Quality Control and Quality

Assurance Guide
Bridge Division, Design Section
January 2021
 Table of Contents

Chapter 1 About this Guide ..................................................................................................... 3

Chapter 2 Goals and Objectives.............................................................................................. 5
Chapter 3 Participants ............................................................................................................. 6
Chapter 4 Quality Control ........................................................................................................ 7
Chapter 5 Quality Assurance ................................................................................................. 12
Chapter 6 Records ................................................................................................................. 14
Appendix .................................................................................................................................. 16

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 Chapter 1
About this Guide

Purpose

The Texas Department of Transportation (TxDOT) Bridge Division, Design Section has
developed and implemented this Quality Control and Quality Assurance (QC/QA) guide to
provide the highest quality products to TxDOT divisions and districts, other state agencies,
federal agencies, consultants, and contractors.

The QC/QA process applies to all types of Bridge Division, Design Section projects. In
addition, the QC/QA process applies to the development of design guidelines, design
examples, spreadsheets, manuals, and specifications. It may be necessary to modify the
QC/QA process based on the complexity of the project. Additional QC/QA procedures may
be required for large or complex structures, railroad bridges, historic structures, and other
special structures.

Updates

The following summarizes the updates to this guide:

Revision History

Version Publication Date Summary of Changes

2012-1 August 2012 New guide published.

2013-1 October 2013 Design Sketch Checklists added.

2017-1 April 2017 Updated figures. Added Procedure for Archiving Bridge Design
Notes.

2019-1 April 2019 Guide was reviewed, but no updates were needed.

2021-1 January 2021 Updated guidance for archiving bridge design notes.

Organization

The information in this guide is organized as follows:

♦ Chapter 1, “About this Guide,” contains introductory information on the purpose
and organization of this guide.
♦ Chapter 2, “Goals and Objectives,” contains general information on the purpose
and goals of Quality Control/Quality Assurance.
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 ♦ Chapter 3, “Participants,” contains descriptions of the roles and responsibilities of
those participating in QC/QA.
♦ Chapter 4, “Quality Control,” contains an overview of the quality control for
calculations and details.
♦ Chapter 5, “Quality Assurance,” contains an overview of quality assurance for in-
house prepared plans, consultant-prepared plans, and during construction.
♦ Chapter 6, “Records,” addresses document storage, control and retention.
♦ “Appendix,” contains the Quality Control Cover Sheet, Design Sketch Checklists,
Flow Charts, and guidance on keeping records.

Feedback

You may direct any questions or comments on the content of this guide to the Design
Section Director of the Bridge Division, Texas Department of Transportation.

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 Chapter 2
Goals and Objectives

The Quality Control/Quality Assurance (QC/QA) program establishes the following goals:

♦ Communicate openly to address concerns and solve problems immediately.

♦ Plan, coordinate, supervise, and provide technical direction.
♦ Employ skilled personnel who perform their work with care to produce a quality
product.
♦ Produce quality work through review and checking by individuals not directly
responsible for the initial work product.
♦ Take responsibility for the QA/QC of a project, regardless of role.

The objectives of the QA/QC program are to produce products that:

♦ Are designed free of errors and omissions.

♦ Contain designs for all elements and are thorough.
♦ Are appropriately designed.
♦ Conform to the policies and procedures defined in the relevant TxDOT manuals, and
to the guidelines on the TxDOT website.
♦ Clearly define the sources of information for the calculations and the interface with
related documents.
♦ Result in constructible plans.

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 Chapter 3
Participants

Participants

♦ Supervisor/Group Leader – A licensed professional engineer who manages a group of

Design Engineers and Technicians. The supervisor/group leader is responsible for
assigning work to Design Engineers and Technicians based on their level of
experience and the complexity of the project. In addition, a supervisor/group leader
is responsible for internal Quality Assurance reviews.

♦ Design Engineer – A licensed professional engineer or engineering assistant working

under the direct supervision of a licensed professional engineer. The Design
Engineer is a person capable of performing analyses and calculations. The Design
Engineer provides the data, such as design sketches, necessary for detail drawing
development. In addition, the Design Engineer checks the details for errors,
completeness, conformity, and consistency.

♦ Checker – A licensed professional engineer or engineering assistant working under

the direct supervision of a licensed professional engineer. The Checker thoroughly
checks the calculations and detail drawings for errors, omissions, completeness,
applicability, and conformance.

♦ Technician – A drafter or engineer who generates and revises details, plan sheets,
and drawings in electronic format.

♦ Engineer-of-Record – A licensed professional engineer who signs and seals the final
plan set.

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 Chapter 4
Quality Control

Quality Control is the process of checking the accuracy of calculations and consistency of
the drawings, detecting and correcting design omissions and errors prior to finalizing design
plans and verifying the specifications for the load-carrying members are adequate for the
service and strength loads. Use the Quality Control Cover Sheet (Appendix, Figure 2), to
document the Quality Control process.

In addition, document the Quality Control process on the plan sheet by filling out the
appropriate initials in the title block on the detail. See Figure 1 for more information.

Figure 1: Detail Title Block

The Engineer-of-Record will sign and seal final details and modified standards. Do not sign
and seal unaltered standards. The signature and seal on the details acts as the signature
and seal for the calculations, as well as the details.

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Quality Control of Calculations

This process applies to calculations, reports, studies, design spreadsheets and any other
documents that are not details, plan sheets, or drawings.

Preparation (Design Engineer)

Prepare relevant, appropriate calculations and sketches containing all information

(input, basis, comments, references and sketches) necessary to convey the purpose
and nature of the calculations. Calculations are standalone, to the extent reasonably
possible.

Present the calculations and sketches in a neat and logical manner that is conducive
to checking.

Conform the calculations and design sketches to the policies and procedures defined
in the relevant TxDOT Manuals. As directed or requested, follow the design guidelines
on the TxDOT website. Use the Design Sketch Checklists provided in the Appendix,
Figure 4 for direction on the information needed on the design sketches.

Perform all calculations on TxDOT calculation sheets, on spreadsheet equivalents

(i.e. personal spreadsheets or design spreadsheets) or software. Provide a header on
the calculation sheets or spreadsheets that provides the County, Hwy, CSJ, ID#,
Design Engineer’s Initials and Date and the Checker’s Initials and Date.

Checking (Checker)

Check each component to ensure compliance with the policies and procedures
defined in the relevant TxDOT Manuals and with the guidelines on the TxDOT website,
as appropriate.

Check the calculations for internal consistency and traceability of sources.

Thoroughly check the calculations, including assumptions, given values, formulas,

omissions, and accuracy of arithmetic.

Check methodology, reasonableness of results, and constructability.

If necessary, ask for clarification from the Design Engineer, request additional
calculations, and if unsure of any particular element, seek technical advice.

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 Check the calculations by the method shown in the Quality Control of Calculations
flowchart provided as Figure 5 in the Appendix. Alternatively, check the calculations
by providing independent calculations. Keep the alternate, independent calculation
with the original. Indicate on the original that an alternate calculation was used for
checking.

When an error in computer input, assumptions, or load calculations is found, consider

what that error will do to the outcome before asking the Design Engineer to redesign
the member. If the error has a negligible impact to the final design, it may not be
necessary to redo the calculation. For instance, it may be unnecessary to re- run a
program for a 0.1 k difference in load or a 1-foot station difference in geometry.

When an error is found that will have significant impact on the remainder of the
calculations, return the calculations to the Design Engineer for correction prior to
completing checking of the calculations. Such an error is one leading to a design
result that is more than 5 percent un-conservative or more than 15 percent
conservative.

Correcting (Design Engineer)

Revise the calculations and sketches based on the mark-ups. If not in agreement
with a mark-up, discuss it with the Checker. Come to an agreement on whether to
incorporate the mark-up. If unable to come to a resolution, consult the
supervisor/group leader.

Incorrect calculations should be removed from the complete calculation packet and
replaced with corrected calculations.

Verifying (Checker)

Back check the revised calculations and sketches against the mark-ups to confirm all
corrections have been incorporated or otherwise addressed.

Quality Control of Details

This process applies to details, plan sheets, and drawings. The Quality Control of Details flow
chart included as Figure 6 in the Appendix provides the process for checking the details.

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 Preparation (Technician)

Develop all details in accordance with Bridge Detailing Guide and applicable Bridge
Division policies and practices.

Checking (Design Engineer or Checker)

Check the details for completeness of the plan set for design intent.

Check the details for technical adequacy and conformity to applicable standards.

Check the details for consistency with the corresponding calculations.

Check individual drawings using appropriate checklists from the Bridge Detailing
Guide for errors, completeness, conformance, and consistency.

Correcting (Technician)

Revise the details based on the mark-ups. If not in agreement with a mark-up,
discuss it with the Checker. Come to an agreement on whether to incorporate the
mark-up. If unable to come to a resolution, consult the supervisor/group leader.
Mark any additional revisions on the originals.

Verifying (Design Engineer or Checker)

Back check the revised details against the marked ups to confirm all corrections
have been incorporated or otherwise addressed.

Quality Control of Details Against Calculations

This process applies to details, plan sheets, and drawings. This process can be done
concurrently with checking the calculations.

Preparation (Design Engineer)

Provide the calculations and the details prepared as outlined in the Quality Control of
Calculations and the Quality Control of Details sections. The Quality Control of Details
flow chart included as Figure 6 in the Appendix provides the process for checking the
details.

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 Checking (Checker)

Check the details for consistency with the corresponding calculations.

Correcting (Design Engineer)

Revise the details based on the mark-ups. If not in agreement with a mark-up,
discuss it with the Checker. Come to an agreement on whether to incorporate the
mark-up. If unable to come to a resolution, consult the supervisor/group leader.
Mark any additional revisions on the originals.

Verifying (Checker)

Check the revised details against the mark-ups to confirm all corrections have been
incorporated or otherwise addressed.

Addendum and Change Orders

It is sometimes necessary to submit revised plan sheets to address a change order or an

addendum. For change orders and addendum, follow the procedures presented within this
Chapter. Remember to update all relevant calculations and details. Notify the shop plan
reviewers in the Design Section of the Bridge Division of any changes to plan details.

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 Chapter 5
Quality Assurance

Quality Assurance is the process of reviewing the quality control process for use and
effectiveness at preventing mistakes and ensuring compliance. The Quality Assurance
process varies depending on the stage of plan development and who develops the plans.

Reviews occur for all plans regardless of who prepared them. These include a District review
prior to finalizing the plans and, optionally, a Division review prior to letting. The District
review occurs in the district where the project is to be constructed and focuses on
constructability, applicability, and conformity. If requested, the Division review focuses on
the same items as the District review and is comparable to a peer review.

In-House Prepared Plans

For in-house prepared plans, the supervisor/group leader is responsible for Quality
Assurance. The supervisor/group leader determines the level and complexity of the Quality
Control process, assigns the Design Engineer, Checker, and Technician. The
supervisor/group leader confirms the Quality Control process by reviewing the Quality
Control cover sheet and the detail title block. In addition, the supervisor/group leader
completes a review of the details for constructability, applicability, completeness, and
conformity.

Consultant Prepared Plans

For consultant-prepared plans, the consultants are required to submit their Quality Control
Plan in writing prior to starting work or as otherwise directed in the contract. TxDOT reserves
the right to review the consultants’ quality control process.

During the development of the plans, TxDOT reviews the plans at 30%, 60%, and 90%
completion (or equivalent). TxDOT reviews the plans for constructability, applicability,
completeness, and conformity. The TxDOT manager of the work authorization or contract
typically handles this review. However, they may assign a representative to complete the
task. Frequently, the District will be involved in these reviews.

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During Construction

During construction District engineers assume the role of Engineer-of-Record and complete
field-engineering reviews. If a complex problem occurs, the District contacts the original
Engineer-of-Record, who will determine a solution and if necessary, provide calculations and
revised details.

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 Chapter 6
Records

Notebook/File

The Design Engineer keeps a binder or folder clearly labeled with the Structure Name,
County, and Control-Section-Job (CSJ) number that contain the following:

♦ Design Request Submittal – This submittal is comprised of the design information

provided by the district. At a minimum, the Information Sheet for Structural Design
and Bridge Layout will be part of this package. The submittal may also include Plan
Profiles, Typical Sections and/or Construction Sequences.

♦ Correspondence – Correspondence includes emails, memos, or other documents

that affect the design of the structure or clarify design requirements.

♦ Calculations – Calculations generated and reviewed in accordance with the Quality

Control Program. Calculations include hand-written documents, spreadsheets, and
output from software. Convert the calculations to PDF for inclusion in the design file
and eventually in the Bridge Database. Appendix: Guidance for Calculation Retention
contains guidance for including documents as part of the PDF and Appendix,
Procedure for Archiving Bridge Design Notes.

♦ Details –Final Plan Sets generated and reviewed in accordance with the Quality
Control Program. During plan set development, check prints may also be kept in the
file.

♦ Any other documents required for design, such as existing plan sheets and review
comments.

After releasing the project as a 100% Plan Set, the Design Engineer converts the notebook
to a PDF format by scanning or other means and saves the resultant electronic
Notebook/File.

After releasing the project as a 100% Plan set, the Design Engineer may dispose of the
Check Prints and only keep an electronic (PDF) copy of the 100% Plan Set. This is not the
official copy of the plan set.

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The Design Engineer documents any changes that occur after the Plan Review, such as
Addendum, and post-letting, such as Change Orders and RFIs by including correspondence,
calculations, and details that relate to the change or request in the electronic Notebook/File
for the project.

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Appendix

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A.1 Quality Control Cover Sheet

Figure 2: Quality Control Cover Sheet

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Some calculations are stand-alone and require an engineer’s seal and signature. For stand-
alone calculations replace the details section on the Quality Control Cover Sheet with the
information shown in Figure 3.

SEAL

Figure 3: Engineer-of-Record Block

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A.2 Design Sketch Checklists

Estimated Quantities
1. Tabular list of bid items

Abutment
1. Width
2. Location of the horizontal control line
3. Wing wall length; Founded (yes/no)
4. Foundation size, location and load
5. Cap size and steel arrangement (if non-standard)
6. Dowels D (yes/no)
7. Girder type and spacing
8. Approach slab (yes/no)
9. Skew angle and direction
10. Phased (yes/no). If yes, label phases, show phase lengths and reinforcing steel laps or
connection
11. Project specific notes
12. Identification of Abutment and Bridge Name, for Title Block
13. CSJ
14. District
15. County
16. Highway
17. Project ID
18. Provide initials of design checker, if checked.

Bent
1. Width
2. Location of horizontal control line
3. Cap size and reinforcing steel arrangement (continuous/cut and stirrups)
4. Footings(yes/no) If yes include size and foundation type
5. Column size, location and load. Provide reinforcing steel arrangement if non-standard.
6. Dowels D (yes/no). If yes, at what bents?
7. Bearing seat size and Girder type (forward and back if different)
8. Girder spacing (forward and back if different)
9. Skew angle and direction
10. Phased (yes/no). If yes, label phases, show lengths and reinforcing steel laps or connection
11. H-Heights
12. Project specific notes
13. Identification of Bent and Bridge Name, for Title Block
14. CSJ
15. District
16. County
17. Highway
18. Project ID
19. Provide initials of design checker, if checked.

Figure 4: Design Sketch Checklists

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 Span
1. Unit length, width, number of spans and span lengths
2. Number of girders, girder spacing and type(s)
3. Location of horizontal control line
4. Skew angle and direction
5. Breakback
6. Slab thickness
7. Reinforcing steel size, spacing and cover, if non-standard
8. Overhang thickness
9. Sidewalk dimensions (and reinforcement if not standard).
10. Panels (yes/no). List any specific prohibition of use.
11. Cross slope and location
12. If phased, label phases, show phase lengths and reinforcing steel laps or connection
13. Joint type
14. Location of PGL in Typical Section
15. Dead load deflections
16. Project specific notes
17. Identification of Span or Unit and Bridge Name, for Title Block
18. CSJ
19. District
20. County
21. FMS project ID
22. Provide initials of design checker, if checked
23. Provide Detailer access to
a. Layout
b. Haunch Calculations (X, Y, and Z values)
c. BGS LS2 file (bridge geometry)
d. BGS LS4 file (beam report and bent report)
e. .dgn file created from BGS

Additional info req’d for Steel Girder Spans/Units

1. Top of slab to top of web dimension (plate girders)
2. top of slab to top of beam dimension (rolled beams)
3. Girder or beam elevations
4. Bolted field splice details
5. Web Camber table plus Dead Load Deflection Table, at 0.10 pts and all field splice points
6. Beam blocking diagram (only if beams are not cambered per standard practice)

Figure 4: Design Sketch Checklists (cont.)

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A.3 Quality Control Flowcharts

Figure 5: Quality Control of Calculations

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Figure 6: Quality Control of Details

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A.4 Guidance for Calculation Retention

Scan or convert to PDF format design notes and computer output, with superstructure
design notes first, followed by substructure design notes.

A hard copy of computer software input files is not required. Hard copies of computer
software output should be included with the following:
• Input echo
• Key pages of output, annotated by hand if necessary, such that the design’s
outcome—including controlling load case and limit state—can be understood
by review of the output and annotation.
• Key pages of output, annotated by hand if necessary, demonstrating that
other load cases and limit states do not control the outcome of the design.

Design Notes Required Design Notes NOT Required

• Calculations and other documentation • Decks, if per current TxDOT Manuals
establishing the bridge’s superstructure and standard drawings
design satisfies controlling load cases • Bearings, if per current TxDOT
and limit states, for the following Manuals and standard drawings
elements: • Railings, if per current TxDOT
o Girders or beams Manuals and standard drawings
o Stringers • Expansion joints, if per current
o Floor beams TxDOT standard drawings
o Trusses, including secondary • Standard round columns if column
elements such as bracing and height and diameter is within
gusset plates prescribed limits of acceptability in
o Arches and hangers, including TxDOT Manuals
secondary elements such as
• Abutment design, if details follow
bracing and gusset plates
current TxDOT Manuals and
o Cable stays
standard drawings
o Other elements not specifically
excluded • Pile and/or Footing design, if details
• Calculations and other documentation follow current TxDOT standard
establishing the bridge’s substructure drawings
design satisfies controlling load cases • Other structural items from current
and limit states, for the following TxDOT standard drawings such as
elements: diaphragms/cross-frames for steel
o Cap beams girders and beams, etc.
o Columns, Towers, and Pylons
o Other elements not specifically
excluded
• Calculations and other documentation
establishing the bridge’s foundation
design satisfies design requirements,
for the following elements:
o Piling
o Drilled shafts
o Spread footings
o Other elements not specifically
excluded

Table 1: Guidance for Calculation Retention

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A.5 Procedure for Archiving Bridge Design Notes

In order to comply with FHWA requirements for maintaining records, the Bridge Division
implemented a procedure for archiving bridge design notes in TxDOT's bridge inspection
database management system. See the TxDOT Bridge Design Manual – LRFD for more
information.

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