precast plant quality system - mccreary...

Precast Plant Quality System Documentation Set

McCreary Concrete Products, Inc. 5001 E. 106th Street

Indianapolis, IN 46280

Using This Document

This document contains an outline with 12 main headings. Each heading is a volume. Each volume represents a set of documentation that is related to one another. Volume 1 is the quality control manual. A basic quality control manual has been written which can be used and modified by the user to add plant specific details. The remaining 11 volumes will be filled with documentation that either currently exists, or should exist in a precast concrete plant to show compliance to a quality system.

Each volume of this documented system is to be contained in (1) three ring binder. The edge of the binder will be labeled with volume heading. The contents can be then separated into subsets using divider sheets. Different size binders will be needed in some instances to hold the volume of documents and records that may exist. This will vary from plant to plant. In most instances, a 1” binder will meet or exceed the volume requirements.

The purpose for using 12 binders is so that they can be kept together in a library where anyone can see them. This accomplishes two goals. First of all, by being accessible, anyone can refer to the documentation when necessary. It also makes it easy to access when an auditor shows up to examine the system for compliance to a standard. And second, displaying the quality control system in this manner demonstrates to employees and visitors that the quality system is important and supported by management.

A basic way of viewing a documented quality assurance system is to think say it, do it, and prove it. You need to say what you do, in other words, document the process. Then do what you say you are doing by following the written procedures. And finally you must prove it. The proof is in the records generated by the system to show evidence of continuous compliance. By following this format, developing a documented quality system can be done in less time, with less resources, allowing the precaster to do what they do best; make quality precast products

Volumes for Documentation Set

1. Precast Concrete Plant Quality Control Manuala. Management Quality Policyb. Company QC Organizational Chartc. Description of responsibilities for QC personneld. Description of training requirements

i. QC personnelii. Production staffiii. Forklift operatorsiv. Batch plant operatorsv. Drivers

e. Housekeeping Planf. Production Procedures

i. Pre pour inspection proceduresii. Post pour inspection proceduresiii. Final inspection proceduresiv. Curing proceduresv. Product repair proceduresvi. Nonconformance procedurevii. Mix qualification procedureviii. Raw material testing proceduresix. Equipment calibration proceduresx. Product performance test proceduresxi. Hot weather concreting procedurexii. Cold weather concreting procedure

g. Minimum strength requirementsi. Strippingii. Shipping

h. Product tolerancesi. Quality control records – Sample of forms and documentation

2. Training Documentation Manuala. Quality Personnel

i. Applicable ACI certificationsii. Concrete fundamentals and quality education

b. Production Personneli. Specific safety trainingii. Vibrator trainingiii. Batch plant operator training

c. QC Meetingsd. Safety Toolbox Talks

3. Purchased Material Compliance Recordsa. Aggregate reportsb. Cement / supplementary cementitious materials mill certificatesc. Reinforcing mill certificatesd. Certificates of compliance

i. Admixturesii. Sealants & connectorsiii. Water

4. Plant Equipment Recordsa. Forming (identification, annual inspection)b. Slings and lifting devicesc. Batching tolerancesd. Batch plant inspection criteriae. Calibration recordsf. Concrete mix formulas

5. Pre Pour Inspection Log

6. Post Pour Inspection Log

7. Quality Inspection and Testing Loga. Daily checks logb. Concrete testing recordsc. Curing recordsd. Weekly Curing Ambient Temperature Chartinge. Absorption testing

8. Final Inspection Log

9. Concrete Batch Reports

10. Product Specific Recordsa. Proof of conformanceb. Stormwater concrete pipe requirements (when applicable)c. Round manhole component requirements (when applicable)d. Box culvert requirements (when applicable)e. Septic tank requirements (when applicable)

11. Standards Manual for Test Methods and Specificationsa. ASTMb. AASHTOc. ANSId. ISO

12. Plant Safety Manuala. Management commitment and employee involvementb. Hazardous communications programc. Confined space programd. Hearing conservation programe. Powered industrial truck programf. Control of hazardous energy program (lockout / tagout)g. Emergency response programh. Employee safety training program

© Copyright 2007 by Sam Lines

Precast Concrete Plant Quality Control Manual

Volume 1Issued February 14, 2008


Management Quality PolicyMcCreary Concrete Products, Inc. is committed to providing quality products to our customers. To meet this objective, we will implement and follow the procedures detailed by this quality system manual.

Our quality objectives are:

Customer satisfaction

On-time delivery

Zero defects

Continuous improvement

The success of this quality management system is dependent on the support of top management and employee involvement. The General Manager of McCreary Concrete Products, Inc., by placing his signature below, is demonstrating his support. Employees at all levels within the organization are charged with the responsibility of following this quality management system.

_________________________

Richard M. Craven

Issue Date: 31 March, 2008 Volume 1: QUALITY CONTROL MANUAL

Approved by: ___________________________________ Page 2 of 26


Company QC Organizational Chart

Designation of Responsibility for QC PersonnelGeneral Manager

Has the ultimate responsibility for the Quality Management System Responsible for dedicating resources to the quality department Ensures Completeness of work orders and product drawings

Site Manager

Responsible for verifying product requirements in process

Oversees daily operations of plant

Human Resources and Operations

Responsible for employee training

Oversees Safety Program

Quality Control Inspector

Responsible for the management of the Quality Management System

Responsible for in process and final inspections and testing to include:

o Quality of raw materials

o Quality of forms

o Concrete quality

o Placement and consolidation of concrete

o Product dimensions

o Positioning of embedded items

o Curing of concrete

o Handling, storing and transporting products

o Recordkeeping

o Has authority to halt production processes for quality issues



General Manager

Sales Manufacturing Controller H/R & Operations Quality

InspectionSite Manager


Description of Training Requirements

Quality Control Inspectors

ACI Field Testing Technician – Grade 1

Concrete Production and Quality Training

o NPCA: Production and Quality School; and/or

o PCA: Concrete Principles and Practices; and/or

o PCI: Level II Certification

o Internal Training per ASTM Standard for Cylinder Breaks

Site Manager

ACI Field Testing Technician – Grade 1


o NPCA: Production and Quality School; and/or

o PCA: Concrete Principles and Practices; and/or

o PCI: Level II Certification

o McCreary Concrete Products Vibration Basics Class

o Internal Training per ASTM Standard for Cylinder Breaks

Forklift Operators

Powered Industrial Truck Training and Certification

Batch Plant Operator


o Determined by our Ready Mix Supplier

Delivery Truck Drivers

Specialized Licensing and Training

o Indiana Commercial Drivers License-Class B minimum

o McCreary Concrete Products- 40 Hour Specialized Loading and Hauling Course

ACI is the trademark for the American Concrete InstituteNPCA is the trademark for the National Precast Concrete AssociationPCA is the trademark for the Portland Cement AssociationPCI is the trademark of the Precast/Prestressed Concrete Institute




Housekeeping PlanSafety is a priority. Good housekeeping is critical to eliminating slips, trips and falls. Each employee is responsible for picking up trash and debris and placing it in the proper container throughout the day. Any spill will be cleaned promptly. Tools and equipment will be put away when not in use. The use of extension cords and hoses will be kept to a minimum, and they will be stored when not in use. All electrical panels/boxes will remain closed unless work is being performed on them. Lockout/Tagout procedures will be used to ensure equipment is not in a “live” state or has the potential to become “live” during maintenance operations. All blocking for structure storage, when not in use shall be stored in bins until time of use.

Storage yard shall be kept free of large debris, blocking materials of all types, especially those small enough to lodge in between dual rims of trucks. Storage yard shall be kept free of tools, cords, hoses, and other items that may pose safety hazards. All employees are responsible for housekeeping in the Storage yard.

The quality control inspector will inspect the plant and storage yard daily to make sure this policy is being followed. Acknowledgement that the housekeeping inspection is completed will be documented on the Daily Plant Inspection Form, located in Volume 7 of the series of manuals.




Production ProceduresA. Pre-Pour Inspection Procedure

A pre-pour inspection will be performed on each form prior to casting. As a minimum, the following items will be checked:

o Form dimensions

o Form tightness

o Form cleanliness

o Form release agent application

o Positioning, size, and securing of reinforcement

o Placement, securing, and location of embedded items

o Placement, securing, and location of blockouts

The record of the inspection will be made on the pre-pour inspection form for the date the product is to be cast. To identify that the pre-pour inspection is complete, and that the form is ready for casting, we will use a laminated two sided, color coded card, affixed to steel forms with a magnet, or hung on a nail on wooded forms. Red side of card (NO GO) to face out until form has received the proper pre-pour inspection. Upon receiving a no deficiencies rating, the card will be turned over so the Green side (GO) is facing out. This GO rating ensures production personal the form has been properly checked and is ready to pour. Forms will not be cast until they have been inspected and approved. Special attention shall be taken in the following matters:

1. Reinforcemen t : Reinforcement should be stored, sorted and accessible. Areas used for fabrication should be clean and orderly. Personnel safety and keeping the material free from contaminates and damage are the primary concerns.2. Sub-assemblies: Sub-assembly areas for forms, steel embeds and reinforcing steel should be accessible, capable of producing desired assemblies and adequate for the facility. Assembly of units should be by specification and follow all current industry standards.3. Casting: Casting areas should be adequate and orderly to control the fabrication process of all types of precast concrete.

a. Placing : Concrete should be deposited in the forms in methodsthat maintain a consistent and uniform finish surface. It shouldnot, by means of placing, disturb or displace any embed itemspreviously placed. Care should be exercised to see that form oilsdo not inhibit the design performance of anchors or reinforcing. prevention of corrosion through and on finished surfaces must be considered when placing reinforcing, reinforcing supports, and ties.b. Consolidating: Vibration in addition to removing air voids should also evenly distribute the concrete and in some cases




orientate the aggregates for a desired finish. At no time will the vibrator be used to move fresh concrete.c. Curing: Protection must be provided during the initial curing ofconcrete placement to attain desired concrete strengths. consistent curing conditions of temperature, humidity and time are required to maintain finish consistency. Controlling excessive heat and air movement reduces conditions that cause shrinkage cracks.d. Stripping: Removal of the product from its form is most critical in regards to its structural capacity. Stripping methods should notdamage the finish surface. Forms should be designed to allowstripping of the product. Concrete strengths are critical for theperformance of lifting devices and reinforcing. Proper concretestrengths prior to stripping must be attained. Lifting equipment

must be adequate and in a condition to allow safe and successfulstripping of the product.e. Finishing: Finish areas must be provided to perform the various methods of attaining the final surface treatment of the product. Special considerations should be given for finishing methods using chemicals or that create excessive dust particles. The product should be supported and positioned for the safety of the personnel working on and around the product. Equipment for finishing techniques must be adequate to maintain consistency from piece to piece. Imperfections which appear may require repair. Patching must be aesthetically acceptable and structurally sound.

4. Storage: Products stored for future shipment should be adequatelysupported and blocked to prevent damage. Position of blocking isdetermined by design and must be maintained in storage. Precautionsshould be taken to prevent chipping, warpage, cracking, contamination, orstaining of the product in the storage area. It should be stored in an orderly and accessible manner.

5. Shipping: Loaded products must be properly blocked to prevent cracking and damage to the finished surface. Panels must be adequately secured during transporting to prevent shifting and damage. Some instances may require protection from contamination to the finished surface. The product should be scheduled for the desired delivery sequence of the installer. If possible, they should be orientated at the desire of the erector.

B. Post Pour Inspection Procedure

A post pour inspection of each product will be performed. As a minimum, the following items will be included in the inspection:

o The evidence of any damage such as spalls or cracks

o Excessive bugholes or honeycombing

o The dimensions of the product and cast in items are within tolerance




o Exposed reinforcing

o Assembly of any components to the casting

o Ambient outdoor temperature for curing purposes

o Permanent identification of the product as required

The results of the inspection will be recorded on a post pour inspection form for the date the product was cast. Any defects noted are to be repaired and re-inspected before the product passes inspection. Any product which cannot be repaired, or does not conform to the required specifications will be permanently identified as nonconforming with the word ‘CULL” clearly marked on said piece. All castings that are approved will be designated with a distinct mark that identifies the casting as accepted. This mark is to be the NPCA Certified Plant logo upon successful completion of the plant certification process. On items too small in nature to me marked with said logo, (ie. Parking bumpers, distribution boxes, risers, survey markers, etc.) a tag will be placed on the skid in which they are stacked for storage and delivery. All structures will be marked with a permanent identification number to include the casting mold from which they were poured, job name or number if required, and date of production. This can be done by either etching said information into piece during casting, spray painting information onto structure after strip, if the exterior finish allows, or with an identification tag affixed to structure and/or the skid structure is stored/hauled on.

All forms to be marked with an identification number, either welded or clearly painted onto exterior in a visible location. Tanks, to have this number etched into corner of top slab during finishing. (see fig. 1) Each gang form (Bumpers) to carry a letter designator. (ie., A, B, C, D, etc.) This designator, in conjunction with the #1, to be etched into the bottom of first bumper of each gang form. (see fig. 2) Bumpers to be stacked as such: the higher letter in alphabetical order remains on top of the lower number (ie. Skid #1 has products from gang E on bottom row, gang D on top of E, Gang C on top of D, Gang B on top of C, and Gang A on top of B. (see fig. 3) Skid # 2, as follows bottom to top: J, I, H, G, F. Bumpers will be stripped in such a way as to always place bumper #1 in each row over bumper #1 in the previous row. (ie., A1 over B1, over C1, over D1, over E1). (see fig. 3)

This process prevents the need for marking all bumpers, and ensures proper quality and inventory tracking of individual units.

C. Final Inspection Procedure

Before shipment, all products will be inspected to assure that the product conforms to requirements and is properly identified.

Shipments containing more than 5 units of the same product will have 1 product for every 13 shipped inspected. If a defect is found, 2 additional products will be inspected. If a defect is found in either of those products, all remaining product will be inspected.

Any defects noted are to be repaired and re-inspected before the product passes inspection. Any product which cannot be repaired, or does not conform to the required specifications will be permanently identified as nonconforming with the




word ‘CULL” clearly marked on said piece. Only products which pass inspection will be shipped unless the purchaser is notified and agrees to accept the product with the nonconformance.

The final inspection, including any nonconformances or customer acceptance of a defect, will be recorded on the final inspection form.

D. Curing Procedures Procedure

The typical curing process for all products is by non-mechanical means. Castings will be protected from moisture loss after pouring and prior to stripping.

For concrete with a temperature above 55° F, the form will be covered with a plastic sheet of no less than 6 mils thick. Alternative curing methods such as a curing membrane may be used when applied at a rate not exceeding 200 SF per gallon.

Heat Curing (only when used) – Accelerated curing by heat or steam may be performed. When it is done, concrete will not be subjected to hot air or steam until after a minimum of 30 minutes or after the initial set of the concrete. The casting will be protected against moisture loss by covering or the addition of steam when using an accelerated method. The concrete curing temperature will be monitored and will not exceed 150° F. The rise in temperature will be limited to a maximum of 40° per hour.

Records for accelerated curing processes, if used, will be kept and include the following information:

o Time of initial set (ASTM C403)

o Ambient curing temperature measured a minimum of once per week

o Inspection of cured products for evidence of plastic shrinkage cracking and documentation of any damage found

E. Product Repair Procedure

A qualified person (General Manager, Sales Manager, Site Manager, or Quality Control Inspector) will determine whether the defect is minor or major in nature. If the defect will not impair the function or expected life of the product, then the defect will be considered minor, all other defects will be considered major. Defects will be repaired according to the following process:

Minor Defects – To repair a honeycomb area or spalling, any loose debris will be removed and the area surrounding will be cut away. The mating surface will be dampened. Depending on type of product and the ultimate end use of said product, Meadow Patch 20 or Meadow Plug will be used to patch the area. Cracks 1/8” to 3/8”, spanning 18” or will be filled with a 2 part epoxy gun, using Simpson Epoxy-Tie ET-22. Cracks longer than 18” will be covered with a 2 part epoxy and ports will be set every 12”. A thin, clear 2 part epoxy will be pumped into the top port until it comes out the next port down. This procedure will be repeated until the lowest port seeps epoxy. If the crack goes through the piece, this procedure will be repeated on both sides of the product. The material will be used in accordance with the manufacturers recommended procedures.

Major Defects – Major defects that affect the function or life of the product will not be repaired. The casting will be scrapped or re-classified if it meets another




specification. Products with defects that are considered major will be clearly designated and will be permanently identified as nonconforming with the word ‘CULL” clearly marked on said piece

All defects will be documented on the inspection records. Any repairs made will be re-inspected before the casting is approved. The re-classification or rejection of any product with a major defect will be documented.

F. Mix Qualification Procedure

Standard slump concrete will be proportioned by a volumetric method by a qualified individual. Each recipe will be proportioned, documented and labeled for identification. The nominal compressive strength will be designed to exceed the required minimum compressive strength by either one standard deviation (when a minimum of 20 test samples are available) or 1,200 psi. Changes in the mix design will be documented. Unless specified, all mixes shall have a water-cement ratio no lower than .35 and no higher than .45.

When Self-Consolidating Concrete (SCC) is used, the qualification process will involve the SCC admixture manufacture. SCC will be tested daily at the beginning of the pouring operation. A specified range for the spread of the SCC will be determined for each design used. The mix will be considered to be within specification when two consecutive tests for spread fall within the specified range.

The air content, maximum water-to-cement ratio and minimum compressive strength will be as specified by the customer’s requirements.

G. Raw Material Testing Procedure

All raw materials will be tested by the supplier, and shipped with a certificate of conformance or mill certificate.

H. Equipment Calibration Procedure

A listing of all equipment used to measure the materials used in making or testing the concrete will be listed and calibrated at least annually. The list will include, but not be limited to, the following:

o Weight Scales

o Admixture dosing equipment / meters

o Moisture sensing equipment

o Air entrainment meter

o Compressive test machine

o Thermometers

o Rule or tape measure

I. Product Performance Test Procedure

Proof of Conformance to Specifications – When required, conformance to specification will be by design calculations or by performance testing. Performance testing will be verified by an independent expert or by a licensed professional engineer.




o Round Manholes – The following inspections will be performed on the applicable round manholes produced:

Reinforcing Steel – A minimum of three cages from each production day, but not less than 3%, will be inspected for compliance to requirements. The cage will be verified with the design, the type of reinforcing used will be verified, and the connection method will be checked. These inspections will be documented and kept on file for a minimum of three years.

Flat Slab Tops – Flat slab tops will be verified by design calculations or by proof testing. A licensed professional engineer or an independent expert will verify the results of proof testing. The design will conform to ASTM C478.

Absorption testing – Absorption testing will be conducted per ASTM C497 a minimum of once per year on the mix design with the lowest amount of cementitious material. The results from this testing will be documented and maintained at the plant for a minimum of three years.

Step Testing – A test of the steps will be conducted a minimum of once per year in accordance with the requirements of ASTM C497. The testing will meet the requirements of ASTM C478.

Sanitary Manhole Vacuum Testing – When required, vacuum testing will be performed according to ASTM C1244. The results from this inspection will be documented and maintained at the plant for a minimum of three years.

Joint Design and Testing – Joints will be designed and verified per ASTM C443, ASTM C990, or as required by the customer’s specification. Leakage testing by either hydrostatic or vacuum testing will be conducted on the gasketed connections annually, or when the joint or gasket material changes. The results from this testing will be documented and maintained at the plant for a minimum of three years.

o Septic Tanks - The following inspections will be performed on applicable septic tanks produced:

Structural Proof of Design – Proof of design will be performed by either calculations or by proof testing. Design calculation will be stamped by a licensed professional engineer. Performance testing will be verified by an independent expert or by a licensed professional engineer.

Watertightness Testing – Septic tanks will be verified for water tightness according to the applicable section of ASTM C1227 or the requirements of local authority with jurisdiction, whichever is more stringent. A minimum of one septic tank produced from each form will be tested at least once per year unless a greater




frequency is required by the customer. The results from this testing will be documented and maintained at the plant for a minimum of three years.

J. Hot Weather Concreting Procedure

It is preferred that the fresh plastic concrete temperature be no greater than 90° F. When the fresh temperature of the concrete reaches 87° F, the batch plant operator will be notified. The concrete temperature will then be monitored for each batch by the batch plant operator.

If the addition of ice and increase in sprinkling aggregates does not reduce the fresh mix temperature to below 90° F, then concrete production will be discontinued.

K. Cold Weather Concreting Procedure

It is preferred that the fresh plastic concrete temperature be no less than 50F. When the fresh temperature of the concrete reaches 55° F, the batch plant operator will be notified. The concrete temperature will then be monitored for each batch by the batch plant operator.

If the fresh concrete temperature falls below 50° F, the concrete production will be discontinued.

Since a significant amount of aggregate can be stored indoors, the aggregate temperature will increase in storage. Therefore, after additional storage time, concrete production may be resumed once the combined temperature of the aggregates and cement exceeds 40° F.

L. Ready Mix Loading/Mixing Procedure

The concrete raw materials loading and mixing will be monitored for each batch by the batch plant operator. The Loading procedure is a follows:

1. The correct/adjusted amount of water for the mix design is added to the revolving mixer drum.

2. The sand* and gravel/stone are weighed and added to the revolving mixer drum. (*Air entraining admixture is added to the top of the sand after weighing and prior to adding to the revolving mixer drum).

3. Cement and/or Flyash are weighed and added to the revolving mixer drum.

4. Remaining admixtures are added to the mix.

5. Batch will be mixed for a minimum of 70 drum revolutions before discharge.




Minimum Strength RequirementsA. Stripping Strength

Stripping strength for sign bases, all parking bumpers and survey markers shall be a minimum of 1500 psi, all other products produced, unless specified by an engineer or deemed job specific shall be a minimum of 3000 psi.

B. Shipping Strength

Shipping strength for all products produced, unless specified by an engineer or deemed job specific shall be a minimum of 4000 psi.

C. 28 Day Strength

The 28 day strength of all products produced, unless specified by an engineer or deemed job specific shall be a minimum of 4000 psi.

Test Cylinders will be made in accordance with ASTM C31/C31M-06- Standard Practice for making and Curing Concrete Test Specimens in the Field.

All products will not be stripped until desired stripping strengths are achieved. This process will be documented through the making, curing and breaking of cylinder specimens. A minimum of 2 stripping cylinders will be made daily for each mix design and/or product line poured. These cylinders will be made per the guidelines set forth in ASTM C31/C31M-06, and the following tests will also be performed: Air Content: ASTM C143/C143M, Slump: ASTM C173/C173M or C231, and Temperature: ASTM C1064/C or C 1064M. Cylinders will be cured at or near the actual form/bed until the product is ready to strip. At said strip time, 1 cylinder will be tested and recorded in accordance with ASTM C39/C 39M-05, Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens and C1231/ C1231M-00, Standard Practice for Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders. If said cylinder achieves the desired stripping strength, the product can be stripped and the other cylinder will be tested to show an average strength. If the cylinder does not achieve desired strength, more curing time (actual time determined by QC personnel) will be provided, then the second cylinder will be tested and documented in accordance with the above stated ASTM’s. If at this time, the cylinders have not achieved the required stripping strength, the product will be allowed to cure for additional time, and tested/documented with a rebound hammer in accordance to ASTM C 805-02, Standard Test Method for Rebound Number of Hardened Concrete. This process will be repeated until desired strength is achieved. If strengths are not met, products will be considered substandard and reclassified or rejected.

7 day and 28 day strength cylinders will be made a minimum of once per week per mix design/product type. These cylinders will be made per the guidelines set forth in ASTM C31/C31M-06, and the following tests will also be performed: Air Content: ASTM C143/C143M, Slump: ASTM C173/C173M or C231, and Temperature: ASTM C1064/C or C 1064M. Cylinders will be cured at or near the actual form/bed until the product is ready to strip. At said strip time the 7 day and 28 day cylinders will be removed from their molds and placed outside to simulate




the curing conditions of the products they are to represent. At the 7 and 28 day times, the cylinders will be tested and recorded in accordance with ASTM C39/C 39M-05, Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens and C1231/ C1231M-00, Standard Practice for Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders. If at these times, the shipping and/or design strength is not met, the product will be allowed to cure for additional time, and tested/documented with a rebound hammer in accordance to ASTM C 805-02, Standard Test Method for Rebound Number of Hardened Concrete. If, after performing this test, strengths are not met, products will be considered substandard and reclassified or rejected.

Per ASTM C1231, pads used in compression testing will be “flipped” after 50 cylinder breaks, and discarded after 100 cylinder breaks. Records of the “flipping” and discard procedure will be kept track of on the QC labs dry erase board as a running total. A start of use date will be documented, as well as a running total via tick marks. When 50 breaks have occurred, the date will be documented, and the pads will be flipped. Upon completion of a cycle of 100, the pads will be replaced and a new cycle will commence.

Product Tolerances

Bugholes, chips, voids, and honeycombing 3/8" maximum depth

Maximum size joint gap 3/8”

Length, width, height, and diameter (inside):0 to 5 ft +/- 1/4” 5 to 10 ft +/- 3/8”10 and over +/- 1/2"

Squareness (determined by inside diagonal dims.):0 to 10 ft 1/2”10 and over 3/4"

Wall thickness +3/8”, -1/8”

Top and bottom slab thickness +1/2”, -1/8”

Standard Weight Concrete:

Minimum cement content 564 lbs.Maximum w/cm ratio .45Slump w/ water reducing admixture 3 1/2” min.,7 1/2” max.Spread (SCC only) 22” to 28”Air content 6%, + 2%, - 2%




Quality Control Records Prepour Inspection Form

Post Pour Inspection Form

Final Inspection Form

Daily Plant Inspection Form

Concrete Testing Form

Concrete Mix Design Form

Tank Watertightness Testing Form

Bi-Annual Quality Control Meeting

Weekly Curing Ambient Temperature Charting

Safety Toolbox Talks

Manhole/Handhole Absorption Test

Rebound Hammer Test




Prepour Inspection FormProduct or Job: ____________________________________

Inspection Date:

Mon Tue Wed Thu Fri Sat

Form Condition

Form Cleanliness

Form Joints

Release Agent / Retarder

Design Length (ft/in)

Set Up Length (ft/in)

Design Width (ft/in)

Set Up Width (ft/in)

Design Depth (ft/in)

Set Up Depth (ft/in)

Blockouts

Squareness

End and Edge Details

Reinforcing Steel

Reinforcing Size

Reinforcing Spacing

Reinforcing Rustification

Cast-in Items

Lifting Devices

Comments:__________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

QC Inspector: ________________________________________ Date: __________________




Post Pour Inspection FormProduct or Job: ____________________________________

Casting Date:

Inspection Date:


Stripping Strength (psi)

Casting Finish

Coating Finish (if applicable)

Cast Length (ft/in)

Cast Width (ft/in)

Cast Depth (ft/in)

Cracks or Spalls

Squareness

Honeycombing / Bugholes

Bowing / Camber

Exposed reinforcement

Embedment Item Locations

Openings and Blockouts

Lifting Devices

Markings

Outside temp </= 25 deg F.

*Outside temp > 25 deg F.

Comments:__________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

____*If outside ambient temp <25 Deg. F. product to remain in building for 24 hrs to cure.

QC Inspector: _________________________________________ Date: __________________




Final Inspection Form For Non-Stock Precast

Final Inspection Date: ____________________________________

Product or Job: ____________________________________

Number of Units: ____________________________________

Casting / Unit Type: ____________________________________

Casting Pour Date: ____________________________________

____ Post Pour Inspection Compete? Yes or No

____ Check product and compare it to the order

____ Check product markings for correct information

____ Check to make sure manufacture name or trademark is visible

____ Check for cracks, spalls, or damage

____ Check installed components

____ Check accessories (manuals, control panels, mastic, etc.) and compare to the order

____ Make sure concrete strength exceeds minimum requirement for shipment





Daily Plant Inspection Form

Monday Check here if Holiday or Plant is Not in Operation

Date: __________

Yards of concrete produced on this day: _________

Housekeeping Inspection Performed By: _________________________________

Storage Area Inspection Performed By: _________________________________

Tuesday Check here if Holiday or Plant is Not in Operation

Date: __________




Wednesday Check here if Holiday or Plant is Not in Operation

Date: __________




Thursday Check here if Holiday or Plant is Not in Operation

Date: __________




Friday Check here if Holiday or Plant is Not in Operation

Date: __________




Saturday Check here if Holiday or Plant is Not in Operation

Date: __________







Safety Toolbox Talks

Date:______________ Instructor:_______________

Topic of Discussion:_______________________________________________________________

Recommendations from Personnel:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Personnel in attendance:_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________




Vibrator Training Course

Date:______________ Instructor:_______________

Type of Vibration: AIR, ROTARY, EXTERNAL STICK, INTERAL BOTH

Personnel in attendance:_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________




Concrete Testing Form

Date of Pour: ________________

Mix Design/Formula Number: ________________

Batch Number: ________________

Specimen ID Number: ________________

Mix Proportions:

Please see daily batching tickets.

Test Results:

Slump/Spread: ________ Temperature: ________

Unit Weight: ________ Air Content: ________ Yield: ________

Stripping Cylinder Compressive Strength: ___________ psi @ _____ days.

Stripping Cylinder Compressive Strength:____________psi @ _____ days.

Average Strip Compressive Strength: _____________psi

7 Day Cylinder Compressive Strength: ____________ psi


Average 7 day Compressive Strength: ____________ psi



Average 28 day Compressive Strength: ____________ psi




Concrete Mix Design Form

Formula Number: ______________ Plant: _______________

Formula Name: ____________________________________________________________

Design Compressive Strength: _________________ PSI @ 28 days

Water-to-cement Ratio: __________

Design Air Content: __________ %

Design Unit Weight, Batched: ___________ PCF

Coarse Aggregate Ratio: __________

Cement (type ___ ): ________________ LBS. from __________________________________

Fly Ash: ________________ LBS. (Fly Ash % = _________ ) from ______________________

Water: _________________ LBS. ______________ GAL.

Coarse Aggregate: _____________ LBS. (SSD) (Type: ______________________________ )

Sand: _______________ LBS. (SSD) (Type: _____________________________________ )

Air Entrainment Admixture: ___________ OZ. (Name: _______________________________ )

Water Reducing Admixture: __________ OZ (Name: ________________________________ )

Set Accelerating Admixture: __________ OZ (Name: ________________________________ )

Notes: ____________________________________________________________________

Mix Design Approval:

_________________________________________________________Production Manager Date

_________________________________________________________Ready Mix Supplier, Quality Manager Date




Tank Watertightness Testing Form

Date Tested: __________________

Location of Test: __________________

Product Tested: __________________

Product Serial # __________________

____________________________________________________________________________

TEST SPECIFICATIONS

Test Requested By: _________________________________

Test Performed By: _________________________________

Test Witnessed By: _________________________________

Description of Test: __*see C-1227 below_________________

Product Tested To: ____ASTM C-1227-9.2.2 Perfomance test methods___

Additional Comments: ______________________________________________

______________________________________________

Water level reading: Start: _________” End: _________” Time: _____ Min.

(Allow the tank to stabilize before beginning the timed test. Refer to the latest edition of ASTM C 1227 for requirements.)*“C-1227-9.2.2 Water-Pressure Testing-Seal the tank, fill with water and let stand for 24 hours. Refill the tank. The tank is approved if water level is held for 1 hour.”

Pass _________ Fail __________

Signature: _______________________________________________




Weekly Curing Ambient Temperature ChartingProduct or Job: ____________________________________

Casting Date:

Inspection Date:


Concrete temp </=55 deg F.

(proceed to next step) N/A N/A N/A N/A N/A N/A

Concrete temp > 55 deg F.

Starting ambient temp deg F.

Low ambient temp deg F.

High ambient temp deg F.

Outside temp </= 25 deg F.

Outside temp > 25 deg F.

Comments:__________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

____*If outside ambient temp <25 Deg. F. product to remain in building for 24 hrs to cure.





Manhole/Handhole Absorption TestProduct or Job: __________________________ Cast Date:__________ Test Date:________

Core #1 2 3

Drying Start Time:

Drying Finish Time:

Dry Weight:

Wet Weight:

Weight Difference:

% Absorption:

Instructions: Test Method B: “Test method B absorption test specimens shall consist of three 1 1/2” diameter cores as taken from the two ends and the center area of each tile, or manhole section.” ASTM C497.7.3.2- Specimens

“Dry specimens in a ventilated mechanical convection oven at a temperature of 221 to 239 deg F.” ASTM C497.7.4.1- Drying Specimens

“Dry specimens for a minimum of 24 hours.” ASTM C497.7.4.1.2-Test Method B

“Weigh the oven dried specimens immediately upon removal from the oven where the drying temperature is 221 to 239 deg. F.” ASTM C497.7.4.2- Weighing Dried Specimens

“Within 24 hours, carefully place the dried specimen that has been weighed in a suitable receptacle that contains clean water at a temperature of 50 to 75 deg F. Use distilled water, rain water, or tap water that is known to have no effects on test results, Heat the water to boiling in not less than 1 hour and not more than 2 hours. Do not apply live steam to the water to shorten the preboil periods until 1 hour of heating by gas or electricity has been completed. Continue the boiling for a period of 3 hours. At the end of the 3 hour boiling period, turn off the heat and cool the specimen for a period of 3 hours by running cold tap water into the boiler, or by placing the specimen in a separate container of water. The temperature of the cooling water shall not exceed 65 deg. F.” ASTM C497.7.3.2-Immersion and Boiling, Test Method B

“Remove the water-cooled specimens from the water, place on an open drain rack, and allow to drain for 1 minute. Remove the remaining superficial water by quickly blotting the specimen with a dry absorbent cloth or paper. Weigh the specimen immediately following blotting.” ASTM C497.7.4.4-Reweighing Wet Specimens

“Weigh specimens weighing less than 1 kg to an accuracy of 0.10% of the specimen mass. Weigh specimens weighing more than 1 kg to an accuracy of 1 g.” ASTM C497.7.4.5- Scale Sensitivity

“ Take the increase in the mass of the boiled specimen over its dry mass as the absorption of the specimen, and express it as a percentage of the dry mass. Report the result as an average of the three 1 1/2” diameter cores as taken from 1 tile or manhole, The absorption, as calculated by the Test Method B procedure, shall be considered satisfactory when its value does not exceed a value that is 0.5% less than the absorption designated in the Test Method A procedure.” ASTM C 497.7.5.2 Calculation and Report

“ The single operator, standard deviation has been found to be 0.157%. Therefore, results of two properly conducted tests by the same operator on the same material should not differ by more than 0.44%” ASTM C497.7.7.1.2

1. (Wet Wt.- Dry Wt. = Difference) 2. (Difference/ Dry Wt.)x 100 = Absorption %

example: (1.) Wet= 399 g – Dry 388 g = 11 g. (2.) 11g/388 g = .0283 x100 = 2.38%

QC Inspector: _________________________________________ Date: _________________

Issue Date: 14 February, 2008 Volume 1: QUALITY CONTROL MANUAL



Rebound Hammer TestProduct or Job: ____________________________________

Casting Date:

Inspection Date:

Mon 1 2 3

Area Tested: 1

Design Strength: 2

Type of Aggregate: 3

Finish of Product: 4

Form Material: 5

Curing Conditions: 6

Exposure: 7

Air Temp: 8

Hammer Orientation: 9

Hammer I.D. : 10

Time of Test:

Average Reading:

Concrete Strength:

Comments for Discarded readings:

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________





Prepour Inspection Form- ManholesProduct or Job: ____________________________________ Date:__________________

Inspection Date:

Design Actual

Product Type Base Barrel Cone Flattop

Form Condition

Form Cleanliness

Form Joints

Release Agent / Retarder

Length (ft/in)

Width (ft/in)

Depth (ft/in)

Block out 1

Block out 2

Block out 3

Block out 4

WWR Reinforcing Size

WWR Reinforcing Style

Steel Area

Wire Diameter

Cage Diameter

Cage Length

Cage Overlap

Reinforcing Rustification

Cast-in Items

Lifting Devices

Comments:__________________________________________________________________

___________________________________________________________________________

* A minimum of 3 steel cages or 3% of each daily run, whichever is greater, chosen on a random basis by QC personnel, regardless of fabrication method, will be checked.





Post Pour Inspection Form-ManholesProduct or Job: ____________________________________ Date:___________________

Casting Date:

Inspection Date:


Product Type

Stripping Strength (psi)

Casting Finish

Coating Finish (if applicable)

Cast Length (ft/in)

Cast Width (ft/in)

Cast Depth (ft/in)

Cracks or Spalls

Honeycombing / Bugholes

Exposed reinforcement

Embedment Item Locations

Lifting Devices

Markings

Internal Diameter

Wall Thickness

Height of 2 Opposite Sides

Block out 1- Height/Size




Invert 1- Elevation/Size




Comments:__________________________________________________________________

____________________________________________________________________________




QC Inspector: _________________________________________ Date: __________________Air Meter Calibration Form

Date of Calibration: __________________

Location of Test: __________________

Meter #: __________________

____________________________________________________________________________

TEST SPECIFICATIONS

Test Requested By: _________________________________

Test Performed By: _________________________________

Test Witnessed By: _________________________________

Description of Test: __*see C-231-A1-Calibration of Apparatus____________

Product Tested To: ____ASTM C-231-A1 Calibration of Apparatus

Additional Comments: ______________________________________________

Initial Pressure As Found:______________________________________________

New Initial Pressure: __________________________________________________

Pass _________

Signature: _______________________________________________

*THIS CALIBRATION TO BE PERFORMED EVERY 3 MONTHS

Date of Next Calibration:: __________________



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