Purdue University
Purdue e-Pubs Joint Transportation Research Program
Civil Engineering
1-1994
Implementation of the Developed Quality Acceptance System for Steel Bridge Painting Construction Luh M. Chang Machine Hsie
Chang, Luh M. and Hsie, Machine, "Implementation of the Developed Quality Acceptance System for Steel Bridge Painting Construction" (1994). Joint Transportation Research Program. Paper 120. http://docs.lib.purdue.edu/jtrp/120
This document has been made available through Purdue e-Pubs, a service of the Purdue University Libraries. Please contact
[email protected] for additional information.
i
i
'
SCHOOL OF CIVIL
ENGINEERING
INDIANA
DEPARTMENT OF TRANSPORTATION : :
JOINT HIGHWAY RESEARCH PROJECT
FHWA/IN/JHRP/94/10 i
Final Report
IMPLEMENTATION OF THE DEVELOPED QUALITY ACCEPTANCE SYSTEM FOR STEEL BRIDGE PAINTING CONSTRUCTION Luh M. Chang
Machine Hsie PwVwV^vW
**
PURDUE UNIVERSfTY
^
JOINT HIGHWAY RESEARCH PROJECT
FHWA/IN/JHRP/94/10 Final Report
IMPLEMENTATION OF THE DEVELOPED QUALITY ACCEPTANCE SYSTEM FOR STEEL BRIDGE PAINTING CONSTRUCTION Luh M. Chang
Machine Hsie
"CHNICAL REPORT STAnOaRO TITLi Roporr No.
1,
j
FHWA/IN/JHRP-94/10 4.
1.
Ciov«rnm«nr Acettsion No.
^.cipi.nr
it
t
3
aGc
Catalog No.
i
Tirtw ona Suortffo
I
Oaf
5m
Rmoorr
3-
Performing Organization CdO«
December 30,
Implementation of the Developed Quality Acceptance System for Steei Bridge Painting Construction
1994
:
1
M Chang _,
Aurhonij
7.
Lun
;
Performing Orgamzarton 3«oorr No.
3.
JHRP-94/10
Machine Hsie P«rrorming Organization
9.
Nam* ona
Aaa/»i»
10.
Work Unit No.
Purdue University I
1
School of Civil Engineering
West 12.
Lafayette,
Sponsoring Aaoncv
.
Contract or Granr No.
Indiana EPR-2C67
IN -7907
13.
Typo
Nomt and Aadros"
IS.
Suppiomomary Notoi
16.
Abstract
July 14,
Psnod Cavoroo
Final Report
-
Indiana Department of Transportation State Office Buildina 100 N. Senate Ave. Indianapolis,
oi Roporr and
1,
1993
-
Dec.
-
30,
19-94
Sponsoring Agency Coda
IN 4620^-2249
The purpose of this research is to implement the steei bridge painting quality acceptance system developed in the Joint Highway Research Project HPR-2029-39-27 and to computerize the developed system into inspectors' daily practice. A training program was conducted. Field experiment of the developed inspection system was initiated immediately right after the inspector training program. Tne new acceptance system was manually tested. Feedback from INDOTs inspectors and other personnel were adopted to refine the inspection system Meanwhile, an interactive computer graphic program was developed to assist the INDOT in designing the doubie sampling plan and deciding the sample size with controlled risks for both the INDOT and painting contractors. In addition, a pen-computer system for painting quality acceptance has been developed. It reduces both the need for inspectors' statistical background, and tedious manual paper work. The collected data will be more accurate, timeiy and providing the INDOT with more information to make better decisions. The electronic network system to transfer data between construction sites and the INDOTs central office was also tested. Once the data are collected in the field, the data inside pen-computers can be transferred to PCs in the central office. The communication between field and office was enhanced. The pen-based computer system developed in this project can be applied to many other highway inspection areas, such as bridges and pavement inspections. Many current inspection works are very time-consuming and may cause errors when the data is re-typed into computers. If the existing inspection forms can be computerized through hand-writing recognition technology, the required efforts and paper shuffling can be largely reduced. Koy Words
17.
IS.
Quality Assurance Inspection Stati stical
Acceptance Plan
Bridge Painting
Distribution Stat
—
nt
No restrictions. This document is available to the public through the National Technical Information Service, Springfield, VA 22161
Pen-Based Computers Security
1?.
Coast f.
(or irtis
Unclassified Form
DOT
F 1700.7
2D.
Security Class! r.
(o»
Unclassified (»•«»)
mis ass>)
21. No. of
107
P
22.
PrW
Digitized by the Internet Archive in
2011 with funding from
LYRASIS members and Sloan Foundation; Indiana Department
of Transportation
http://www.archive.org/details/implementationofOOchan
Final Report
IMPLEMENTATION OF THE DEVELOPED QUALITY ACCEPTANCE SYSTEM FOR STEEL BRIDGE PAINTING CONSTRUCTION
Luh M. Chang JHRP Research Engineer Purdue University and
Machine Hsie Research Assistant Purdue University
Joint Highway Research Project
Project No: File No:
C-36-26H 4-4-8
Conducted in cooperation with the Indiana Department of Transportation and
Federal Highway Administration
The contents of this report reflect the views of the authors who are responsible for the facts and the accuracy of the data presented herein. The contents do not necessarily reflect the official views of policies of the Federal Highway Administration and the Indiana Department of Transportation. This report does not constitute a standard, specification or regulation.
Purdue University West Lafayette, IN 47907 December 30, 1994
DISCLAIMER
Many competent men and women serve the painting industry; however, in this report, masculine pronouns are occasionally used in reference to engineers, technicians and other personnel." This convention is intended to avoid awkwardness in style and in no way reflects sexual bias on the part of the authors. All reasonable care has been taken in the preparation of this Manual. However, the Federal Highway Administration can accept no responsibility for the consequences of any inaccuracy or omission. The Federal Highway Administration does not endorse products or manufacturers. Trade or manufacturers' names appear herein solely because they are considered necessary to the object of .this publication.
Implementation Report
Under the
Joint
Highway Research Project HPR-2029-89-27,
statistical
quality
acceptance systems have been developed. Nevertheless, the benefits from the research results cannot
be
fully realized until the
The purpose of
daily practice.
this
systems are incorporated into painting inspectors'
research
is
to implement the steel bridge painting
quality acceptance system developed in the previous research project
and to computerize
the developed system into inspectors' daily practice.
A
training
program was conducted. Field experiment of the developed inspection
system was initiated immediately right after the inspector training program. The
INDOT's
acceptance system was manually tested. Feedback from personnel were adopted to refine the inspection
computer graphic program was developed to
system.
assist the
new
inspectors and other
Meanwhile, an interactive
INDOT
in
designing the double
sampling plan and deciding the sample size with controlled risks for both the
INDOT
and
painting contractors. In addition, a pen-computer system for painting quality acceptance
has been developed. tedious manual
providing the
It
reduces both the need for inspectors'
INDOT
also tested.
background, and
paper work. The collected data will be more accurate, timely and with more information to
make
network system to transfer data between construction
was
statistical
Once
be transferred to PCs
better decisions.
sites
The
electronic
and the INDOT's central office
the data are collected in the field, the data inside pen-computers can in the central office.
The communication between
field
and office
the
following
was enhanced.
According
to
the
experiences
recommendations are proposed:
obtained
in
this
research,
1.
Finalize the Inspection
Forms
The new inspection forms have not
2.
common
integration.
processing
effort
investigation
is
Once
made
is
new
CRA and
of computerization
benefit
information
is
the
not
office
and job
sites
into official
is
needed to
inspection system.
Pen-Based Computer System
only time savings but
information
automatically.
To
recorded
is
optimize
improved
also
electronically,
further
benefit,
this
the
suggested to highly integrate the data structure of the pen-
computer and the
3.
agreement about the
Integrate Data Structure Between
The
been formally incorporated
communication between the
specification. Further
achieve a
yet
existing Construction
Recorder Administration (CRA) database.
New Computer Hardware
Continually Survey the
pen-computer has been
In this research, the preferable
of the tough and harsh operating environment
selected.
However, because
at construction sites,
pen computers
need to be more durable and feature higher shocking resistance and water-proof standards
It
is
foreseeable
that
tight
among
competition
pen-computer
manufactures and the rapid advancement of computer technology
4.
more powerful and
solid
continually survey the
new pen-computer technology
pen-computers with lower
prices.
will bring us
INDOT
should
before massive purchasing.
Conduct More Inspector Training Program The
field
trial
stage
showed
operate the developed system
should be very helpful
in
that the users
More
training
how
is
recommended. The short courses
strengthening inspectors' capability
should focus on essential issues, such as a painting job,
need more computer knowledge to
how
to
make
The
training
program
decisions to accept or reject
to ask contractors to fix defective jobs,
and
how
to process
the inspection paper work.
5.
Apply
Pen-Based
Computer
Systems
To
Highway
Other
Construction
Inspection Process
The pen-based computer system for other
to
inspection areas, such as bridges and
current inspection
is
can be regarded as
pilot
INDOT's field inspection processes This technology can be
many other
data
in this project
re-typed
pavement
computers.
the
If
computerized through pen-technology,
inspection
existing
the
required
efforts
also applied
inspections.
works are very time-consuming and may cause into
research
when
errors
forms
can
be
Many the
can "be reduced,
eliminating paper shuffling. Further evaluation needs to be conducted for
many
other inspection processes that are candidate areas for adapting the hand-writing
recognition technology.
In
applied
summary, the pen-based computer system developed
to
inspections.
when
in this
project can be
many other highway
inspection
Many
works are very time-consuming and may cause
the data
is
current inspection
re-typed into computers.
areas,
If the
such
as
existing
bridges
and
pavement errors
inspection forms can be
computerized through hand-writing recognition technology, the required efforts and paper shuffling can be largely reduced.
Table of Contents
Chapter
1
Introduction
1.1
1
Problem Statements
1.2 Objective
1
of the Study
1
1.3
Background
2
1.4
Work Plan
4
'
1.5 Structures
and Contents of the Report
6
Chapter 2
Methodology
2.1
8
Four Major Tasks
8
Double Sampling
2.2 Interactive
Computer Graphic Program
2.3 Field Trial
of the Developed Quality Acceptance System
2.4 Inspector Training 2.5
Chapter
for Attribute
Program
9
10 10
Development ofPen-Computer System
10
3
Attribute
Double Sampling and
3.1
Interactive
Computer Graphic Program
Background
12
12
Double Sampling
3.1.1
Single and
3.1.2
Attribute and Variable Sampling
13
3.1.3
Operating Characteristic (OC) Curve
14
3.1.4
Producer's/Owner's Risks
15
3.2 Reasons for Adopting Attribute
12
Double Sampling System (ADSS)
16
3.3
Procedures of Attribute Double Sampling System (ADSS)
19
3.4
Theory of the Double Sampling Acceptance System
20
3.5 Interactive
Systems
Computer Graphic Program
for Designing Sampling
26
1
3.6 Rules for Designing the Attribute
Double Sampling System
33
Chapter 4 Trial
ofDesigned Inspection Forms
35
4.1
Background
35
4.2
Results and Feedback from Field Trails
35
Chapter
5
40
Training Session
5.1
40
Needs of Training Session
5.2 Inspection Training
40
Program
Chapter 6
42
Development of the Pen-Computer System
6.1
The Needs
6.2
Review of Pen-Computer Technology
43
6.3
Advantages of Using Pen-Based Computers
43
6.4
Hardware
44
42
for Computerization
6.4.1
Evaluation of Different Pen-Computers
45
6.4.2
Selection of Pen-Computers
46 48
6.5 Software
6.6
6.7
Development of the Pen-Computer System 6.6.1
PEPSI Overview
49
6.6.2
Methods of Data Entry
50
6.6.3
PEPSI Design Objectives and
Network and Data
Functions
54 57
6.7.1
Data Transfer
57
6.7.2
Needs
59
6 7 3
Network Between Offices and Job
for
Data Integration Sites
of Pen-Computer System
Trial
6.9
Advantages of the PEPSI system
6.10 Extension 1
Its
Integration
6.8
6.
48
To Other Highway Construction
Potential Problems and
Recommendations
59 61
62 Inspections
63
66
1
Page
Chapter 7 Conclusions and Recommendation
7.
7.2
68
Achievement of this Research Recommendations for Future Work
68 69 72
References
Appendix A:
Specification
Summary
75
Pen-Computers
76
Appendix C: Major Revision Tasks of The PEPSI System
77
Appendix B: Field Test Questionnaire
Appendix D:
for
Steel Bridge Painting Inspection Training
Manual
80
List of Tables
Page
Table 3.1
Rules for Designing Attribute Double Sampling System
34
List of Figures
Page
Figure
2.1
Methodology and Major Tasks of
the Research
8
3.1
Typical Operating Characteristic (OC) Curve
15
3.2
Flow Chart
26
3.3
Direct Screen Output in the First Trial
29
3.4
Direct Screen Output in the Second Trial
30
3.5
Direct Screen Output in the Third Trial
31
6.1
The Screen of Hand Writing Recognition
51
6.2
Simulated Keyboard for Data Input
52
6.3
Pop-Up
52
6.4
Control Buttons for Data Input and
Form Navigation
53
6.5
A
PEPSI System
56
for Attribute
List for
Double Sampling Play
Data Input
Defective Area
is
Marked on
the
Chapter
Problem Statements
1.1
The is
Introduction
1
current Indiana Department of Transportation
(INDOT)
standard specification
inadequate to ensure the quality of current painting construction. The specification, a
guide to the inspectors' practice, does not specify:
how many measurements level is acceptable.
As
are needed to
1)
where
make acceptance
to take measurements; 2)
decisions;
and 3) what quality
a result, the inspections are largely based on the inspectors' personal
judgments, thus making the acceptance or rejection of the painting project based on an ambiguously-defined inspection process.
To
solve these problems, a research project
Highway Research
were developed
to
set
fulfill
of step-by-step checklists (inspection forms) and control
the proposed acceptance systems.
control charts can serve as a manual for inspectors' daily
inspectors
make
know where
to inspect,
work
how many measurements
practice.
fully realized until the
plans.
With them, the
are necessary, and
how
to
systems are incorporated into painting inspectors' daily
Before adopting the new systems, inspectors need to be trained and the potential
problems need to be solved. Efforts need to be made to ensure
1.2
These checklists and
acceptance/rejection decisions. Nevertheless, the benefits from the research results
cannot be
the
the Joint
Project HPR-2029-89-27, statistical quality acceptance systems have
been developed. Meanwhile, a charts
was conducted. Under
new
efficient
implementation of
systems.
Objective of the Study
The purpose of system into
INDOT
this
research
steel bridge
is
to
implement the developed quality acceptance
painting projects.
To
reach this goal, the following
objectives must be achieved:
To
1.
teach painting inspectors the basic quality control concepts and corresponding
statistical
To
2.
acquaint painting inspectors with the quality acceptance system developed
the Joint
To
3.
background.
Highway Research
To
HPR-2029-89-027.
apply the developed quality acceptance system into
painting projects and refine 4.
Project
it
into
in
IKDOT
current steel bridge
implementable inspection procedures.
construct a computer system for facilitating and simplifying painting inspectors'
operation for steel bridge painting projects.
To
5.
test
incorporate
1.3
developed
the
computer system on current
projects
and
into inspectors' daily practice.
it
Background Corrosion has been the major threat to
established that corrosion reaction.
During
this
reaction takes place.
it
painting
is
steel bridge structures.
date,
it
is
well
the result of an electrochemical process involving an anoxic
reaction the metal goes into solution as an ion, and a cathodic
Because of steel's natural tendency
has been extracted from
its
ore, the steel reacts with
to return to
its
process of corrosion requires four elements, including electrolyte,
To
1)
its
original state after
environment and corrodes. The an anode, 2) a cathode, 3) an
and 4) a conductor Only when these four components are present
at
the
same
time can corrosion occur. Methods such as protective coatings and cathodic protection protect steel against corrosion by eliminating one or
more of
the
above elements.
Steel
contains both anodes and cathodes, due to grain boundaries, grain orientation, thermal treatments,
surface
roughness,
and
strains.
Additionally,
steel
serves
as
an
efficient
conductor Atmospheric moisture serves as an electrolyte. Without protection, corrosion will
thus occur on steel structures
To
prevent corrosion on steel bridges,
highway agencies have spent several
hundred million dollars every year painting them. However, many painted have been
failing
prematurely, and highway departments have not adequately protected the
(Appleman, Bernard
nation's bridges against corrosion
University and
an
bridges
steel
INDOT
efficient quality
R.,
1988).
As
a result, Purdue
cooperated with the Federal Highway Administration to develop
assurance system for bridge painting contracts (Chang,
Luh-Maan and
Hsie, Machine, 1992b).
The
INDOT
quality. This
is
now
using a recipe type of specification to control bridge painting
type of specification includes details such
as: materials to
Inspections of materials and
preparation, paint application, and so forth (Indiana, 1988).
work
are required at various stages
involved quality
in
be used, surface
of painting before acceptance. With the many variables
the painting process, the current specification does not always guarantee the
of the
final painting
the contractors to control
Painting quality could be better assured by allowing
product.
more of
their operation,
and by having
INDOT
emphasis on specifying and checking the end-results. That
is,
more
INDOT would
responsibility
for
quality
process
control,
responsibility for specifying the quality requirements
inspecting
the
responsibility
products.
This
type
and
of specification,
between owners and contractors,
is
with
better
its
would take
the contractors
and the acceptance
place
assume
criteria,
allocation
the
and by of the
(QA) or
designated Quality Assurance
End-Result Specification.
To
solve the aforementioned problems, a research project
was
initiated
by
INDOT
under the Joint Highway Research Project HPR-2029-089-27. The purpose of research
was
to develop a
QA
specification for steel bridge painting constructions.
research project has been completed and
was approved by the JHRP board on
this
The
April 22,
1992.
The research unveiled many for
INDOT's
steel
pitfalls that interfere
bridge painting.
Several
possible
with obtaining adequate quality solutions
were proposed. The
acceptance plan was developed and incorporated into a format of step-by-step check (inspection forms) and control charts. Also, the existing specification the
was
revised based
on
knowledge obtained from the research. sampling systems are the core of QA specifications. In the research, four
Statistical
statistical
sampling systems were constructed for painting contracts including Variable Single Sampling System,
1).
Quality
Attribute
Double
Index Sampling System,
2).
Sampling System, and
Attribute Proportion Sampling System (Chang,
Hsie, Machine, 1992a).
(ADSS) was The
charts.
1)
lists
finally
4).
Among
3).
Luh-Maan and
the four systems, the Attribute Double Sampling System
adopted and formatted into a
set
of inspection forms and control
inspection forms and control charts can be divided into four stages including
Pre-inspection
Stage,
2)
Surface
Top/Intermediate Coating Stage.
It
Inspection
Stage,
Priming
3)
Stage,
and
4)
covers detailed inspection steps, supplying a precise
proposed to
guide to inspectors' daily practices. Meanwhile, a computerized system
is
reduce the tedious paper work and the need for inspectors'
background to
statistical
process inspection data. With the power of computers, advanced
systems could be programmed into software. The system
will
statistical
acceptance
allow the inspectors to
simply input the results of their measurements, and the decisions are automatically
With the help of the computer, an
by the computer
efficient,
feasible
made
and paperless
inspection process can be achieved.
Work
1.4
The
Task
Plan
steps for accomplishing the goals of this project can be outlined as follows:
Conducting Inspector Training Session
1.
First, the
basic statistical concepts for quality control and acceptance systems will
be introduced. Herein, the terms of
lot,
sampling
size,
single/double sampling,
attribute/variable
sampling,
producer's/owner's
risks,
will
Second,
checklists
the in
step-by-step
the
forms)
and
be demonstrated. control
The use and
charts benefits
of the Developed System
obtain
inspectors
the
principles
acceptance plans, new painting projects Field experiments will be set up. tested.
curve),
be clearly explained.
Manual Implementation After
(inspection
the previous research project will be presented. will
(OC
be covered. In addition, numerical
steel bridge painting inspection will
of the checklists
2.
and quality index
curve
characteristic
examples with application to
developed
Task
operating
Feedback from
INDOT
will
and
theories
behind
the
be accessed with help from
The double sampling method
will
quality
INDOT.
be manually
inspectors and other personnel will be solicited.
Based on the feedback, the inspection system
will
be refined to an implementable
and effective system.
Task
3.
Computerization of the Developed System
A
computer program
need for inspectors'
for the developed quality acceptance system can reduce the
statistical
background and tedious paper work. In
this task, the
data input of field measurements and statistical data process will be computerized.
The
application of pen-based computers
transmitting
computer
technologies
is
into
proposed to break the barriers painting
construction
acceptance or rejection decision needs to be automatically
made
sites.
in
The
right after data are
entered into the computer.
Task
4.
Training for the Computer System Since
many INDOT
inspectors
computers, basic training
is
do not have enough experience to
handle
necessary to introduce computer technology to them.
Inspectors will be taught
how
to apply the developed
computer inspection program
through desktop computers and pen-computers. The program include data input, data processing and
Task
filling
expected to
is
out inspection forms.
Implementation of Computer Program
5.
Once
the inspectors have adequate experiences to apply the developed computer
program, the program
will
be tested
in
both
fields
and
Again, feedback
offices.
regarding friendliness and simplicity for using the program will be collected to
continuously refine the program.
Task
Electronic Networking between Fields and the Central Office
6.
With the increased use of computers or share information
connecting
Task
INDOT's
among
in
almost every discipline, the need to access
users has surfaced. In this task, electronic networks
central office and fields will be investigated.
Final Report
7.
A
technical report will be prepared and submitted to
INDOT
for final approval.
The methodologies used, developed computer system, references experience
obtained from the research will be compiled
in
the
cited,
final
and
report.
Meanwhile, a balanced viewpoint of shortcomings and benefits of using the acceptance plans and their corresponding computer programs will be detailed
in
the report
1.5
Structures and Contents of the Report This report
Chapter
1
is
divided into seven chapters reflecting specific subject areas.
provides a general introduction that addresses the need for the research and
its
major tasks. The benefits of the research are also noted. Chapter 2 explains the methodology used to Chapter
3
fulfill
the goal of the project.
gives a deeper review of the attribute double sampling method. interactive
computer graphic program
is
introduced to
facilitate
Also,
design
an
work of
the attribute double sampling plan.
Chapter 4 describes the course of the
field test in the
new
inspection system.
The pros and
cons of the system are also summarized.
Chapter
5 presents the inspector training
program conducted by the
INDOT
and Purdue
University.
Chapter 6 contains detailed information about the developed pen-based computer system.
A recommendation for applying the new Chapter 7 concludes the findings could be beneficial to
in this research,
INDOT.
computer technology
is
proposed.
and proposes further research areas that
Methodology
Chapter 2
Four Major Tasks
2.1
The methodology used
in this
research
is
shown
in figure 2.
There are four major
tasks including:
Computer Graphic Program
1.
Development of
2.
Field Trial for Inspection
3.
Inspector Training Program
4.
Development of Pen-Computer System
Attribute
Interactive
for Attribute
Forms
Double Sampling
>• Interactive
Computer Graphic Program
Revise Collect Feedback
Field Test
Inspection
Inspection
Form
from Field and Offices
Forms
I f
Revision j
Write
Conduct
Training
Training
Manul
Session
Collect Feedback
from Training Session
T
Revision
T Networking from: Pen-computer to PC
Seciect
Review Pen-Computer ->•
Suitable
Technology
and Writing
Develop Pen-Program and Data
Recognition
Structure
Pen-Computer
Program
Figure 2.1
Office
&
Field
PC
to
PC
Testing for
through
Pen Program
Null
Modem
and Telephone Line
Methodology and Major Tasks of the Research
Double Sampling
2.2
Interactive
Computer Graphic Program
In the previous research,
which could be summarized
in
for Attribute
Double Sampling
the double sampling acceptance plan
was developed
the following equation:
rl-l
Pa = P(xl
then reject the lot
if
cl
rl
< xl
c2
then reject the
3.4
is
necessary, continue the following processes: lot.
lot.
Theory of the Double Sampling Acceptance System According to the
is finite,
statistical
sampling theory,
if the lot size
(underlying population)
the hyper-geometric distribution should be used to describe the probability of the
sampling. In other words,
if
the lot size
is
much
larger than the sample size, the binomial
21
distribution should be used to calculate the probability
of the sampling (Burr, W. Irving,
1976). In the inspection
dry film thickness structure
of
steel
bridge painting construction, almost infinite numbers of
(DFT) measurements can be taken within any one
member. Consequently, the
piece of the painted
(underlying population) of the sampling
lot size
is
regarded as unlimited. However, only a few measurements are usually taken to define the binomial distribution should be used to develop the sampling
quality.
For
this reason,
system.
The
notations used
pd
x
sample
:
size
.
number of non-conforming found
:
P(
the equations are:
Underlying percentage of non-conforming (percentage of defect).
:
n
in
the sample
in
.
binomial distribution.
):
Given
of non-conforming of the product
that the underlying percentage
is
pd
(percent of defect), according to the binomial statistics, the probability for getting x non-
conforming items under the sample size of n
Kenneth
P(x);
S.
is
(Wadsworth, M. Harrison and Stephens,
A. and Godfrey, Blanton, 1986): x
= (x!)(n-x)!
pd F V(l-pd) F ;
(n " x)
For example, assume that the sample size percentage of defect
is
15%
is
By plugging
(pd=0. 15).
10 (n=10), and the underlying the parameters into the previous
equation, the probability of getting three (x=3) non-conforming measurements will be:
P(3)
-
=
(3!)(10-3)!
3
015Jy( 1-0.1 w
5)°°" 3) )
P(3) = 12.98% As another example, is
25%
be:
if
sample size
is
7 (n=7) and underlying percentage of defect
Cpd=0.25), the probability of getting two (x=2) non-conforming measurements will
T>
2
= P(2) v
(2!)(7-2)!
95J (l-0.25) wJ v
»
to serach
a, and
P
take the
program
AQL RQL
take the
dvnamic computer
$>
cl
n2
Uhen the product is Rejectable Quality Leuel ===> When the product is
c2=l
(AQL) == Zv. of Defect Zx of Defect, the probability of acceptance is 95/ (RQL) ==27x of Defect the probability of reject is 95x 27x of Defect,
to clear the screen; '' to Turn on/off the sound Strike '' or any other key to continue :
Percent of Defect
Press Ctrl-C to Terninate
Figure 3.4
The Third
nl and n2 are kept at 10.
respectively.
AQL
5).
and
Output
in the
Second Trial
Trial
The
Figure
Direct Screen
The
The
RQL
resulting
AQL
and
The
RQL
cl, rl,
become
original expected conditions are
and c2 are
6%
and
AQL=5%
39%
and
set to
3,
and 2
RQL=35%. The
resulting
are quite close to the expected design. Therefore, the attribute double
more accurate match between trials
1,
respectively (please see
sampling system with the parameters: nl=10, n2=10, cl=l, rl=3, c2=2
more
be
the expected conditions and the results
should be done to obtain a closer solution.
is
is
accepted. If a required, then
31
n2=lB
nl=18
Uhen:
cl=l
Acceptable Quality Leuel ===> Uhen the product is Sejectable Quality Leuel ===> Uhen the product is
rl=3
cZ=2
(AQL) == b/. of Defect of Defect, the probability of acceptance is 95x (RQL) ==39x. of Defect 39x of Defect, the probability of reject is 95x
6x
to clear the screen; ' or any either ken to continue
Strike
'
:
'
to Turn on/off the sound
'
lOO-
\ a
nl = 10
r>2 = 10
ci = l rl=3 c2=2
so -
:
a «
«
60
-
40
-
20
-
c
3 -
\
«
« * BL
20
40
Press Ctrl-C to Terminate
Figure 3.5
Assume
that the
60
ao
Percent of Defect
Direct Screen
Output
highway agency would
like to
in the
Third Trial
design an attribute double sampling
system having the conditions:
.After
the
AQL
=
5% =
RQL
=
35% =
05
and
0.35 and
ct=
5%
p= 5%.
designing the double sampling system
highway agency chooses a nl
=n2=
cl
-
1
c2 = 2
,
rl
10
=3
set
in
the interactive
of parameters:
computer graphic program,
which closely match the pre-set
This set of parameters controls the following
criteria.
conditions:
AQL=6% = 0.06
a = 5%
RQL=39% =
(3=5%
0.39
For example, with the above information, the highway agency can specify the acceptance system for
Example
DFT
in
primer (or top-coating) as follows:
Specification:
The lower mils. In
limit (L)
each
lot,
for the dry film thicknesses of primer
is
2.5
the first inspection sample of size 10 should be
taken by inspectors
and
the
number of non-conforming items
found is designated as xl.
ifxlrl=3
then accept the
then reject the
lot;
lot;
< xl < rl, then a second sample of size 10 should be
Non-conforming items found
in
the
taken.
second sampling are
designated as x2.
So xl+x2 non-conformings
in the
two samples of size nl+n2 are
found ifx2+xl c2=2
then reject the
The Risk Control Points
AQL= 6% = 0.06
RQL=39%
= 0.39
at
are:
a = 5%
atfi
= 5%
lot
lot
.
Rules for Designing the Attribute Double Sampling System
3.6
When
using the above computer graphic program,
it
is
not
recommended
users just randomly assign the five parameters: nl, n2, cl, c2, and rl.
be lucky enough to obtain the desired system
these are also summarized in Table
When
1.
the nl, and n2 are increased, the slope of the
ADSS
some
are as below;
in
OC
will
become
distinguishing
steeper; the
good and poor
RQL
side (decrease). Also, because the
OC
curve becomes steeper, the interval between
and
When looser.
When
3.
there are
not
and
AQL
Rule
may
AQL
quality. In other
2.
However,
users
1
acceptance sampling system has more power
Rule
trials.
work. The rules for designing the
rules that can facilitate the design
Rule
few
in a
The
that the
RQL
words, the
will decrease,
will
both switch toward the
all
AQL
and
RQL
five parameters:
RQL
decrease, and vice versa.
will often increase,
OC
will
become
will decrease.
The
becomes
and vice versa
nl, n2, cl, c2, and rl
proportionally, the slope of the will increase, but the
hand
and vice versa.
the cl, c2, or rl are increased, the acceptance sampling system
Both the
left
increase simultaneously and
steeper. In this situation, the
interval
between
AQL
and
AQL
RQL
will
34
Table 3.1
Rules for Designing Attribute Double Sampling System
nl, n2 increase
cl,rl,c2 keep the same
Effect sharper slope of
AQL
and
keep the same
increase
increase
proportionally
proportionally
keep the same
increase
decrease
decrease
between
looser acceptance plan
AQL keep the same
curve
AQL and RQL decrease flatter slope of OC curve AQL and RQL increase interval between AQL and RQL increase sharper slope of OC curve AQL increase; RQL decrease interval between AQL and RQL decreased interval
decrease
RQL
OC
and
stricter
AQL
RQL
increase
acceptance plan
and
RQL
decrease
3 5
Chapter
4.1
Trial of Designed Inspection
4
Background
To
increase the feasibility of the designed inspection system,
continuously collect the feedback about the use of the
job
Forms
sites
new
the researchers
inspection system.
By
visiting
and conducting four interviews to two inspection teams, the processes of using
the inspection forms were observed. Valuable knowledge and information are obtained
from inspectors and resulted
in a
modified inspection contents and forms. The revised
inspection forms are presented in the second part of Appendix D.
4.2
Results
To
and Feedback from
Field Trails
continuously collect feedback about the
visited job sites
new
inspection system, the researcher
and conducted four interviews of two inspection teams. The processes for
using the inspection forms were also observed. Valuable knowledge and information were obtained from inspectors and resulted in modified inspection contents and forms.
The
three types of questions asked of the inspectors were: 1).
How do you
like the
2).
What do you
think about the designed inspection procedures?
3).
What changes would you
The
•
results
The INDOT's
paper forms provided?
from the
like to
trial
inspectors
suggest to improve the inspection forms?
of the new inspection system are summarized as follows:
like
the
inspection
forms.
They provide step-by-step
inspection guides and supply a place to keep the results of inspections. Before the inspection forms
were developed, inspectors simply recorded measurements on
their
36
personal
field
However,
books.
the
designed
inspection
forms
are
much more
complete and convincing.
•
The
of 8.5" x 11" inspection forms was too large when the inspectors accessed
size
bridge structures. Currently, inspectors record data in smaller informal field books that are
more
by the
•
The
easily kept inside their pockets.
first
Smaller inspection forms (5.5" x 8" required
team; 5.5" x 4" by the second team) were requested.
inspection forms require measurements to be taken
on the bottoms of top
flanges.
These areas take more time to measure because of the vibration caused by heavy vehicles.
•
SSPC
1-89 surface cleanliness standard does not
steel-shot blasted.
•
The summary
The
table
cleanliness of air
on Form 3
inspectors suggested that
•
The
inspection system
is
is
is
is
X3 power
new
currently checked by coffee
The
was not designed
used because
first
of
filters.
be deleted.
it
for the use of spot painting. Inspectors have is,
and where the new
is.
In spot painting,
adheres better to the old paint. The organic can adhere
organic paint will penetrate into the old primer and
paint peel.
are
lens to check the cleanliness
to the inorganic; the inorganic cannot adhere to the inorganic.
the
when bridge beams
considered to be repetitive and redundant. The
no way of knowing where the old paint organic paint
well
The appearance of blasted surface changes between sandblasting
and steel-shot blasting. One team has used a the blasted surface.
work
team disagreed with spot painting.
However, the solvent
make
in
the old inorganic
37
•
The question about when of paints won't cure
•
measure the dry film thickness was
until several
around
(a solvent) takes
to
5
MEK
hours or days of application. For example, the
days to cure.
For environmental concerns, the
INDOT
requires contractors to apply steel shot
blasting instead of conventional sand blasting.
recycled
raised. Several types
The reason
is
that the steel shots
can be
and the contaminated dusts can be separated with recycling devices.
However, the cost for
blasting a bridge increases
The environmental problems have become
from S1.75/sq-foot to $4.0/sq-foot.
crucial.
Additional items for checking
environment controls, such as the treatment of removed lead paint should be added to the inspection forms.
•
The INDOT's
field
engineers have their
own
required equipment for inspection. There
•
The workload
for using the inspection
work without
performing similar
official
engineer
kits
(Tool Box) containing the
no equipment support problem.
is
form
is
acceptable.
inspection forms.
Inspectors have been
Now
the inspection forms
can provide inspectors with clear guides and places to keep the measured
•
Inspectors' short courses
chance to attend
it
were
helpful.
again, like the
One team hoped
one held
in the spring
that they could
of 1990. The
"Training short courses definitely strengthen inspectors' capability." also attended the
opposite opinions
same inspection
came from
training course held in the spring
the second team.
The second team
results.
have another
team
first
said,
The second team
of 1990. However,
said "this
program
is
inefficient
and useless." The training program only taught inspectors the theory of
corrosion,
how
mask, and so
paint materials can pass the state laboratory test,
forth.
These teaching contents are not major concerns.
how
On
to
wear the
the contrary,
38
the training course should, but did not teach inspectors 1) to reject a defective job,
process
the
inspection
2)
how
to
ask contractors to
They need
paper work.
knowledge instead of background of corrosion considered
•
It
difficulties
and 3)
practical
how
to
inspection
The opinions were
that the painters did not speak English.
communicating with the
difficult to
the car into the
is
fix defects,
the decision
sincerely
The inspectors
painters.
be a problem transporting computers up to the bridge structures. The computers
will
were
make
researchers designed the training session.
The second team pointed out had
•
when Purdue
to
more
a
theories.
how
handle and apt to be damaged.
A
lap-top computer operated inside
acceptable. Inspectors can record the results on paper forms and key
is
computer
after returning to the car.
One
day's data are not
the data belonging to several projects in several months.
of data
paper form
in
.Also, the
is
them
much. The problem
Keeping the complete
files
troublesome. Computers can help with some database systems.
FAX modem will
be useful
in
communicating between
sites
and
offices.
•
The space
•
For the second team, the contractor did not notify the inspectors before they worked. It
for recording
beam
location needs to be enlarged in the inspection forms.
happened that the contractor urgently put the top coating over the primer without
allowing the inspectors to check whether the primer had been properly applied. Therefore, defects such as contaminated surface, bubbling, and mud-cracking of the
primer serious
may be
hidden.
improvement
Communication between inspectors and contractors needs Personal
pagers
"contractors must notify inspectors before
hold points should be strictly enforced.
could
be
helpful.
work" should be
The requirement
that
clearly specified. Several
The following recommendation
is
made by
the
39
second team: The
state
should specify that contractors must get signatures
hold points, or no payment will be made. There
460"
that requires the signatures
is
a similar
document
at certain
called "form
of both contractors and inspectors to process the
payment.
The second team pointed out but on
how
that the serious
in
one
project.
how
the contractor should
were found, the contractors
fix
knows
his
disagreement with
this
fail
them,
when
state specification, the
However, there
away
when
is
no clear
the bubbling
the bubbling spots and
One member of
the second team
and claimed that he has no
repair procedure
in the state specification. First,
the inspection? Second,
that.
just simply scraped
specifications as a support to stop the contractors.
be answered
For example, problems of
the problems. Currently,
put additional top-coat over the small pin holes.
voiced
not on the inspection forms,
According to the
bubbling area should be corrected. Everybody
defects
is
to ask the contractors to fix the defective areas.
bubbling happened seriously
guide of
problem
The following two questions must
how many
bubbles are found,
bubbles should be counted to
how
should the contractors
fix
by scraper, or sand-blasting? The specification missed several-real world
problems.
40
Chapter 5
Training Session
Needs of Training Session
5.1
Under the
Joint
Highway Research Project HPR-2029-89-27,
quality
statistical
acceptance systems have been developed. Nevertheless, the benefits from the research results
cannot be fully realized
practices.
To adopt
the
new
until the
systems are incorporated into inspectors' daily
systems, inspectors need to be trained.
Inspection Training Program
5.2
The
INDOT
central office and
inspection training
program
program was held
in the Indiana
Ten bridge
Purdue University conducted a
to introduce the designed
QA inspection
steel bridge painting
system.
Government Central North Building
at the
The
training
end of May.
painting inspectors from six different districts attended this training program.
In response to the feedback obtained from interviews,
it
is
apparent that inspectors
are not concerned about the underlying statistical theory of the acceptance system.
other hand, what they need to
on job
control
sites.
know
Therefore,
in
is
a set
of clear procedures for doing
the training
background was reduced to the minimum.
the
daily quality
program, the content of
In short, the training
On
statistical
course was designed to
teach inspectors: (1)
how
to take samples,
(2)
how
to
(3)
how
to process the inspection
make
decisions to accept a quality job or reject a defective job,
and
paper work on the provided inspection forms.
In the training course, a series of simple but comprehensive examples
was used
to
describe the double sampling system. Meanwhile, the inspection forms for four stages
were introduced to the
inspectors, including:
41
(1) pre-inspection,
(2) surface preparation, (3) priming, and
(4) Top-coating stages. In general, the inspectors' response to this training
At the end of the training course, the inspectors to try the
new
However, the decision
INDOT
quality assurance system
to reject or accept
program was
was
still
positive.
central office
and inspection forms on job
new system can be
can be the
fully
adapted.
QA computer
using the
a valuable reference.
Also,
is
results obtained
from
needed before the system
QA inspection system was presented.
software was distributed to both office and job
QA program was observed.
and the central
More feedback
The computerized
sites.
based on the original system, which
depends heavily on inspectors' personal judgment. The inspection the
encouraged the
sites.
Then
The process of
Valuable advice was obtained from both inspectors
office.
After the training session, inspection forms right away.
program can be found
in
The
many
inspectors expressed their willingness to use the
training
Appendix D.
menu and
inspection forms used in the training
42
Chapter
6.1
The Needs
6
Development of the Pen-Computer System
for Computerization
Maintaining construction quality
is field
engineers' major responsibility.
However,
processing inspection data at construction sites takes field engineers a considerable
amount of
time. First, they
need to record many measurement on inspection forms. The
daily inspection data can be tens
of pages. After the data are recorded on paper format,
they are brought back to the offices. If computers are utilized, these data need to be
manually typed into computers for further processing. In requires additional utilized, the
paper forms
work and may cause
paper inspection forms will quickly
will
errors.
On
double-data-entry
this case, the
the other hand,
if
computers are not
among of
be piled around offices and the
become out of control. Many
efforts
have been made
the
in collecting
and processing inspection data of highway constructions. The growing construction data are overwhelming field engineers.
Due
to the lack of an efficient data process,
inspection data
is
usually reduced to
its
the requirement for maintaining
minimum. In conventional
steel
bridge painting,
the inspectors do not record and process inspection data. After the project
information associated with the products
made without
To
is
gone. Therefore,
many
is
finished, the
inspection decisions are
sufficient supporting data.
solve the above problems, inspection procedures on construction sites need to
be computerized. transmitting
The pen-based computer
is
proposed
computer technologies onto constriction
sites.
to
break
the
barriers
in
Thus, a PEn-based computer
system for Painted Steel bridge Inspection (PEPSI) was developed. Currently, a menudriven interface for data capture and process has been built inside the
Since the inspection forms have been computerized and the
field
PEPSI
system.
engineers can directly
input measured data into the computers, statistical data processing will be
done with the
43
power of computers. The acceptance or after the finish
statistical
of data
rejection decision
input. This not only
is
automatically
made
right
reduces the necessity of inspectors having
background, but also eliminates tedious paper work.
Review of Pen-Computer Technology
6.2
The pen-based computer
is
one of the most recent developments
technology (Barr, Christopher, 1992; Baran, Nicholas, 1992b).
pen as the input device for a portable computer.
It
A
in
computer
pen-computer uses a
features a handwriting recognition
system that allows users to write directly on the screen and then convert the input to characters, just as if they had
come from
handwriting recognition technologies
Markov modeling, fuzzy
logic,
a keyboard (Miastkowski, Stan,
applied
included
neural
networks,
1992).
The
probabilistic
dynamic programming and clustering algorithms (Quain R.
John, 1993) Currently, there are
two types of
Digitizer technologies used by the pen-based
computers including Restrictive and Electro-Magnetic (EM) Digitizers. •
A
Restrictive digitizer
The pen mark
is
overlaid onto the surface of Liquid Crystal Display (LCD).
directly contacts the
LCD's
surface.
A
conductive coating on the surface
sends x and y pen coordinates by determining the voltage emitted by the screen. •
An
Electro-Magnetic
(EM)
digitizer
is
embedded beneath
the
LCD. The
has certain advantages over the resistive digitizer. For instance,
lower the
light transmitted
by the
LCD
some
EM
digitizer
restrictive units
due to an extra coating of wires on the screen
(Barr, Christopher, 1992).
6.3
Advantages of Using Pen-Based Computers Pen computers are proposed
want
to utilize the
for people
who
are
away from
their offices but
still
power of computers. Unlike laptop or note-book computers, pen-based
44
computers can be used while standing or walking. Therefore, they are good for highway engineers
and
who work on
start typing
computer
is
construction
in the
sites. It is
middle of working.
inconvenient to pull out a laptop computer
However
writing on the screen of a pen
no more unwieldy than taking notes on a clipboard (Miastkowski, Stan.
1992).
Pen computers provide another advantage
that
in
they can be used to keep
handwriting records for legal purposes. For example, United Parcel Service (UPS) has replaced
its
drivers'
traditional
clipboards with electronic versions
—
a form of pen
computer. Package recipients no longer sign paper forms; instead, they sign their name directly
on the
drivers' computers.
time and date.
The
signature image
is
stored together with the delivery
For public highway construction projects, numerous signatures are
necessary for processing paperwork. The benefit can be even more tremendous
if
the
signatures and relative documents can be maintained in electronic format that can be easily
processed and transferred between offices. In another area, evolution. just
The
pen computing
in
applicants can directly sketch
the
CAD
markup
market seems to be a natural
in the field
on
their
pen computers,
drawing an "X" over the defective beams that need repairing. Engineers checking
installations
could carry pen computers on their arms rather than
rolls
field
of detailed
drawings.
6.4
Hardware With the explosion of computer technologies over the past one year, a tremendous
number of pen-computers with more powerful functions have become choose the pen-computer
that
is
most
suitable for the data collection for
bridge painting inspection, the state-of-art pen computers were reviewed.
available.
INDOT's
To steel
45
Evaluation of Different Pen-Computers
6.4.1
In evaluating pen-computers, "portability"
is
one of the most important
criteria. In
other words, the candidate pen-computers should be both small-sized and light weight
ENDOT's
enough
to allow
criteria,
four pen computers are
Poqetpad
Plus, 3)
AT&T EO
initially selected.
Under
the above
Dauphin DTR-1,
2) Fujitsu
easily to job sites.
They
are 1)
System, and 4) Grid PalmPad. Appendix in brief
A
more
contains
are as follows:
Dauphin DTR-1 The
pound Dauphin DTR-1
2.5
computing. Coming with Microsoft
Windows
Fujitsu
The
3.1.,
is
only 1.25 by 9 by 5 inches, but
MHz 486SLC
computer. Using a Cyrix 25
•
them
of the above pen-computers. Their features
detailed descriptions
•
inspectors to carry
4MB and
of
RAM
Windows
and
processor,
20MB
it
is
of hard
is
a high speed
a best bet for multi-purpose disk,
it
runs with
MS-DOS,
for Pen.
Poqetpad Plus Fujitsu
PoqetPad plus
is
a lightweight (1.6 pounds) hand-held computer.
provides up to 12 hours of continuous computing time.
The
It
built-in infrared link transfers
data without a cable connection.
.
AT&T EO The
The
440
AT&T EO
AT&T EO
devices.
It is
by 7
1
is
another powerful pen-based communicator for office users.
440 system
is
a
good device
designed for use by workers
on the road or CIO. 8
440
at
construction
sites.
for cooperating with the
who want
telecommunication
Fax, e-mail and voice contact while
Compared with other pen-computers, EO440
by 0.9 inches, and weighting 2.2 pounds). Nevertheless
communication device.
it
is
a
is
large
handy
46
GRID PalmPad
.
The PalmPad has
the dimension of 1.9 x 9 x 6.2
a rugged, lightweight, and small pen computer.
It is
use and aimed primarily environments. seals
at
ruggedly
It is
users
field
built
The PalmPad
who abuse machines
and has an exterior that
it
is
The
small,
CPU
comes with a
it
or
who work
entirely plastic.
allows the inspectors to attach the wrist or
used
in
2MB RAM
GRID PalmPad and has a
have an ejection mechanism. The link users to the outside world,
is
in
slot
30MB.
PCMCIA
The rubber spills.
belt.
with a built-in
Unfortunately, the
IDE
It
controller that can
PCMCIA
slot
does not
card must have a pull tab before inserted.
To
PalmPad features an optional communication model.
Besides cable connection, choosing an integrated 902-928 wireless
harsh
slow and only good for simple application.
PCMCIA
hold sundisk flash-memory cards up to
communication allows
computers. In summary, the PalmPad in
is
designed for rough
is
around the screen and control buttons make the product safer for drops and
Because
for
inches and weight 2.9 pounds.
this
is
device
good
can
MHz
Spread Spectrum Radio
communicate with other host
for use as a device for data-collection tasks
harsh environments.
6.4.2
Selection of
The
Pen-Computers
pen-computers
introduced
in
the
previous
section
have
their
own
characteristics.
To choose one
considered:
the features in bridge construction sites, and 2) the data needed in painting
1).
suitable
computer from them, two
criteria
need to be
inspection.
After
we
evaluated the above
preferable pen-computer.
The reasons
criteria,
the Grid
are as follows:
PalmPad was suggested
as the
47
Construction
A
sites
have severe environments.
and water may
spill
on the computers.
A
absolutely necessary. For this reason, the the
Dauphin DTR-1
CPU. This can be the
power much
to recharge
A
may be over
construction site for steel bridge painting
large
A
its
is
designed with
and
Dauphin DTR-1
many openings
for cooling
it
may
its
high speed
CPU
consumes
use up the power before the inspectors get a chance
needed
is
amount of data
is
in
the painting inspection processes.
required in painting inspection: usually
pages of data for one painted bridge. For this reason,
it is
computer which can contain more information on one reason,
down
high speed
its
because
not the choice,
is
is
battery.
amount of data
large
complete protection of the computers
a dead point for the equipment. Also,
faster,
a river or a highway. Rain
the Fujitsu
x 480 resolution.
designed
in
or more.
As
Due
is
less
better to choose the pen-
single screen page.
PoqetPad was rejected because
resolution screen, which
to this limitation, the inspection
a result, inspectors
to
flip
PC
this
monitor of 600
program would have
The required pages
would need
For
only has a 600 x 200
it
than the half size of the general
a rather small screen page.
more than 20
to be
increase up to 40 pages
around the screen pages too
much.
Other Advantages of Using Grid PalmPad Being use.
classified as a palm-sized
It is
cushioned by a rubberized plastic casing, which
mini seconds. This feature sites.
The PalmPad has
general in
two
pen computer, PalmPad
PC
makes
a screen of
the
PalmPad
640 x 400
is
light for
resists
long periods of
shock of 273G
at
2
the best bet in harsh construction
resolution,
which
is
very close to the
used every day. Therefore, the pen-computer program can be designed
parallel versions that are exactly the
same
including:
one run under pen-
48
computers and the other under PCs. Also,
program to use features a
printing screen function.
600 x 200 resolution
On
screen,
high resolution screen allows the
its
the other hand, Fujitsu Poqetpad only
which
will
make
function very limited, because only half a side of the paper
6.5
used.
Software
Four major operation systems are currently market.
is
the printing screen
They
PenRight
are
from
Window GRiD
for
available in the pen-based
Pen from Microsoft, Penpoint from
system
corporation,
PenDOS
and
from
GO
computer
Corporation,
Communication
Intelligence Corporation (O'Connor, Thorn, 1992).
Grid's PenRight applications.
PenRight
is
system was chosen to develop the inspection form-oriented a software platform for executing mission-specific applications
on top of MS-DOS. PenRight has performed which the computer performs one 1992).
successfully in several vertical applications in
specific type
Under the PenRight system,
of task for the users (Intorcio, John,
the data entry system
was developed under the
package "PenPAL" from Pen Pal Association. For detailed functions of please refer to
6.6
its
this
system,
user manual.
Development of the Pen-Computer System The
inspection procedures for field bridge painting were divided into four stages
including: (1) pre-inspection, (2) surface preparation inspection, (3) primer inspection, (4) top-coat inspection. In these four stages, inspectors
need to record surface cleanliness,
coat thickness, ambient conditions, material used, and
whole inspection procedure
is
and
many more
data. Currently, the
incorporated into a series of inspection forms. Inspecting a
bridge painting usually needs tens of pages of paper forms.
49
The PEn-based computer system
for Painted Steel bridge Inspection
been developed to provide an electronic version of inspection forms. established under a pen-based
is
a data base
computer environment. This database features a user-
which inspectors can
friendly interface with
It
(PEPSI) has
measured data on construction
easily enter the
sites.
PEPSI Overview
6.6.1
The PEPSI represents
a
PEn-based computer system
Inspection. In this system, contractor and structure
database.
By
numbers are used as key
fields in the
specifying the contractor and structure numbers, inspectors can create and
assess the data belonging to different projects.
the system.
for Painted Steel bridge
The PEPSI system
directly input
There are a
total
of 20 pages of forms
in
features a user-friendly interface, allowing inspectors to
measured data by using a pen. Meanwhile, the acceptance or rejection
decisions will automatically be
made when
reduces the necessity of inspectors'
data input
statistical
is
completed. This approach not only
background, but also eliminates tedious
paperwork. In addition, after the data are entered, the data can be efficiently transferred to a host
computer
in
the central office to establish a global database.
Hardware: The "Portability"
state-of-art pen
is
computers were reviewed
one of the most important
to select a suitable pen-computer.
criteria in selecting the
pen-computers. The
candidate pen-computers must be both small-sized and light-weight. Finally, the Grid
PalmPad was considered preferable
for inspection applications.
As mentioned
before, the
Grid PalmPad features some basic water-proof capability. Being classified as a palm-sized
pen computer, the PalmPad has the dimensions of 1.9 x 9 x 6.2 inches. Weighting 2.9 pounds,
it
is
light
plastic casing,
enough
which
for long periods
resists
shock of
of use. Because
273G
at
2 ms,
it
is
it is
cushioned by a rubberized
ideal candidate in harsh bridge
50
construction
to the general
two
The PalmPad
sites.
PC
features a screen of
640 x 400
resolution,
which
is
close
used every day. Therefore, the PEPSI database has been designed
parallel versions:
one
for the
in
pen-computers and the other for the PCs.
Software PenRight hardware.
It is
MS-DOS. The
was chosen because
it
is
compatible with the
Grid's
proprietary
a software platform for executing mission-specific applications on top of
pen-based data entry system was developed under the package
"PENPAL"
from Pen Pal Association.
6.6.2
Methods of Data Entry In the
1)
system, four methods have been designed for data entry including:
Hand Writing Recognition,
2) Simulated
3)
PEPSI
Pop Up
Keyboard,
List,
and
4) Control Buttons.
•
Hand Writing
Recognition
For hand writing recognition, simply place the pen
up a large field.
field to facilitate users'
The user can
and
digits
recognize the hand writings and convert them into the
accept the input.
on the
hand writing input. Figure
directly write alphabets
writing entries, they touch the
tip
"OK" button on
the
on the
ASCII left
6.
1
field,
it
will
zoom
shows the zoomed up
field.
texts.
and
Then
the system will
After users finish hand
bottom of the zoomed
field to
51
place your pert
Please
Enter
Contract
tfte
on the
JteCcC.
»
Contract Nunber Fornat Coding: A88888 A
Alphabet
M
#:Digit
7
3
^_^___ (
OK ^) (CflMCEL)
Text
rust
12345-abcde
(Beam/Lot
#)
.165.
Erase Drawing
Eraser Mode On/Off
IS Copy Text Mode On/Off Figure 6.5
A defective area
is
marked on
the
PEPSI system
basic
shows
marked on the bridge drawing.
Structure 8
al2345
the
three
I
that
57
5.
Allow Freedom
The PEPSI
to
Navigate
Among Forms
designed to allow the users to jump
is
among
the inspection forms.
During the course of a painting construction, the contractor many have two work teams for sandblasting and priming
on
different areas
in the
PEPSI
at the
same
time. In this case,
Many
control
are designed to provide the users with freedom to navigate
around
the inspectors need to efficiently
buttons
of the bridge
flip
among
different inspection forms.
different forms.
6.
Incorporate with Decision-Making Algorithms In the
PEPSI
system, the algorithm of the statistical acceptance sampling plan has
been encoded into the system. Inspectors should just enter the measured data
in
the
system, then the decision can be automatically made. This capability can break the barrier
of applying advanced decision-making algorithms to construction
6.7
Integrate Data Currently,
sites.
Through Network
PCs have become
the major environment
where
INDOT
handle daily data. Therefore, once the data are collected on construction inside the
6.7.1
sites,
engineers the data
pen-computers need to be transferred to PCs.
Data Transfer There are many ways to transfer inspection data from pen-based computers to host
computers. Selecting the best method of data transfer depends on to be processed. If the data
how soon
the data need
must be processed as soon as possible, then real-time radio
frequency data communication should be employed. However, for steel bridge painting inspection, the acquisition of inspection data does not have to be real-time
computer and host computers.
A
serial
RS-232 cable was proposed
between pen-
to transfer data
from
58
pen-computers to PCs. Tremendous data transfer programs are currently
Three
available.
popular data transfer programs were tested. The test results are described as follows:
1.
Norton
Commander
Data transfer
is
one function of the Norton Commander software.
several procedures to establish the connection.
confuse non-experienced users. project
showed
A
The complex
setting
It
requires
may
procedures
recent implementation in the Ryder's truck inspection
that users frequently got lost in the process
of data transfer when using the
Norton Commander.
2.
LapLink This
is
a high-end product for data transfer.
also parallel ports, to speedily transfer data.
It
can use not only
However, the program
is
serial ports,
but
complicated for
non-computer-literate users.
3.
InterLnk
&
InterSvr
This system consists of two parts: InterSvr used in Server computers. that
come with
the
MS-DOS
6.0.
1)
InterLnk used
in
Master Computers, and 2)
The InterLnk and InterSvr
This system
is
small but easy to use. Only
required to link the sever to the master including:
1)
computers (server computers), and 2) typing "interlnk" After establishing the connection, the
are the standard
steps are
typing "intersvr" in the pen-
in the
two computers are
two
programs
PCs (master computers).
linked together like
one
unit.
Users of the master computers, which are usually the PCs, can copy, delete, write, read, edit
and run the
files in
Of the above
INDOT because they
the server computers.
three programs, the InterLnk and InterSvr are
are easy to use and
recommended
come with standard MS-DOS.
for the
59
The above programs can solve the problems of data computers and PCs. But they have the limitation that a to transfer data.
modem
mat the pen-computers and PCs must be
implies
It
null
transfer
the short distances of the lengths of the cables.
On many
cable at the
is
between penalways needed
same
site
within
occasions, the data need to be
transferred from job sites to the central offices. In this case, the above data transfer
programs are
useless.
However,
if
the central office
card driver, inspectors can simply send their offices
where data can be
6. ~.2
Needs
for
retrieved
is
memory
equipped with a
PCMCIA memory
cards containing inspection data to
and integrated into a global database.
Data Integration
After inspection data are collected, they are only a bunch of non-related data. fully utilize the
power of
further integration. central office to
The
To
the data, they need to be transferred to the central office for
inspection data integration provides valuable information for the
monitor quality
the job sites, the performance of contractors, and the
at
work of inspectors.
Network Between
6.7.3
Offices
and Job
Sites
There are basically three approaches to build networks for inspection data between job 1).
and the central
sites
Memory
Storage
2).
FAX of the
3)
PC
PC
to
Memory
office.
They
are:
medium
inspection results, and
connection with
Storage
modems through
telephone
lines.
Medium
Perhaps the easiest way to transfer data from construction office
do
is
sites to
the central
by sending memory storage media such as memory cards and floppy diskettes.
so, the inspectors
need to have spare
PCMCIA
To
flash-memory cards, and the central
60
office needs to
have a
PCMCIA
each project, the inspectors
flash-memory card
may send
their
PCMCIA
at the
end of
card containing inspection results to
the central office. In the central office, the data inside the
hard-disk of a PC.
As an example,
driver.
memory
The hard-disk and PC then become a
cards are copied to a
where the
global database
300
inspection results can be quickly retrieved. In this case, a hard-disk no less than
megabytes around
is
recommended. According
70KB of memory. Based on
to recent field tests,
one bridge usually requires
the above configuration, one hard disk can store
inspection data of around 5000 bridges.
Another option offices,
is
downloading the data from pen-computers to PCs
copying the data onto a floppy diskette and sending
it
medium
is
way, the cost can be reduced because the storage
much cheaper then
the
PCMCIA
learn
how
FAX
the inspection results
to transfer data
In recent years,
to the central office. In this
a floppy diskette, which
flash-memory card. However, the inspectors need to
fax machines have
may need
become common
in
offices.
Under
with
a
results to the central office.
fax
modem
connected
to
To do
so, the inspectors
pen-computers.
the
approaches, the inspection data can be faxed to the central office
PC
to
PC
Connection with
Modems Through Telephone
in just
quickly update inspection data by mailing
Faxing, the second approach, has the other
is
two drawbacks. One
the difficulty of database integration.
hard
fast
need to be
By programming a few minutes.
Lines
The memory storage approach has a drawback of long-updating difficult to
certain
to receive the inspection information rapidly.
Faxing the data to the central office becomes a valuable approach, providing a
equipped
is
between a pen-computer and a PC.
circumstances, the central office
copy of inspection
in district
memory
period.
It
is
cards or floppy diskettes.
is
the expensive telephone fee and
One
fax page usually takes a large
61
amount of memory, which
costs significant telephone fees. Also, the non-electronic data
(fax hard copy) can not be used in database integration unless they are re-typed into the
computers. This not only takes more time, but also creates an opportunity for error.
Connecting PCs
recommended. To do
in the
so,
with a high-speed modem.
70KB, equal
to
local
and central offices through telephone network
is
both the inspectors and the central office need to be equipped If a
14,400 baud protocol
is
used, the inspection data (around
20 pages of inspection forms) can be transferred
approach provides a timely and inexpensive way to transfer
in
or 2 minutes. This
1
The above network
data.
for
transferring data has been successfully tested in this research.
Trial of
6.8
Pen-Computer System
The PEPSI system summarized
has
been demonstrated to
Feedback
inspectors.
field
is
as follows:
At the beginning, some technologies into construction
computer experience. about what
this
When
the
field inspectors
sites,
balked
perhaps because
PEPSI system was
at the idea
of introducing computer
many of them
first
toy could do for them. After a few
interface convinced the inspectors that the pen-based
shown
did not have
to them, they
trials,
much
were curious
the PEPSI's user-friendly
computer
is
a powerful tool in
helping inspection data process.
Now,
they like the unlimited pages of electronic forms. With this device, they
not need to carry help
many pages of paper
them record defective
manage
areas.
forms.
The most
The sketch
attractive
function
advantage
is
is
also preferable to
that they
do not have to
the paper forms as before. Using the conventional paper forms, they had to
paper forms carefully. Sometimes, data recorded
in
the paper forms were missed.
the data can be stored inside one unit: the pen-based computer.
do
file
Now,
the all
62
However, some of inspectors were
The system has
difficulty
still
frustrated by the handwriting recognition.
understanding some inspectors' handwriting.
some inspectors were not
simulated keyboard provides another alternative for data input, familiar with the
Although the
arrangement of the standard keyboard. Therefore,
took them a few
it
seconds to find each key. Also, they complained that the pen-based computer big and too heavy at construction
were
damage
also worried about
lost
smaller and lighter design
to the computer, in case they
the contrast on the computer screen
sometimes they got
A
sites.
when they
is
The most
not clear.
tried to transfer data
preferred.
is
dropped
serious
is still
it.
too
They
Additionally,
problem was
that
from the pen-computer to the
host computers.
The general
reactions from the inspectors are encouraging.
responses were due to the hardware limitations.
The major negative
The concept and design of
the software
design were accepted.
Although the developed inspection computer software has been revised a number
of times, continuous improvements are
still
needed before the software can be delivered to
the users. Improvements in the software are central office
and
at
job
sites.
Appendix
made by
B shows
major revision tasks are described chronologically
testing the
program
in
both INDOT's
the questionnaire used in the tests. in
Appendix
The
C.
Advantages of the PEPSI system
6.9
The PEPSI system outdoes
the traditional
paper form with several advantages,
summarized as follows: It
provides an intuitive data input scheme such as handwriting recognition, pop up
lists,
and control buttons. With these input schemes even users without computer
experience can operate the computers efficiently. •
It
supplies a paperless
on data process. Thus,
work environment field
to field engineers and reduces the
engineers can spend
more time on other
work load
critical tasks.
It
saves time by eliminating the requirement of double data entry
to computers. In addition, errors that occur
when
data
—
from paper forms
transferred from paper to
is
computers can be reduced. It
can apply advanced
plan.
statistical
The advanced algorithm most
the capability of
processes such as the variable acceptance sampling
usually requires intensive computation,
field inspectors.
which
beyond
is
With the PEPSI system, the computation
is all
taken care by the computer. It
reduces the required training time for
new
The PEPSI
inspectors.
is
designed to
provide a friendly input interface and detailed instruction of the inspection procedure. It
facilitates the
communication between the central
office
and construction
sites
by
using electronic data communication. Thus, an integrated quality database can be established.
6.10
Extension
To Other Highway Construction
The interviews with system can be
Inspections
the field engineers revealed that the pen-based
computer
many
applied to not only the steel bridge painting inspection, but also to
other inspections of highway constructions.
For example, the developed pen-based computer system can be applied to inspection processes such as bridge deck corrosion and pavement inspections. report
showed
that the
Kansas
DOT
INDOT
needs to continuously process
reports for each bridge. Therefore, the inspectors in
construction
sites,
1 1
first
and then bring the data back to
computers The work involved
is
recent
needs to gather approximately 8.5 million bits of
information each year for their 20,500 bridges (Roads and Bridges, 1994).
example, the
A
field
pages of
need to offices,
very time-consuming and
fill
field
As another
inspection coding
up the inspection forms
and re-type the data into
may cause
errors
when
the
64
data are re-typed into computers. If the inspection forms can be computerized through
pen-technology, the required efforts can be reduced. In another area, pen computing in
CAD
markets seems
The
the construction industry (Intorcio, John, 1992).
users can directly sketch
the field on their pen computers. For example, the inspectors defective
beams
computers on
that
their
need repairing. Engineers checking
arms rather than carrying
rolls
of
The
task to identify which steel
detailed drawings.
challenging work. Errors
computers and
CAD,
in this
could carry pen
For
instance, in a
are piled
By
on the 3-D
CAD
connection
among
model. If the
field
on the job
members
will blink
is
linking pen-based
the field engineer simple write the code numbers of
the screen; the corresponding structure
in
the
erected in which position
phase cause delay of construction.
members on
look
members
members should be
markup
may drawing an "X" over
field installations
large-scale steel structure construction, thousands of steel sites.
to be a natural evolution in
the steel
or change colors
engineers do not understand the installation and
the members, they can
zoom up
the
3-D
CAD
model to get a close
at the designs.
Recently, expert systems are gaining in popularity. Several expert systems have
been developed for highway construction, especially
However, a computer
is
human
For
users.
has been developed.
computer system, the diagnostic Shiu.;
the application
of diagnosis.
needed for expert systems to process algorithms and heuristic
rules to generate solutions for pile defect diagnostic
in
By
results will
instance, an expert system for concrete
inputting several inspection items into a
be obtained (Yeh, Yi-Cherng.; Hsu, Deh-
Kuo, Yau-Hwaug, 1991). Unfortunately, computers are commonly unavailable
construction
sites.
Without computers on hand, the inspectors must
inspection results on paper.
Then the data
the expert systems are installed.
Then
the
is
carried to offices
first
at
write the
where the computers and
inspectors carefully type in the results of their
inspection into the expert system. After obtaining the output from the expert systems, the inspectors bring the results and rush back to the construction
sites,
and pick up the
65
defective concrete piles.
The
project could be delayed because the inspection decision
cannot be make right away. The inspectors need to take the trouble to travel between construction sites and offices.
The whole process
is inefficient.
The cost
to the contractors
and the highway agencies increase, especially when the distance between available computers and construction
A site,
sites is long.
solution to the above
dilemma
is
the pen-based computer.
At the construction
the field engineers can carry a pen-computer loaded with a related expert system.
writing
down what
By
they see, the pen-computer can respond to the diagnostic results right
on the construction
sites.
The
repair action
may be
taken right away. Significant savings
can be achieved by reducing the delay of construction. With the availability of more powerful pen-computers,
field
engineers carry not only an electronic clipboard, but also a
brain of experts for decision making. In
summary, many other inspection processes are
candidate areas for adapting the pen computing technology as long as they meet the following
1.
criteria:
The
INDOT
would
like to
reduce the tedious paper works on the construction
sites.
2.
The INDOT would
3.
The INDOT would statistical
like to collect electronic
like to
data
to build
integrated databases.
apply advanced decision-making algorithms such as
acceptance sampling plan, neural network, and expert system on the
construction
sites.
66
6.11
Potential Problems
and Recommendations
Since the current inspection forms have not been formally written into the specification, the
developed pen-computer system cannot be
steel bridge painting inspection.
Agreement between the
fully
new
implemented
in field
and job
sites is
central office
required before the electronic inspection system can be fully adapted. Currently, the most
important task
is
to finalize the inspection forms.
Only
after the paper inspection
forms are
completely accepted can the pen-computer system be designed to match the
final
inspection forms.
Also, the field
trial
shows
that users (inspectors) need to have a basic level
of
computer knowledge to operate the system. The bottleneck of the system has been found in data file transfer. Currently, data is transferred
have a certain "dir,"
and so
level
using a serial port. This requires users to
computer knowledge such as basic
DOS
command: "copy,"
"delete,"
forth.
Because of tough and harsh operating environments
at
construction
sites,
pen
computers must be rugged and durable. Shock-resistance and water-proof standards must be improved.
Although the pen-computer can can also create a disaster for the that a
computer hard-disk
is
efficiently store a
INDOT
if
tremendous amount of data,
improperly used.
It is
not
uncommon
mistakenly formatted, containing data of
work. Therefore, a foolproof file-backup procedure
many
obtained
in
this
most of the
is
hard
is critical.
INDOT
prototype pen-computer system, the
computerized inspection to many other areas
to hear
years'
This research shows that the elaborately designed pen-computer system for non-computer-literate users like
it
inspectors.
INDOT
in the future.
The
is
suitable
With the experiences
can efficiently expand
benefit
of computerization
not only on the time savings. In addition, the downstream benefits from the electronic
data are important.
made
Once
the information
simpler. This project provides an
is
recorded electronically, the processing effort
automated system that stores
all
is
the information in
67
format.
electronic
No
conversion effort
Moreover, with the power of computers,
it
is
needed
for
downstream data processing.
can automatically make the decision to accept
or reject the painting products. In
summary, a pen-based computer system
will
provide
many
Tedious
benefits.
paperwork can be reduced. The downstream benefits are valuable for electronic data integration.
As
a result, the collected data will be
more
accurate, providing the
INDOT
with more information to make better decisions. Before pen-computers really change the current data input practices, certain barriers must be overcome.
down. The increasing competition and advancing technology
The will
price needs to
come
probably prompt the
popularity of the pen computers. Handwriting recognition accuracy needs to be improved. It is
of no doubt to the researchers that the explosion of computer technology
bring us
more powerful and
solid
pen-computers with lower
prices.
will
soon
63
Chapter
The purpose of
Conclusions and Recommendations
7
research
this
is
to implement the steel bridge painting quality
acceptance system developed in the previous research project (HJRP:HPR-2029-89-27)
and to computerize the developed system into inspectors' daily
7.1
practice.
Achievements of this Research
The
research
accomplished
has
several
essential
tasks
that
make
implementation of the new quality acceptance system not only possible, but also
the
efficient.
In summary, the research has achieved the following objectives:
1.
An
interactive
computer graphic program was developed to
assist the
INDOT
in
designing the double sampling plan and deciding the sample size with controlled risks for both the
INDOT
and painting contractors. With
method can be updated
2.
to adapt to the evolution
new
required quality levels in the future.
The
training
as:
lot,
sampling
size,
sampling, operating characteristic curve
were introduced
to
the
INDOT
single/double
(OC
program, the sampling
of new painting technology and
program was successfully conducted. Basic
concepts such
risks
this
statistic
and quality control
sampling,
attribute/variable
curve), and producer's and owner's
painting inspectors.
The
revised
manual
inspection forms were also presented. After the training program, the inspectors
obtained better background in painting quality control and acceptance sampling system.
69
3.
Field experiment of the developed inspection system after the inspector training
tested.
program. The
new
was
immediately right
initiated
acceptance system was manually
Feedback from INDOT's inspectors and other personnel were adopted to
refine the inspection system.
4.
A
pen-computer system for painting quality acceptance has been developed.
reduce both the need for inspectors'
work. The collected data information to
5.
The
electronic
INDOT's field,
make
will
background, and tedious manual paper
be more accurate, providing the
INDOT
network system to transfer data between construction
central office
was
successfully tested.
Once
Recommendations to
with more
for
the
field
Future
sites
the data are collected
the data inside pen-computers can be transferred to
According
can
better decisions.
The communication between
7.2
statistical
It
PCs
in
and the
on the
the central office.
and office was enhanced.
Work
experiences
obtained
in
this
research,
the
following
recommendations are proposed for future research.
1.
Finalize the Inspection
The new
inspection forms have not yet been formally incorporated into official
specification. Further
achieve a
Forms
communication between the
common agreement
about the
new
office
and job
inspection system.
sites is
needed to
70
2.
The
benefit
of computerization
information integration.
processing investigation
effort
is
Once
made
is
not only time savings but
is
the
Pen-Based Computer System
information
automatically.
To
is
improved
also
recorded electronically,
optimize
further
benefit,
this
the
suggested to highly integrate the data structure of the pen-
computer and the
3.
CRA and
Integrate Data Structure Between
Recorder Administration (CRA) database.
existing Construction
New Computer Hardware
Continually Survey the
In this research, the preferable
pen-computer has been
of the tough and harsh operating environment
selected.
However, because pen computers
at construction sites,
need to be more durable and feature higher shocking resistance and water-proof standards.
It
is
foreseeable
that
tight
competition
among pen-computer
manufactures and the rapid advancement of computer technology
4.
INDOT
more powerful and
solid
continually survey the
new pen-computer technology before massive
pen-computers with lower
will bring
prices.
us
should
purchasing.
Conduct More Inspector Training Program The
field trial stage
showed
operate the developed system.
should be very helpful
in
that the users
More
training
how
is
recommended. The
strengthening inspectors' capability.
should focus on essential issues, such as a painting job,
need more computer knowledge to
how
to
make
The
short courses
training
program
decisions to accept or reject
to ask contractors to fix defective jobs,
and
how
to process
the inspection paper work.
5.
Apply
Pen-Based
Inspection Process
Computer
Systems
To
Other
Highway
Construction
71
The pen-based computer system for other
to
pilot research
re-typed
computerized
also applied
inspection areas, such as bridges and pavement inspections.
current inspection is
can be regarded as
ENDOT's field inspection processes. This technology can be
many other
data
in this project
Many
works are very time-consuming and may cause errors when the into
computers.
If
through pen-technology,
the the
existing
required
inspection efforts
forms
can
be
can be reduced,
eliminating paper shuffling. Further evaluation needs to be conducted for
many
other inspection processes that are candidate areas for adapting the hand-writing recognition technology.
72
References
Abdum-Nur, A. Edward
(1981), "Contractual Relationships— An Essential Ingredient of
the Quality-Assurance Systems," Transportation Research
Anon, (1990), "Asphalt cost control without
quality loss," Better
Record 792,
Roads
pp. 1-2.
v 60 n 2 Feb.
1990 p 36-38.
Appleman, Bernard R. (1988) "Improving Bridge Painting Specifications," Journal of Protective Coatings
and Linings, September 1988,
Baran, Nicholas, (1992a), "Rough Gems: First Pen System
pp. 37-47.
Show
Promise, Lack
Refinement," Byte Magazine, April, pp. 212-222. Baran, Nicholas, (1992b), "The Out Looking for Pen Computing," Byte Magazine,
September, pp. 159-163 Barr, Christopher, (1992), "Pen PCs,"
PC Magazine,
November,
Barr, Christopher and Neubarth, Michale, (1993), "Pen
PAL"
10, pp.
175-178.
PC Magazine,
October 22,
1993, pp. 117-182.
Blaschke, Byron
C,
(1989), "Specifications and constructibility," Proceedings of
Construction Congress I
San Francisco,
-
CA USA
Excellence in the Constructed Project, 1989
Mar
5-8.,
p 87-92.
Bower, Dwight, (1991), "Task force on innovative contracting Transportation Research Circular, No. 386,
Brown, Bruce, (1992), "Pen-Software,"
December
practices,"
1991. pp. 28-30.
PC Magazine, November,
Brown, Bruce, (1993), "Pen Operating Systems,"
TRB,
PC Magazine,
10, pp.
202-203.
October 22, 1993, pp.
172.
Burr,
W.
Irving, (1976), Statistical Quality Control Method,
York. pp. 225-232, pp. 324-336.
Marcel Dekker
Inc.
New
73
Chang, Luh Maan and Hsie, Machine, (1992a), "Development of Quality Assurance Specification for Steel Bridge Painting Contract," Joint
Project:
Highway Research
Purdue University, W. Lafayette, Indiana, FHWA/IN/JHRP/92/10.
Chang, Luh-Maan. and Hsie, Machine, (1992b), "Realistic Specifications for Steel Bridge Painting, Materials":
Performance and Prevention of Deficiencies and Failures,
1992 Material Engineer Congress, ASCE, Materials Engineering Congress; Atlanta,
Crosby, Philip B. (1979), Quality
New
American Library,
is
Inc.,
New York, NY, USA. GA, USA; 1992 Aug.
New
York,
NY,
management
Gendell, David S. and Masuda, Allen, (1988),
Journal of Professional Issues Gentry, Claude and Yrjanson, William
in
The
pp. 250-274.
Journal of Professional Issues in Engineering v
"Highway
issue
on highway construction,"
15 n 2 April 1989 p 162-167.
1
Specifications:
Engineering v 114 n
1
Jan.
Link To Quality,"
1988 p 17-26.
A (1987), "Specifications For Quality Control: A
Case Study," Transportation Research Record, n
USA
10-12.
Free: "The Art of Making Quality Certain,"
Erickson, Jim, (1989), "Meeting the quality
DC,
p 299-310, 1992
1
126 1987, ISA, Washington,
1987 p 37-41.
Intorcio, John, (1992),
"The Pen
is
Mightier than the Sword," CADalyst, June, pp. 106-
110.
Lynn, Cheryl, (1989), "Development of a contract quality assurance program within the
Department of Transportation," Transportation Research Record, n 1234 1989 p 39-47 Maslin, R. William, Stephens, B. Louis and Arnoult, D. James, (1983), "Quality
Assurance for Local Governments," Federal Highway Administration. Report No.
FHWA-IP-83-1
pp. 31-61.
McCullouch, G. Bob, (1993)"Construction Field Data Acquisition with Pen-Based Computers," Journal of Construction Engineering and Management, v June, 1993, pp
374-384.
1
19 n 2
74
Miastkowski, Stan (1992), "Keyboardless Sense," Byte Magazine, February, pp. 36-37. O'Brien, James
J.
Control,
(1989), Construction Inspection
Van Nostrand
Reinhold,
Handbook: Quality Assurance.'Quality
New York,
NY.,
pp. 1-32, 451-456.
O'Connor, Thorn (1992), "Pen-Techniques on the Desktop," 10, pp.
PC Magazine,
November,
182-200.
Quain R. John, (1993), "No Tabula Rasa: Handwriting,"
PC Magazine,
October 22, 1993,
pp. 176.
Roads and Bridges (1994), "Kansas'
Roads and Bridges, March,
New BRISK Program 1994,
p. 44.
Rowell, Dave, (1993), "Pen-Based Computers
May SSPCM:
Increasees Accuracy of Data,"
~ The Next
Generation,"
PC Sources,
1993, pp. 157-184.
Steel Structures Painting Council
- Volumes
Manual
1
and
(1989) Published
2.
by The Steel Structures Painting Council, Pittsburgh, PA., Vol.
1
pp. 19-31, 68-
74, 78-89, 150-167, 183-206; Vol. 2 pp. 9-56, 357-374.
Wadsworth, M. Harrison and Stephens, Kenneth
Modern Methodfor
Quality Control
A. and Godfrey, Blanton (1986),
S.
and Improvement. Wiley
Inc.,
New York.
pp.
460-467. pp. 545-546. pp. 445-447, pp. 581-582.
Weed, M. Richard, (1989).
DOT.
Statistical Specification
Development. 2nd
ed.
New Jersey
pp. 38-58, pp. 297-309, pp. 181-206.
Weseman, William A. and Erickson, James K, "Future of quality assurance," (1988),
ASCE, Highway Div.,
New York, NY, USA.
& Transportation Officials, Conference:
Washington, DC,
American Assoc of State Highway
USA. Eng.
21st Century Highway,
ASCE, New York, NY, USA. pl20-127.
Yeh, Yi-Cherng.; Hsu, Deh-Shiu.; Kuo, Yau-Hwaug, (1991) "Expert system for diagnosing
damage of prestressed concrete
Engineering and Management, v 117 n
1
pile."
Mar
Journal of Construction
1991 p 13-26.
75
Appendix A
Specification
Summary
Specification
Summary
Dauphin DTR-1
Fujitsu
PoqetPad
GRID PalmPad
Plus
$1,995
$2,895
NEC7MHz
NEC
1.25x9x5
1.25x9.65x4.5
1.9x9x6.2
Weight (pounds)
3.5
1.9
2.9
RAM
2MB
2MB
2MB
6-inch Backlit
640 x 200
640 x 400
Electromagnetic/
Contact Resistive
Electromagnetic/
Codeless Pen
Codeless Pen
Codeless Pen
Hard Drive
20MB
None
None
PCMCIA
None
2
Operation System
PenDOS,
PenDOS,
PenDOS,
(Ten OS)
PenRight,
PenRight
PenRight
Dauphin
Fujitsu Personal
GRID
Technology
System (Santa
(Westlake,
(Lombard, DL)
Clara,
800-7827922
800-831-3183
List Price
$2,500
CPU/Clock Speed
Cyrix
25MHz
10
MHz
486SLC Dimension
(HWD
inches)
(standard)
Display
VGA Pen/Digitizer
PCMCIA
1.0
1
PCMCIA
1.0
Penpoint,
Pen Windows
Company
Information
CA)
System
TX)
800-934-4743
.
76
Appendix B:
1.
Field Test Questionnaire for
Pen-Computers
Generally speaking, what do you think about the
:
QA computer program?
Is
it
user-
friendly?
to operate the
QA
inspector to learn to operate the
QA
you think that the INDOT inspectors have enough background program including, DOS and pen-computers?
2.
Do
3.
How long
do you think
it
will
take for a
INDOT
program? 4.
What do you
think of the operation of the pen-computers
too big to operate?
Any power
duration problems?
What
in is
the field? Is the the battery
life
GRID
pad
required
(hours)?
5.
Do you think if the GRID PalmPad
were only
half-sized
it
would improved the
situation?
6.
7.
Did you
try the
equipment out doors?
Is the
Are there problems for writing recognition
LCD
in
the
screen
difficult to
read?
QA program? How do you
solve the
problem?
8.
Do you
think,
it
will
be beneficial for
INDOT
to computerize the inspection system
with PEN-Computers?
9.
What
are the advantages and disadvantages of using pen-computers in the field
compared with paper forms? 10.
What
are the potential difficulties
when INDOT
tried to
computerize the inspection
the fields?
1 1
How do
12.
Do you recommend
QA computer program? Please point out the items that need to
you like the be improved?
that
INDOT
use the pen-computer in the future for painting
inspection data collection?
13.
Look you
at the pictures?
like?
which computers (Fujitsu Poqet pad and
GRID
PalmPad) do
in
77
Major Revision Tasks Of The Pepsi System
Appendix C
May, 1993:
The
QA painting inspection program was
In general, offices.
PCs
instead of pen-computers will be the
Therefore a
version that
is
delivered to the central office for testing.
PC
QA
version of the
same
exactly the
as the
working environment
program was developed
program run
in
in the
a parallel
inside pen-computers.
June, 1993:
After the
QA
program was tested
Feedback about using the
for a
QA program was
and the functionality.
friendliness
few weeks, an interview was conducted.
A
lot
collected to improve the level of user-
of advice was obtained, and several
malfunctions were pointed out. The major changes of the program are summarized bellow:
numbers should become one sub-key
Structural
field
Originally, the designed database used only a contract
manage
data.
structure
However,
in
not
numbers can be assigned under one
be
redesigned.
stored
number
as a key field to
the current system, several bridges with different
original database structure, different bridges
can
of contact numbers.
separately.
To
solve
The redesigned database adds
single contract number.
With the
under the same contract number the
problem,
structure
the
database
numbers as sub-key
was fields
to contractor numbers.
The redesigned data
structure stores the collected data in
two
levels.
one, the database creates the sub-directory using the contract
For
number
level
as the
73
name of
the sub-directory.
number are
Then the data
stored inside the
sub-directory,
same sub-directory. For numbers
structure
the
that belongs to the level
attached
are
same contact
two, inside the same
to
each
filename
to
distinguish which structures (bridges) the data belong to.
Malfunctions of the decision-making mechanism concerning the number of defect
The
were found. They were
printing function did not
to be corrected.
work on
INDOT
office's
EPSON
dot printers.
July, 1993:
The improved finished
QA program correcting the problems found
and delivered for further
in June's
interview were
test.
August, 1993:
A
few minor changes were requested based on the
test
during July, 1993.
The
changes concerned the date display and need for more control buttons to navigate
around the program. and worked well
in
was
It
the
also reported that the printing function
INDOT's
was
fully tested
central office.
September, 1993:
The
refined
delivered to
QA
INDOT's
field inspectors.
the
program, based on the
GRID HD,
central office.
August, 1993, was finished and
test in
Meanwhile, an interview was conducted with
The program was introduced a larger pen-computer,
step by step to field inspectors. Also,
was used
in field testing.
79
The reason
for using
smaller one)
GRID HD
because the
is
(the larger pen-computer) instead
GRID
Co. was sold to
AST
of PalmPad (the
Co. The company
transition tremendously delayed the purchase
of PalmPad. However,
coincide with the timing of field testing, the
GRID HD
PalmPad) was
still
used to
in
order to
(double the size of the
start the field test phase.
In October, 1993: .After
two weeks of testing, the
field trial
the field testing are quite positive.
program works are
still
varies
well;
it
A
was
finished.
sentence from one inspector was:
had no problems that
I
a few points that need to be changed.
in
"The
could figure out." However, there
The format of
structure
numbers
from bridge to bridge. For instance, one bridge structure number can be
123-456-98-ABC, and another can be 11-23-78-XYZ. format
The responses obtained
in structure
number
is
#########-AAAA
designed under the instruction of the structure
number
redesigned.
is
INDOT
Originally, the template
(#: digital
central office.
and A: alphabetical),
Because the format of
variable, the template design for structure
number needs
to be
80
Appendix
Steel
D
Bridge Painting Inspection Training Manual
81
FOUR MAJOR INSPECTION STAGES
A.
The inspection procedures
for field bridge painting construction are divided into
four stages including:
(1)
pre-inspection
(2)
surface preparation inspection
(3)
primer inspection
(4)
top-coat inspection
Figure
1
shows the relationship and order between painting and inspection.
c "5
C3
c
o
c
o
to
Q.
o CD
Surface Pre-lnspection
Preparation
Primer
Top-Coat
Inspection
Inspection
Inspection
Figure
1
The Relation And Order Between
Painting
And
Inspection.
.
82
B.
INSPECTION FORMS OF THE FOUR INSPECTION STAGES The followings
are inspection forms for the four inspection stages.
the pre-inspection stage. 1,
Form
2
is
Form
for the surface preparation inspection stage.
and 3-2 are for the primer inspection
stage.
Forms
FORM1 Stage-I (Pre-inspection For Painting)
Date
Inspected by
Structure
Contract
Contractor or Sub.
1
Has
2.
Did the contractor submit
Yes
the contract of the project been reviewed?
Did the contractor submit the application plan/schedule?
4.
Has
Yes
No
Yes
No
Yes
No
the traffic control and accessing plan been
discussed with contractors? 5.
No Yes
the paint manufacture's instructions? 3.
Is the
following equipment ready to be use?
Psychrometer
Surface Temperature Thermometer
No Yes No
Dry Film Thickness Gauge
Yes
Testex Micrometer with X-coarse Tape
Yes
US Weather Bureau
SSPC
NBS
Yes
Psychometric Tables
Surface preparation Specifications
Calibration Standard
(SSPC
is
for
4-1, and 4-2 are for the top-coat
inspection stage.
District
1
Forms
1-89)
..
Yes
Yes
Tape Measure
Yes
Flash Light
Yes
No No No No No No
No
3-
83
FORM 2 Stage-II (Surface Preparation Inspection For Painting)
Date
Water Wash Cleaned Solvent Cleaned
Required
Inspected by Time/Date of Wash
Yes No. Yes No.
Yes No.
Air Cleanliness
mils
Profile:
Required Surface Cleanliness Grade:
«First SamDline»
Beam No.
/
Time/Date
Location
SSPC
Profile
Is
Reading
Grade
Visual Cleanliness
OK?
No
Yes
1
o 3
4 5
6 "
8
9 10
Nun iber of Defect If
(xl=):
If(x 1=0, 1) then Accept
(xl=2) Take Second Sampling
«Second Sampling» Beam No. / Location
If(xl=3,
4, 5....)
SSPC
Profile
Is
Reading
Grade
Reject
Visual Cleanliness
OK? Yes
11
:: 13
14 15 |
16
|
17
|
18
19
20
Number of Defect If0c2 = 3,4,
5,
(x2=): )
Reject
If (x2
=
0, 1, 2)
then Accept
No
84
FORM 3-1 Stage-Ill (Primer Inspect on For Field Painting)
Date Insps;cted
by
Structure
District
Contract
Contractor or Sub Cleanliness of steel surface before painting (please check with a white napkin) Is the
dry film thickness gage calibrated?
Yes No.
Air-less spray?
Name of paint manufacturer Batch # of paint: Paint material approved? Is paint
power mixed? Yes No.
well
if
"No"
air
supply clean?
and the amount
Yes No. Yes No. Yes No. gallons used.
Yes No. Yes No.
Thinning approved
Time/Date of priming
Time between
blasting
& priming
Hrs. (maximum
Did the contractor cooperate with INDOT by helping inspectors access the bridge in primer inspection? Daily working ambient condition:
Date
Time Dry Bulb
(F)
Wet Bulb
(F)
Relative Humid. (%)
Dew Point (F) Steel
Temp.
Steel
Temp.-
(F)
Dew Point
Wind Speed (MPH) Is the
Ambiance
OK?
Weather Comments:
(Y/N)
24 Hours)
Yes No.
:
85
FORM 3-2 LlO-. 9
'
Requir ed Primer Coating Thickness
T> Beam No. / Location
Time/Date
SSPC
Profile
Is
Reading
Grade
Visual Cleanliness
OK? No
Yes
1
2 ^ j
4 5
6
8
9
10
Number of Defect If
(xl=):
If (x 1=0, 1) then
(xl=2) Take Second Sampling
«Second Sampling» Beam No. / Location
If(xl=3,
4, 5
SSPC
Profile
Is
Reading
Grade
Accept
....)
Reject
Visual Cleanliness
OK? Yes
11
12 13
14 15
16 17 18 V>
20
Number of Defect Iffx2 = 3,4, 5,
(x2=j: )
Reject
If(x2 = 0, 1,2) then Accept
No
102
FORM 2 Stage-H (Surface Preparation Inspection For Painting) Date Inspected by
Water Wash Cleaned Required
Time/Date of Wash
Yes No. Yes No.
Solvent Cleaned
Yes No.
Air Cleanliness
mils
Profile:
Required Surface Cleanliness Grade:
«First Sampling»
Beam No.
/
Time/Date
Location
:
SSPC
Profile
Is
Reading
Grade
Visual Cleanliness
OK? No
Yes
1
2 3
4 5
6 7 8
9
10
Number of Defect If (x 1=2)
(xl=):
If (x 1=0, 1) then
Take Second Sampling
«Second Sampling» Beam No. / Location
If(xl=3,
4, 5
SSPC
Profile
Is
Reading
Grade
Accept
....)
Reject
Visual Cleanliness
OK? Yes
11
12 13
14 15
16
17 18
19
20
Number of Defect If(x2 = 3, 4, 5,
(x2=): )
Reject
If (x2
=
0, 1, 2)
then Accept
No
102
FORM 3-1 Stage-Ill
(Primer Inspection For Field Painting) Date Inspected by Structure
District
Contract
Contractor or Sub. Cleanliness of steel surface before painting (please check with a white napkin) Is
the dry film thickness gage calibrated?
Yes No.
Air-less spray?
Name
if
"No"
air
supply clean?
Yes No. Yes No. Yes No.
of paint manufacturer and the amount
Batch U of paint:
gallons used.
Yes No. power mixed? Yes No. Thinning approved Yes No. Paint material approved? Is
paint well
Time/Date of priming
Time between
blasting
&
priming
Hrs. (Maximum 24 Hours)
Did the contractor cooperate with INDOT by helping inspectors access the bridge in primer inspection? Dailv working ambient condition:
Date
Time Drv Bulb
(F)
Wet Bulb
(T)
Relative Humid. (%)
Dew
Point (F)
Steel
Temp.
Steel
Temp
(T) -
Dew
Point
Wind Speed fMPH) Is
the .Ambiance
OK 9
Weather Comments:
(Y/N)
Yes No.
::
104
FORM 3-2 Lo_ 2
9
I
3 I
A.
.
5 6
Requir ed Primer Coating Thickness If Visual
Primer Inspection
Date of Measurement
OK? First
Yes Sample
Beam/Lot#
No
Second Sample Beam/Lot#
Location of Measurement l
bottom of top flange
3
web web
4
top of bottom flange
2
edge of bottom flange
5
vertical
6
bottom of bottom flange
7
bottom of bottom flange
8
top of bottom flange
9
diaphragm
10
bottom of top flange
Number of Defect =
Accept
Reject
Remark:
If Visual
Primer Inspection
Date of Measurement
OK? First
Yes Sample
Beam/Lot#
Second Sample
Beam/Lot#
Location of Measurement l
bottom of top flange
3
web web
4
top of bottom flange
5
vertical
6
bottom of bottom flange
7
bottom of bottom flange
8
top of bottom flange
9
diaphragm
2
10
edge of bottom flange
bottom of top flange
Number of Defect =
Accept Remark:
No
Reject
'
105
FORM 4-1 (Top-Coating
Stage-IY
Immediate-Coating Inspection For
/
Field Painting)
Date Inspected by Cleanliness of steel surface before painting (,please Is
Yes
check with a white napkin)
Yes No.
the dry film thickness gage calibrated?
Air-less spray
Name
.
...Yes
No.
If
"No"
air
No
Yes No.
supply clean?
of paint manufacturer
and
Batch # of paint:
well
amount
gallons.
is
Yes No.
Paint material approved? Is paint
its
Yes No.
power mixed?
Yes No.
Thinning
TimeyDate of top-coating
Time between priming
&
days
top-coating
Daily working ambient condition:
Date
Time Dry Bulb
(T)
Wet Bulb
(?)
Relative Humid. (%)
Dew
Point (F)
Stee!
Temp.
Steel
Temp- Dew
(?)
Point
Wind Speed (MPH) Is
the
Ambiance
OK°
(Y/N)
Weather Comments:
Did the contractor cooperate with inspectors access the bridge?
INDOT
by helping
Yes
No
::
106
FORM 4-2
^
-10-
E cr
Required Top-Coating Thickness
If Visual
Primer Inspection
Date of Measurement
OK? Sample Beam/Lot# First
Yes
No
Second Sample Beam/Lot#
Location of Measurement 1
bottom of top flange
3
web web
4
top of bottom flange
5
vertical
6
bottom of bottom flange
7
bottom of bottom flange
8
top of bottom flange
9
diaphragm
2
10
edge of bottom flange
bottom of top flange
Number of Defect =
Accept
Reject
Remark:
If Visual
Primer Inspection
Date of Measurement
OK? Sample Beam/Lot# First
Yes
Second Sample
Beam/Lot#
Location of Measurement 1
bottom of top flange
3
web web
4
top of bottom flange
5
vertical
2
edge of bottom flange
6
bottom of bottom flange
7
bottom of bottom flange
8
top of bottom flange
9
diaphragm
10
bottom of top flange
Number of Defect =
Accept Remark:
No
Reject
107 F.
FIELD INSPECTION
SUMMARY
of steel bridge painting inspection are described. The double sampling method is explained. The beam coding system is used to designate the locations of measurements. A case study is used to illustrate the application of the In this handout, the four stages
inspection forms. Figure 8 summarizes the whole inspection procedures.
Less than 24 Hours
_c CO
o
09
O
c E
c en
Q.
O
J2 a.
CD
^
Pre-lnspection
Surface Preparation
>
Inspection
C Form Form
3-1
Form 2
1
^
Primer Inspection
J
Top-Coat Inspection
f Form 4-1
)
1 f Form 3-2
J
fForm
4-2J
Check
Check
Paint Material
Paint Material
Check
Check
Project Information
Air-Cleanliness
Mixing Process
Mixing Process
Traffic Control
Surface Cleanliness
Ambient Conditions
Ambient Conditions
Equipernent
Roughness
Surface Cleanliness Dry Film Thickness
Surface Cleanliness Dry Film Thickness
Figure 8
of Profile
Summary of the
Entire Inspection Procedures.
z
I
SI a
I
SI o\
r.
I
.)
I
o
I
