research Lab. The laboratory portion
will be scheduled and offered to the participants of the presentation portion. Attendees
will be notified of the lab section dates and should come prepared to choose a preferred
lab section and an alternate section, if necessary. The signed lab section sheet
will need to be faxed or mailed to our offices to insure our records indicate that
this module is completed. The presentation portion agenda items are:
- Structural Steel
- Structural Materials Testing
- Prestressed Concrete Plant Inspection
- Precast Drainage Inspection
- Reinforced Concrete Pipe Inspection
- Ready-mixed Concrete Plant Inspection
- Soils Testing
- Subsurface Investigation
- Pavement Design/Evaluation
- Cement Physical Unit
- Cement Chemical Unit
- Asphalt
- Quality Assurance
- Matlab
- Examination
The manual includes sections with handouts for all items except Examination.
IV: Construction Management:
The module consists of 1.5 days of presentations followed by a short test. It regularly
follows the Materials module (after a lunch break) on Day 2 to ease travel requirements
for the participants. The agenda items are:
- Project Development Process
- Project Initiation
- Scheduling
- Construction Management – General
- Construction Management – Road
- Construction Management – Bridge
- Project Closeout
- Examination
The manual includes sections with handouts for all items except Examination.
V: Intelligent Transportation Systems (ITS):
The module consists of one day of presentations and discussion followed by a short
test. The agenda items are:
- Introduction to ITS
- ITS Elements I
- ITS Elements II: Resident Engineers & ITS
- Incident Management / Freeway Operations
- State Emergency Management Division (EMD)
- Traffic Engineering Road Data Services
- Examination
The manual includes sections with handouts for all items except Examination.
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