Maintenance Quality Assurance Program Manual - WisTrans

1 Maintenance Quality Assurance Program Manual Kansas Department of Transportation Bureau of Construction and Maintenance 2007 i Acknowledgements The Kansas Department of Transportation would like to acknowledge the following personnel for their contributions to the development and implementation of this Maintenance Quality Assurance (QA) Program : Marshall Stivers (of Eres Consultants, Inc.) who established the framework for developing Maintenance Quality Assurance programs in NCHRP Report 14-22 and kicked off KDOT s initial effort, in October 1998, by providing a six-hour class on the concepts to Maintenance supervisors. Bob Kardian (Virginia DOT) who provided valuable information, related to the development of the Virginia DOT Maintenance QA Program , that assisted in the KDOT development effort.

2 Jong-I-Perng (KDOT Bureau of Materials and Research) who provided statistical information and assistance for the Maintenance QA Program development. Ron Balsters (KDOT Bureau of Transportation Planning) who provided the CANSYS database information that was used to generate randomly selected sample sites for inspection. Tom Brewer and Mark Reddy (KDOT Bureau of Computer Services) who provided the programming effort to generate randomly selected sample sites for inspection, to enter the inspection data, and to perform the calculations for Maintenance Rating values. The Maintenance Quality Assurance Committee (listed below) whose professionalism, extensive technical expertise, numerous years of experience, candor, and genuine commitment to the Maintenance QA Program were critical to the development and implementation effort. Original Maintenance Quality Assurance Committee Clay Adams, District Maintenance Engineer, District One Jim Williams, Area Superintendent, District One, Osage City Peter Wiehe, Area Supervisor, District One, Kansas City Ken Shivers, Area Superintendent, District Two, Clay Center Kevin Jirak, Area Supervisor, District Two, Marion Doug Driggs, Area Superintendent, District Three, Phillipsburg Marvin Withington, Area Superintendent, District Three, Atwood (now retired) Wesley Roecker, District Superintendent, District Four (now retired) Doug Vogel, District Superintendent, District Four Charles E.

3 Mills, Area Supervisor, District Four, Pittsburg (now retired) Leon Cziske, District Superintendent, District Five (now retired) Donald Brittain, District Superintendent, District Five Steve Smith, Area Superintendent, District Five, Great Bend (now retired) John Clayton, Area Superintendent, District Five, Great Bend Mike Pittman, Construction/Materials Engineer, District Six, Dodge City Ron Munyan, Sub-Area Supervisor, District Six, Garden City Chuck Oldaker, Area Engineer, District Six, Ulysses Janis Rowland, MMS Coordinator, Bureau of Construction and Maintenance (now retired) Chuck Protasio, IMMS Engineer, Bureau of Construction and Maintenance ii Table of Contents i Overview of the Maintenance Quality Assurance 1 1 Rationale.

4 1 1 Intended 1 Sample Segment Length .. 1 Exclusions to the Population of Sample Segments .. 1 Stratification .. 2 Maintenance Categories .. 2 Rating 2 Maintenance Rating Criteria .. 4 Target Maintenance Rating Values .. 4 Simple Illustration Using Maintenance Rating Values as a Management Tool .. 4 Comparison Charts .. 6 Maintenance Rating Criteria Summary 7 Maintenance Rating Criteria .. 9 9 Flexible Rigid Shoulders .. 14 Paved Unpaved Roadside .. 18 22 Traffic 25 Evaluation 30 Survey Frequency .. 30 Choosing the 30 Field Inspections .. 30 Upon Completion .. 30 Analysis of the Data .. 30 Maintenance Quality Assurance Inspection Form .. 30 30 Inspection Form 30 Categories & Rating Inspection 31 31 Unusual Conditions .. 31 Inspection of Divided Road .. 31 Two Separate 31 Shoulder/No Shoulder Guidance .. 32 Handling of Unusual Inspection 32 Sample Under 32 Sample on Bridge.

5 32 Sample with Both Rigid Pavement & Flexible Pavement .. 32 Sample with Intersections & Adjacent Ramps .. 32 Variances in Urban Undivided Roads .. 32 iii Table of Contents Sample with Paved Median Crossover or Mailbox 32 Sample with Composite 33 Sample with One Paved Shoulder & Unpaved Shoulder .. 33 Sample is Connecting Link .. 33 Sample overlaps Subarea, Area, or District Boundaries .. 33 KDOT forces performing Maintenance 33 Raised Medians .. 33 Urban Areas .. 33 Sample in Another District .. 33 Right-of-Way Diagram Associated with 34 KDOT Maintenance Quality Assurance Inspection Form .. 35 Inspection Team & Equipment .. 37 Inspection Team Organization & Responsibilities.

6 37 Equipment & 37 Maintenance Rating Calculations .. 39 Scope .. 39 MR Value for a Specific Sample 39 Calculating the Rating Element Maintenance Rating .. 39 Calculating the Maintenance Category Maintenance 39 Adjusted Travelway Value .. 41 Calculating the Overall Maintenance 41 MR Reports .. 42 Maintenance Rating Reports ..42 Statistics .. 43 Sample Size 43 Current Sampling Effort .. 43 Expected Failure Rate .. 43 Definitions .. 44 Bibliography .. 49 Traffic Guidance Signs .. 51 1 Overview of the Maintenance Quality Assurance Program Purpose. The purpose of this Manual is to outline KDOT s Maintenance Quality Assurance Program . The Maintenance Quality Assurance Program is a management tool to help Maintenance managers to identify and prioritize Maintenance needs.

7 This management tool will also assist Maintenance managers in prioritizing Maintenance projects and resources (personnel, equipment, materials, and funding) as part of an annual, quarterly, or monthly planning process. Rationale. The reasons for implementing the Maintenance Quality Assurance (MQA) Program are as follows: The Maintenance QA Program is consistent with the KDOT Strategic Management Plan, which emphasizes customer service, Quality , and the need to measure performance. The Maintenance QA Program provides a means of measuring the value or results of KDOT s Maintenance efforts on the overall highway level of service. In its implementation, the Maintenance QA Program contributes to doing the right thing at the right time at the right location at the right cost to satisfy the traveling public s needs (as identified in External Customer Surveys) and KDOT s mission.

8 The Maintenance QA Program assists in identifying Maintenance needs and prioritizing KDOT s Maintenance efforts and the related resources. Concept. The Maintenance Quality Assurance Program involves a physical inspection of randomly selected sample segments using identified Maintenance Rating (MR) criteria for highway rating elements. Rating elements are specific components of the highway, such as regulatory and warning signs, or specific conditions in the highway system, such as cracking or rutting. Based upon the inspection results, the Maintenance Rating values for the Kansas highway system at various organizational levels (State, District, Area, or SubArea) are calculated. For planning purposes and prioritizing projects and resources, the resulting MR values are then compared to target MR values. Over time, this Program also provides a process for assessing Maintenance efforts statewide, and considering Maintenance consistency over the entire system as well as any special needs due to local conditions.

9 Intended Users. The primary users of this Manual are as follows: Maintenance QA inspectors, who will determine the pass/fail condition assessment of sample segments based upon the MR criteria. Maintenance managers, who will use the results of the Maintenance QA Program as a management tool to identify Maintenance needs to prioritize Maintenance projects and resources. Sample Segment Length. The sample segment length of was chosen to allow the Maintenance QA inspection teams to walk the sample segments and thus improve the accuracy of the collected inspection data. Exclusions to the Population of Sample Segments. The following are excluded from the population of sample segments in the Maintenance QA Program : Turnpike Bridges Frontage roads Ramps Segments under construction ( construction signs are up ) City connecting links maintained by cities 2 Auxiliary lanes (as part of the travelway), side roads and entrances (as part of the roadside), and spur routes are part of the Maintenance QA Program .

10 Stratification. The stratification represents the management focus of the Maintenance QA Program . Analysis of the Maintenance Rating and the resulting management decisions involve grouping of roads by type and/or jurisdiction. The Maintenance QA Program for KDOT primarily divides the total roadway segment population into the following jurisdiction subgroups for MR analysis: Maintenance Areas within Districts. Maintenance SubAreas within Maintenance Areas. The MQA Program uses 30 randomly selected samples per SubArea (which generates 90-180 samples per Area depending upon the specific Area). Maintenance Categories. Maintenance categories represent a grouping of highway rating elements and Maintenance activities into like categories for the purpose of evaluating Maintenance Quality . For instance, pavement striping, pavement markers, signs, guardrails, etc.