CHAPTER 1

Introduction

State departments of transportation (DOTs) rely on construction inspectors to verify that the construction means, methods, and processes to ensure the quality standards of completed facilities are in compliance with all contract documents. NCHRP Research Report 1039: Risk-Based Construction Inspection: A Guide (Scott et al. 2023) states that key inspection activities include interpreting contract plans and specifications, maintaining project records, conducting construction surveys, performing field inspection and testing, and overseeing construction. According to the FHWA, the primary goals of construction inspection relevant to a bridge construction project are:

• Ensuring that the project is completed in accordance with plans and specifications;
• Gathering information about issues and changes in construction and allowing for timely corrective actions;
• Encouraging the involvement in and awareness of construction issues and problems by other state agencies to prevent future occurrences;
• Evaluating the capabilities and effectiveness in managing inspection resources, such as qualifications, training, and certifications;
• Encouraging the creation and implementation of quality management programs; and
• Providing technical and procedural advice and recommendations for enhanced construction techniques and engineering supervision (FHWA 2004).

Bridge construction inspectors require technical expertise and knowledge related to bridges. Bridge construction may be related to both permanent structures and temporary works. Permanent structures encompass foundations, abutments, piers, columns, decks, girders, superstructures, and other essential components that contribute to the structural behavior and functions of a bridge. On the other hand, temporary works consist of forms and falsework, shoring systems, and other elements specifically designed to provide support during the construction of a bridge.

NCHRP Research Report 1039: Risk-Based Construction Inspection: A Guide (Scott et al. 2023) emphasizes that state DOTs had been encountering significant difficulties due to decreasing budgets and a notable decline in the quantity and expertise of construction inspectors over the previous decade. This has resulted in a loss of experienced construction inspection personnel for many state DOTs, while the demand for inspection has risen along with the number of projects.

According to NCHRP Research Report 1027: Guide to Recruiting, Developing, and Retaining Transportation Infrastructure Construction Inspectors (Harper et al. 2023), a substantial challenge faced by many state DOTs is high attrition rates and the loss of institutional knowledge within their organizations. This issue stems from the retirement of experienced construction inspectors, reductions in construction inspection staffing levels, and the migration of skilled personnel to the private sector. These factors collectively contribute to a decreasing pool of experienced professionals within state DOTs, posing a major challenge to their operational efficiency and

expertise. This report highlights the following challenges in the development of construction inspectors for transportation infrastructure projects:

• The number of DOT positions is limited or capped,
• Attracting individuals to construction inspection positions is challenging,
• There is high variability in training and certification programs for construction inspectors,
• Clear career paths for inspection are lacking,
• The resources available for creating and providing training are limited,
• Inspection practices vary among state DOTs,
• Opportunities for on-the-job learning experiences are scarce,
• There is a high demand to efficiently educate and train construction inspectors,
• It is difficult to align training needs with education and experience for construction inspectors, and
• Inspector skills and abilities are evolving with technology (Harper et al. 2023).

A number of state DOTs have implemented diverse training approaches and programs aimed at enhancing the knowledge, skills, and abilities (KSAs) of their construction inspectors for effective bridge construction inspection. However, there exists variability in the current practices for training bridge construction inspectors across different state DOTs. There is a lack of comprehensive documentation that consolidates information on roles and responsibilities, training approaches, processes, programs, and resources used by state DOTs for the purposes of training and of managing their bridge construction inspections. Such documentation could provide substantial value to other state DOTs seeking to improve their bridge construction inspection training and management processes.

Synthesis Scope, Goals, and Objectives

The objective of this synthesis is to collect resources and document practices used by state DOTs in training or setting the qualifications of the bridge construction inspection workforce. To achieve this objective, the main goals of this synthesis are as follows:

• Identification of various types of training used for bridge construction inspection, such as classroom-based training, on-the-job training, mentoring, online/virtual-based training, and self-paced training. This also includes identifying the resources and tools used for training, such as manuals, pocket guides, and checklists; training opportunities and a road map for inspectors’ career development; written training materials, documents, reports, and curricula; and performance data on the effectiveness of training.
• Documentation of the organizational structure for bridge construction inspection, along with inspector responsibilities and minimum qualifications.
• Identification of the core competencies necessary to perform bridge construction inspection effectively.
• Documentation of the opportunities and requirements for bridge construction inspection certification.

Furthermore, the synthesis documents particular experiences and discoveries from state DOTs regarding the training and supervision of their bridge construction inspection staff. Lastly, the report identifies areas where knowledge is lacking and offers opportunities for potential future research.

Synthesis Methodology

In order to achieve the goals of the synthesis, the synthesis team adopted a systematic approach that involved:

• Conducting a literature review of bridge construction inspection,
• Surveying state DOTs by using a web-based questionnaire sent to voting members of the AASHTO Committee on Bridges and Structures (AASHTO COBS),
• Conducting structured interviews with selected highway agencies, and
• Exploring case examples of specific DOT agencies that have experience in bridge construction inspection training and certification.

The synthesis team began with a thorough literature review of documents related to bridge construction inspection, including academic literature, FHWA literature, industry publications, and state DOT websites, reports, documents, policies, and tools. This comprehensive effort explored the training resources and qualifications for the bridge construction inspection workforce and identified the most current trends in bridge construction inspection training resources and practices. Furthermore, the synthesis team conducted a thorough review of archival data to document the progression of training techniques and tools employed in bridge construction inspection. This encompassed an analysis of how these advancements have contributed to the current standards for training and qualifying individuals in the bridge construction inspection workforce.

Following the literature review and consultation with the NCHRP project panel, the synthesis team formulated a comprehensive questionnaire to conduct a survey of state DOTs. The primary objective of the survey was to gather detailed data on the current methodologies and approaches employed in bridge construction inspection training across the United States. Additionally, the questionnaire enabled state DOT respondents to share links to documents, references to websites, or attachments containing specific information about bridge construction inspection training resources and practices within their respective DOTs.

The survey questionnaire was sent out electronically to voting members of the AASHTO COBS, which contains representatives from all 50 state DOTs and those of the District of Columbia and Puerto Rico. The synthesis team received 43 completed questionnaires, which represents an 83% response rate. After collecting the responses, the synthesis team carefully analyzed and summarized the data, then followed up with additional phone calls and emails to clarify any points, as necessary.

The case examples were used to support and confirm the results of the survey. The synthesis team used the case study method outlined by Yin (2009) to develop a systematic approach for gathering data related to specific instances. Yin emphasized the importance of carefully planning the data collection process to ensure the acquisition of relevant and accurate information. The selection of case examples was informed by a thorough literature review and survey feedback indicating the willingness of agencies to participate. Case examples were conducted with the state DOTs of California, Colorado, Georgia, Michigan, Minnesota, and Pennsylvania. These six states have been actively employing a range of resources and methods to educate bridge construction inspectors and expressed an interest in engaging in this synthesis. The instances cited contain thorough documentation from DOT personnel and provide examples of models, resources, and insights acquired related to bridge construction inspection training practices.

Synthesis Organization

The synthesis contains five chapters, each addressing specific aspects of bridge construction inspection training:

• Chapter 1: Introduction. This introductory chapter has provided an overview of the subject area, including a detailed description of the study’s scope, objectives, and methodology.
• Chapter 2: Literature Review. Chapter 2 offers a thorough review of existing resources and practices related to bridge construction inspection training, drawing on a wide range of available literature.

• Chapter 3: Survey Results. This chapter presents the results of the survey conducted among state DOTs to capture the current landscape of bridge construction inspection training practices.
• Chapter 4: Case Examples. This chapter features case examples from six state DOTs, showcasing the implementation, utilization, benefits, challenges, and key takeaways from their bridge construction inspection training efforts.
• Chapter 5: Summary of Findings and Future Research. The final chapter encapsulates the synthesis’s key findings, highlights prevalent practices, and outlines areas for potential future research to address any identified gaps.