Risk Management Plan for Masonry Construction

[SeanStructural]

I have been assigned as a PM to a construction job that has a lot of special reinforced masonry walls. In our preparatory meeting with the masonry guys, I asked for their risk management plan. I got a blank expression from all. Then I simplified by asking for a list of items that could go wrong on the this job and how they will deal with it, the response was better but not by much. "oh we don't have it but will get it to you."

It is very clear that they have no clue.

I hope that I could get some brain storm ideas her.

If I am posting this in the wrong place, please let me know. And no we don't have lesson learned to get it from.

Thanks,
Sean

 

[XR250]

It may be easier for you to make a list of possible issues and let them provide answers.
I would have had a blank expression as well.

 

[Ingenuity]

If this is for field/trades/journeymen consider amending the title from "risk management plan" to the more familiar 'work hazard analysis' or 'work safety plan'.

Giving them a proforma written outline/example always helps them start a plan that best defines their full scope of activities and associated risks.

I think the Army Corp of Engineers EM-385 has some guidance here.

 

[hawkaz]

I gather that you will have a special inspector on site. Make sure he knows what is going on - and make sure he knows how to crack a whip.

 

[SeanStructural]

The Army Corp of Engineers EM-385 looks like safety issues. I am looking for mistakes that needs corrective actions. Two folds for risk management, one is to identify the problem that could happen after you do all the precautions, and how to remedy it should it happen. For example the mortar strength did not meet spec. What is your remedy for that.
ExcelEngineering - That is exactly what I hoping to accomplish here. Coming up with the list.
Hawkaz - We will have a special inspector. The only way to find out if he knows what is going on, is after the job starts. Making this another risk. The special inspector is not good. The remedy would be either change him or educate him.

 

[KootK]

Alright, let's get to work on this list:

1) Starter dowels may be cast such that they are not centred on cores.

2) Vertical bars may not be centred on cores.

3) Grout may be under strength.

4) Grout may be dropped from too great a height.

5) Mortar joints may not be tooled properly.

6) They may install splices within your plastic hinge if you've got one.

7) Walls may be built out of plumb or out of tolerance in plan.

8) You may not get bond beams where you want them.

9) Anchors intended for grouted cells may wind up in hollow cells.

10) Unexpected control joints may turn single long shear walls into multiple short ones. Or flanged shear walls into unflanged ones.


The greatest trick that bond stress ever pulled was convincing the world it didn't exist.

 

[XR250]

Seems like a risk management plan would cover how to "prevent" those issues from occurring, not how to fix them. How to fix them should come from an Engineer.

 

[EngineeringEric]

Is this part of the Special Inspection process for Special Masonry Walls? if not it seems like an odd exercise and one that a mason well simply reply with "No" or "Not in my scope". I agree that a list would be nice in theory, but the items that Kootk came upw ith (I agree 100%) will only be discovered/pointed out by the SI agents 1/2 and will be reported back to EOR who will determine the correct actions... I do want a mason having a blanket repair to everything, i want them to do it right in the beginning.

 

[jgailla]

I smell an MBA.

 

[KootK]

The items that I mentioned above would normally be on the agenda for a pre construction meeting for me.

The greatest trick that bond stress ever pulled was convincing the world it didn't exist.

 

[EngineeringEric]

Yesterday I just got from the site where the concrete guy had nearly all the dowels in the wrong location. did not account for doors, shear walls, special details, pilasters, anything. All dowels were spaced at 24 " o.c. or 36" o.c. I even had masonry elevations shown for the complicated areas, and the shops were 100% accurate. So this issue is one of concern to me, positioning conflicts that arise between trades. I always recommend that the mason meet with the concrete guy prior to concrete placement of the first few wall foundations and verify placement with the SI.

 

[dcarr82775]

I recently had a mason do a 20 ft lift of grout. Would not have been a problem if there were not multiple intermediate bond beams, but fear not, as always the special inspector signed off saying all is well. So add that to your list of things a mason will screw up. In my experience masons are the work of all the structural trades, but could just me my run of bad luck

 

[EngineeringEric]

dcarr, not worse than the mechanical guys and their saws/hammers! on that note, add review of all penetrations through the walls, especially shear walls.

 

[dhengr]

SeanStructural:
In all fairness, why don’t you spend the next 45 years building a list of all the things that can possibly go wrong, including problems caused by construction documents, poor design, poor specs., problems caused by the PM team, problems caused by other contractors which cause difficulties with the masonry. You’ll find slightly different ones on every job. You should start writing your fixes for each problem right away, and don’t miss all possible solutions, or you’ll never get done. What a crazy, open-ended question, I’d be dumbfounded too.

Why not discuss some typical problems and see how they respond. Or, just give them the list of problems which will occur on your job and let them respond to them. If they do good, then you guarantee that there will be no other issues. Are they a qualified masonry contractor? Have you looked at some of their earlier work for its quality, etc. Have you talked with some of their earlier customers, some of the G.C.s. they’ve worked with in the past?

 

[SeanStructural]

I appreciate all.
dhenger:
Let me give you an example from the same job on another trade. The concrete contractor had a cold joint in a 20' high wall. We have anticipated that such a problem could happen. We, the PM team, the concrete inspector and even the contractor did everything we could do. Yet, the concrete came late. We either had to stop the pour or continue it. There was already 25 cu-yards in the wall and left 35. The concrete contractor decided to continue the pour. Sure enough, we got the cold joint. As I mentioned, we have anticipated that such a problem might happen and already had a repair plan approved by the EOR. All we had to do is to execute the plan. Of course, we could have waited until such a problem happen and then prepare the plan and get the EOR to approve it.
In risk management planning, you list almost everything that could happen on a job site. Then you qualify only a few (as you mentioned) and prepare a response plan, get it approved and execute it should it happen.
What dcarr82775 mention is a perfect example. Everyone knows that should not happen. And you already took every precaution to prevent it from happening. But it did. Then what would you do?
Every trade should have that plan and it should be part of the submittal.
Kootk, a great list. I would qualify, 1, 3, 5, 7, 8, and 10.
Again, thanks for everyone.
Sean

 

[KootK]

A pessimistic mentor of mine once told me to be wary of designing anything that I couldn't fix somehow. It's a good philosophy in general although I've found it to not be universally applicable. Some things need to either be done right or done over. Owners can't be expected to cover gross inefficiencies.

The greatest trick that bond stress ever pulled was convincing the world it didn't exist.