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nguyen-tran-2024-exploring-the-use-of-quality-control-plans-for-alternative-contracting-methods-in-highway-projects (1)
nguyen-tran-2024-exploring-the-use-of-quality-control-plans-for-alternative-contracting-methods-in-highway-projects (1)
Abstract: Quality control (QC) is an essential component of quality assurance (QA) programs used to monitor and ensure the highway
construction projects’ quality. After receiving the contractor’s QC plan, state departments of transportation (DOTs) conduct review and
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acceptance, monitor the QC process, and ensure construction quality by performing inspection activities. Given that state DOTs are increas-
ingly implementing alternative contracting methods (ACMs), including construction manager/general contractor (CM/GC), design-build
(D-B), and public–private partnerships (P3), it is essential to consider the impact of shifting more responsibility to the contractor on quality
management activities, including developing and monitoring QC plans throughout the project development. The objective of this paper was to
investigate the implementation of QC plans for administering QA specifications in highway infrastructure projects delivered using ACMs.
The data collected from a national survey questionnaire of 43 DOTs in the US and structured interviews with seven DOT representatives were
employed to investigate this research’s objective. As a result, eight typical requirements of QC plans in ACM projects were identified in terms
of certification and qualification of QC personnel and process control. Additionally, the standard of care of QC staff in ACMs was not found
to be higher than that in design-bid-build. Nine risk factors related to the oversight of QC plans in D-B, CM/GC, and P3 highway projects
were identified. There was no statistical difference in the nine risk scores among D-B, CM/GC, and P3 projects. The findings from seven
case studies provide insights regarding the implementation of QC plans for ACM highway projects. This study contributes to the body of
knowledge by advancing the understanding of how state agencies execute and oversee QC activities in ACM projects. The outcomes of this
study may help state DOTs identify optimal QC practices to administer the QA process in ACM projects. DOI: 10.1061/JCEMD4.COENG-
14123. © 2024 American Society of Civil Engineers.
Practical Applications: This study investigates the current state of practice in implementing QC plans to manage and improve QA proc-
esses for highway projects delivered using ACMs such as CM/GC, D-B, and P3. This study synthesized and documented typical QC require-
ments used by state DOTs in reviewing, accepting, and monitoring contractor compliance with their QC plans. Additionally, the descriptive
and inferential testing results of nine risk factors in implementing QC plans in highway projects found in this study enable highway agencies
to effectively justify their monitoring process of the QC plan implementation. Further, the results from seven case studies provide insights and
key lessons learned regarding (1) the guidance and templates for developing a QC plan; and (2) risk perceptions in managing the QC plan
implementation in ACM highway projects that can benefit both the contractors and state DOTs. The outcomes of this study also shed light on
exploring the optimal allocation of responsibilities between state DOTs and contractors in implementing QC activities to administer QA
programs in ACM highway projects.
Author keywords: Quality assurance (QA); Quality control (QC); Alternative contracting methods (ACMs).
management of QC processes (Tran and Hoyne 2022). One of the QC acceptance decision to be made based on the contractor’s test
obvious changes is the roles and responsibilities between agen- results for its D-B projects (CDOT 2020).
cies and contractors in implementing and managing QC activities Under a CM/GC agreement, the project quality is managed and
(Molenaar et al. 2015b). For instance, under a D-B-B agreement, assured throughout the design and construction processes with in-
the agency has the main responsibility for managing the project puts on quality provided in the design stage by the contractor
quality. On the other hand, under ACMs, such as D-B and P3, the (CDOT 2015). Using the CM/GC delivery method allows the early
agency can shift the responsibility of managing project quality to involvement of the contractor to improve communications between
the contractor depending on how their roles and responsibilities for project parties and make prompt changes in the designs given the
QC are defined in the contract (FHWA 2012). Therefore, the im- feedback from a construction expert (FHWA 2014). As a result,
plementation of ACMs created a new environment for quality man-
CM/GC helps reduce conflicts between design and construction
agement in highway construction projects, which challenges the
and minimize any changes causing cost and schedule overruns
traditional QC process (Scott and Molenaar 2017). This challenge
(FHWA 2014). Due to some similarities in the contractual relation-
affects the efficiency of conducting the QA program and the de-
ship between the agency and the contractor, highway projects de-
velopment of QC plans in highway construction projects (FDOT
livered by CM/GC and D-B-B might have the same process for
2020b). A research gap exists regarding the consideration of the
managing construction quality (Molenaar et al. 2015a). In fact,
impact of shifting more responsibility to the contractor on quality
management activities, including developing and monitoring QC some state DOTs, such as California DOT, have utilized its QA
plans throughout the project development. program for both CM/GC and D-B-B highway projects with min-
This study aims to investigate the implementation of QC plans imal adjustments (Caltrans 2015).
for administering QA specifications in highway infrastructure proj- Under a P3 agreement, the traditional approaches of QA are not
ects delivered using ACMs. Specifically, this study concentrates on essentially considered (FHWA 2019). For P3 projects, state agen-
identifying the typical QC plans’ requirements for contractors in cies across the US have employed a best-value procurement ap-
ACM highway projects and synthesizing the practical experience proach, which lists out the quality management experience as one
of state DOTs in executing QC processes to manage and advance of the evaluation factors for the contractor’s selection (Tran and
their QA programs. The results of this study are expected to provide Hoyne 2022). The US Federal Highway Administration (FHWA)
guidance for contractors to prepare better QC plans for ACM- (FHWA 2019) stated that state DOTs need to consider the P3 con-
delivered highway projects and highlight the implementation of tractual structure and specifications with specific incentives to en-
QC activities in particular ACMs, including CM/GC, D-B, and P3. courage the delivery of a final product that meets the DOT’s QA
requirements. In P3 projects, the contractor (i.e., concessionaire)
performs all QC activities specified in their QC plan, and the
Literature Review agency conducts review and acceptance, inspections, and verifica-
tion of the QC process (Kraft and Molenaar 2015).
In this section, an overview of implementing QA and QC proce-
dures in ACM highway construction projects is summarized. This
section also specifies the points of departure of this study. Point of Departure
The preparation and implementation of QC processes are essential
Overview of QA Programs and QC Plans for ACM to effectively administer QA programs in highway construction
Highway Projects projects (Clifford 2020). Recently, state DOTs have shifted the QC
Under a D-B agreement, the design and construction processes of a responsibility to contractors due to two main reasons (Tran and
project are delivered by a single entity (e.g., design-builder), which Hoyne 2022). First, state DOTs can monitor and control the con-
leads to differences in the quality management process compared tractor’s QC process and perform inspections and verification for
with D-B-B projects (AASHTO 2008; ITD 2014). In D-B projects, acceptance of the product quality. Second, the contractor is pro-
state agencies need to thoroughly communicate the project’s qual- vided with more control over the materials, personnel, and equip-
ity requirements and specify all regulative processes and technical ment used for the QC process. To optimize the QC process, the
specifications that it intends to implement to monitor the quality of contractor is required to develop a proactive QC plan based on the
the design and construction processes (AASHTO 2019). Although state DOT’s requirements and expectation of the project quality
the use of D-B necessitates the design-builder to be responsible for (TxDOT 2017; VDOT 2018). The goal of implementing a well-
design, construction, and procurement of materials, the agency still developed QC plan is to maximize the QC outcomes, reduce re-
needs to monitor and perform testing and inspections to ensure the work, and improve project performance. However, contractors
quality of work. (Tran and Hoyne 2022). Thus, it is important that often develop QC plans solely to meet the DOT’s requirements
Research Methodology regarding the use of QC plans for ACMs are as follows:
The existing literature shows that the increasing use of ACMs in • Does your agency require contractors to submit any QC plans to
highway construction projects challenges the traditional quality the state DOT? If “No”, is your agency considering requiring
management process in managing the DOTs’ QA programs, espe- contractors to submit any QC plans to the DOT?
cially when they have shifted the responsibility for QC processes to • Which alternative contracting methods (D-B, CM/GC, or P3)
contractors. Therefore, this study focuses on exploring the current are used by your agency? (Please check all that apply.)
practices of executing QC plans for ACM-delivered highway proj- • Compared to traditional D-B-B projects, does your agency hold
ects by (1) identifying the QC requirements for ACM projects to the contractor QC staff to a higher standard of care for ACM
help contractors better prepare their QC plans; and (2) analyzing (D-B, CM/GC, and P3) projects?
how state DOTs implement and monitor QC processes in ACM • How does your agency conduct QC plan review and approval
highway construction projects to provide lessons learned. The re- processes?
search methodology of this study includes a mixed use of a content • From your agency’s perspective, please rate the importance/
analysis of standard procedures, reports, and manuals for QA and criticality of the risk factors (i.e., areas of concern) in oversight
QC processes related to ACMs in the existing literature, a survey of of QC plans.
50 state DOTs, and detailed case studies as shown in Fig. 1. Finally, structured interviews were conducted with selected
First, a systematic literature review was performed to synthesize DOTs to further investigate the practices of implementing QC plans
the relevant documents regarding the requirements and implemen- in ACM highway projects. The selection criteria included (1) QC
tation of QA programs and QC plans in ACM highway construc- plan’s requirements, (2) types of QC plans required, (3) experience
tion projects. The search included current industry publications, with QC plans, (4) experience with CM/GC, D-B, and P3, and
academic literature, guidelines and reports from state DOTs, and (5) availability of the state DOT’s representative to participate in the
federal regulations and manuals to synthesize the current practices follow-up interviews regarding the implementation of QC plans for
of QA programs and QC inspection and testing activities in ACM- ACMs. As a result, this study initially identified 11 state DOTs for
delivered highway projects. This study attempted to seek both the the follow-up interviews. The research team contacted each DOT
most recent documents and historical information to promptly take via phone calls and emails inquiring their willingness to participate
into account any changes in the state DOT’s guidelines and man- in the case studies about implementing QC plans to advance their
uals, if any, in their QA programs and requirements for QC plans QA processes in ACM projects. Accordingly, seven state DOTs,
for ACM highway projects. including Florida, Idaho, Kansas, Nevada, North Carolina, Utah,
Second, a web-based survey questionnaire and its paper-based and Virginia, were selected for the subsequent case studies.
forms were developed and initially distributed to all state DOTs The representative of each DOT was provided with the same
across the US, including the District of Columbia DOT. Each DOT list of detailed questions relevant to implementing QC plans for
was requested to respond to the survey questionnaire or forward it CM/GC, D-B, and P3, for the structured follow-up interviews. The
to the person or people with the relevant knowledge to be able to DOTs that participated in the interview were asked to provide docu-
complete the survey. The survey was designed to investigate how ments, guidelines, manuals, and lessons learned related to their QA
• What challenges have your agency experienced in the review or the QC staff who are responsible for QC activities and can be de-
oversight of a contractor QC plans? What strategies has your termined by assessing the level of prudence of the QC staff in the
agency taken to overcome such challenges? same activities (Banik and May 2006). The following sections pro-
• How does your agency monitor the implementation of the QC vide specific requirements and contractor’s QC’s staff standards
plan after approval? for implementing QC plans in ACM projects in comparison with
• Do the risk factors in oversight of QC Plans vary corresponding traditional D-B-B delivery. In addition, descriptive and inferential
to each different delivery method (D-B-B, D-B, CM/GC, and analysis of typical risk factors in oversight of QC plans in D-B,
P3)? Please explain briefly. CM/GC, and P3 projects are presented.
Table 1. Distribution of state DOT responses and ACMs used in their highway projects
State DOT D-B CM/GC P3 State DOT D-B CM/GC P3 State DOT D-B CM/GC P3
Alabama x — — Louisiana x — x Oregon x x —
Alaska x x — Maine x x — Pennsylvania x — x
Arizona x x x Maryland x x x Rhode Island x — —
Colorado x x x Massachusetts x — — South Carolina x — —
Connecticut x — — Michigan x — — Tennessee x x —
Delaware — x — Mississippi x — — Texas x — x
Florida x x x Missouri x — — Utah x x x
Georgia x — x Nevada x x x Vermont x x —
Idaho x x New Hampshire x — — Virginia x — x
Indiana x — x North Carolina x x x — — — —
Kansas x x — Ohio x — x — — — —
In this study, a five-point scale from 0 to 4 was used to provide (69.2%) indicated that no correction following QC results and no
semantic insights regarding the severity of the risks and whether or QC personnel onsite are High to Very High risks in oversight of
not the risks have an impact on the monitoring process for QC plans QC plans. Additionally, eight state DOTs (61.5%) rated contractor
in ACM-delivered highway projects. Monitoring the implementa- operating at the lower end of specifications as High Risk to Very
tion of QC plans in ACM highway projects was found to contain High Risk in monitoring the implementation of QC plans. On the
the following risks: (1) no correction following QC results, (2) no other hand, four state DOTs (30.8%) indicated that inexperienced
QC personnel onsite, (3) contractor operating at the lower end of agency personnel are a Low risk in oversight of QC plans for P3
specifications, (4) validity of QC test data, (5) incorrect sampling projects.
methods, (6) inexperienced QC personnel, (7) control of the mate- The Kruskal-Wallis H-test was performed to investigate
rial provider, (8) DOT losing expertise, and (9) inexperienced whether or not there is any difference in the risk scores among
agency personnel. To standardize the measurement of the risks in CM/GC, D-B, and P3 projects. As reported in Table 3, the
monitoring QC plan implementation, the following risk score (RS) p-values of nine risk factors were greater than 0.05, indicating that
is calculated using Eq. (1): there was no statistically significant difference in the nine risk fac-
P tors among these ACM highway projects although the risk scores
ðnkp × rp Þ
RSk ¼ P ð1Þ of implementing QC plans in D-B projects were found greater than
nk that of CM/GC and P3 projects. A possible reason is due to the
small sample size of CM/GC (n ¼ 11) and P3 (n ¼ 13) compared
where RSk = risk score of the factor k; nk = total number of re-
with D-B (n ¼ 32). Another reason is that the majority of the risk
sponses to the factor k; nkp = total number of responses to the factor
factors in monitoring the implementation of QC plans in D-B high-
j associated with the rating rp ; and rp = risk rating of the factor k.
way projects had a Moderate RS, similar to the risk factors in
For D-B highway construction projects, the survey results show
CM/GC and P3 projects. Although the risks of contractor operating
that the nine risk factors in oversight of QC plans had RS rang-
at the lower end of specifications and incorrect sampling methods
ing from Moderate to High. Out of 32 responses, 24 state DOTs
were found with the highest RS in oversight of the QC plan im-
(75.0%) rated contractor operating at the lower end of specifica-
plementation in ACM highway projects, the risk of inexperienced
tions as High Risk to Very High Risk in monitoring the implemen-
agency personnel was found with the lowest RS across the three
tation of QC plans. Additionally, 20 state DOTs (62.5%) rated
ACMs.
inexperienced QC personnel and incorrect sampling methods as
Moderate Risk to High Risk in oversight of QC plans. On the other
hand, 24 state DOTs (75.0%) rated inexperienced agency personnel Discussion
as Low Risk to Moderate Risk in oversight of QC plans for D-B
projects. The results of this study are supported by the case studies where
state DOTs discussed the implementation of QC plans for their
ACM highway projects with regard to the requirements of a QC
plan for contractors, guidance and templates for developing a
QC plan, and risk perceptions in oversight of the QC plan imple-
mentation. Table 4 summarizes the implementation of QC plans in
ACM highway projects of the case studies. The following sections
discuss the QC implementation in each ACM highway construction
project (D-B, CM/GC, and P3, respectively) in detail.
adequate statements about how the contractor will perform QC Some DOTs require the contractor to have separate QC plans
activities for its highway projects delivered using D-B and describing specific QC processes and responsive actions for both
Progressive D-B. Kansas DOT also requires the D-B contractor design and construction activities. For example, Florida DOT re-
to submit a QC plan that delineates how their QC activities for quests the contractor to have two sets of QC plans for managing
specific items of the work, such as planning, design, construction, (1) design quality compliance, and (2) construction QC for D-B
geotechnical analysis, and environmental consideration, are com- highway projects. Specifically, the QC plan for design quality
plied with the DOT’s QC requirements included in the contract compliance includes QC activities related to reviewing, checking,
documents. and verifying essential drawings, specifications, and other design
found that the reliability of the contractor’s testing results is one enced QC personnel (RS ¼ 2.36), and incorrect sampling methods
of the main risk factors in monitoring the implementation of QC (RS ¼ 2.18). To reduce the risks in oversight of implementing QC
plans in ACM highway projects. Virginia DOT also indicated that plans in their CM/GC projects, North Carolina DOT authorizes res-
it is difficult to clearly define the QC responsibilities in D-B high- ident engineers to evaluate and verify the contractor’ test results to
way projects. Therefore, in its D-B projects, Virginia DOT seeks make sure the QC process complies with the contract requirements.
to adequately transfer the risks in managing QC activities to the Florida DOT utilizes a quality management system for material
contractor. testing and acceptance to verify the use of materials in their CM/
The findings of this study show that the top three risks in over- GC projects and confirm whether the contractor QC testing data
sight of the QC implementation in highway projects delivered using meets their requirements. The Florida DOT’s quality management
D-B included contractor operating at the lower end of specifications system for materials employs automated checks and balances to
(RS ¼ 3.00), inexperienced QC personnel (RS ¼ 2.81), and incor- make sure that the contractors comply with the use of materials
rect sampling methods (RS ¼ 2.81). State DOTs, including Idaho, specified in the contract.
Kansas, Nevada, North Carolina, and Utah, required the contractor
to establish and maintain an independent quality management sys-
tem to check and verify the outcomes of implementing QC plans in QC Plan Implementation in P3 Projects
D-B highway projects. State DOTs also requires the design-builder The results of this study show that state DOTs provide similar re-
to select and assign a QC manager who oversees and ensures that quirements related to QC plans for P3 and D-B-B highway projects.
the contractor follows the QC requirements specified in the con- Specifically, P3 contractors are required to provide quality manage-
tract. Accordingly, if any QC activities and testing processes are ment for both QA and QC processes in highway construction proj-
found not to follow the DOT’s procedure, the assigned QC manager ects. State DOTs, such as North Carolina DOT, necessitate P3
is authorized to stop work until corrective action is taken. contractors to have individual QA and QC plans for the design
Performing QA activities by independent firms can help the and construction stages. The contractor needs to ensure that their
agency avoid several risks in monitoring the implementation of QA and QC plans meet the DOT’s minimum QC requirements
QC plans, including inexperienced QC personnel and no QC per- specified in the P3 contract. Similarly, Florida DOT requires the
sonnel onsite. For example, the Idaho DOT representative indicated P3 contractor to a QC plan in accordance with the DOT’s Standard
that, under D-B contracts, the contractor designates a QC manager Specifications.
to oversee QC activities, and the DOT performs verification and In the Nevada DOT’s P3 highway projects, the contractor is
inspection of the quality management activities. required to prepare a responsive QC plan for testing and monitor-
ing the QC process, and the DOT performs regular checks and veri-
fication to ensure the contract compliance. Accordingly, Nevada
QC Plan Implementation in CM/GC Projects
DOT has shifted the responsibilities in overseeing the material
The results of this study show that state DOTs necessitate the same providers, checking the QC tests, and ensuring the sampling results
requirements for preparing QC plans for CM/GC and D-B-B high- to the P3 contractor.
way projects. For instance, in their CM/GC projects, Nevada and Under P3 contracts, Virginia DOT requires the contractor to sub-
Utah DOTs have used requirements for contractor QC plans similar mit a proactive QA/QC plan, which outlines a systematic process
to the D-B-B projects. Specifically, the contractor is expected to to monitor and enhance the quality management for design and
submit a proactive QC plan to check the quality of work complied construction activities. The QA/QC plan for design activities needs
with the QC requirements stated in the contract. It was noted by to include actions regarding (1) reviewing design standards, draw-
Utah DOT that a QC plan for CM/GC projects should highlight the ings, specifications, and constructability, (2) checking the accuracy
importance of achieving high quality during the beginning of the of design reports, (3) communicating the reviews’ outcomes be-
work, improving communications between project stakeholders, tween QC staff, and (4) preparing QC checklists. The QA/QC plan
and ensuring the work compliance to avoid rework. Florida DOT for construction activities needs to specify QC staffing, testing pro-
also emphasizes the responsibility of the contractor in CM/GC cedures, verification process, and inspection agenda.
highway projects to oversee the subcontractors’ work, evaluate the Similar to other ACM projects, state DOTs identified various
efficiency of construction methods and processes, and make sure risks in monitoring the implementation of QC plans in P3 highway
that high-quality work is performed. projects related to the reliability of the quality testing results and
State DOTs indicated that the majority of the risks in oversight nonconforming work due to the QC responsibility being shifted to
of the QC plan implementation in CM/GC highway projects were the concessionaire entity in P3 highway construction projects. The
ranged in Low (RS < 2.00). A possible reason is that using CM/GC top three risks in oversight of the QC plan implementation in P3
delivery method allows the contractor to be involved early in the projects included no correction following QC results (RS ¼ 2.46),