quality assurance quality control plan - …€¦ · f-1e1 earthwork - excavation 09/30/15 ......

Quality Assurance Quality Control Plan

Rev: 2 10/21/15 2 of 93

Dome Technology Quality Assurance Quality Control Plan

Table of Contents

List of Forms ................................................................................................................................................. 5

QAQC Quality Assurance / Quality Control Overview .................................................................................. 7

Purpose ......................................................................................................................................................... 7

Scope ............................................................................................................................................................ 7

Referenced Documents ................................................................................................................................ 7

Responsibilities ............................................................................................................................................. 7

Organizational Chart (Project Specific) ......................................................................................................... 8

QAQC 1.0: Civil/Foundation Work ................................................................................................................ 9

QAQC 1.1: Earth Work .................................................................................................................................. 9

QAQC 1.1.1: Excavation ............................................................................................................................... 9

QAQC 1.1.2: Backfill ..................................................................................................................................... 9

QAQC 1.2: Piles/Piers ................................................................................................................................. 10

QAQC 1.2.1: Precast Piles.......................................................................................................................... 10

QAQC 1.2.2: Aggregate Piles ..................................................................................................................... 11

QAQC 2.0: Materials & Equipment QC ....................................................................................................... 13

QAQC 2.1: Materials QC ............................................................................................................................. 13

QAQC 2.1.1: Concrete ................................................................................................................................ 13

QAQC 2.1.2: Steel Reinforcement .............................................................................................................. 14

QAQC 2.2: Equipment QC .......................................................................................................................... 15

QAQC 2.2.1: Formwork ............................................................................................................................... 15

QAQC 3.0: Dome Construction ................................................................................................................... 16

QAQC 3.1: Ringbeam ................................................................................................................................ 16

QAQC 3.1.1: Ringbeam - Lean Fill ............................................................................................................ 16

QAQC 3.1.2: Ringbeam - Rebar ................................................................................................................ 17

QAQC 3.1.3: Ringbeam - Forms ................................................................................................................. 17

QAQC 3.1.4: Ringbeam - Concrete ............................................................................................................ 17

QAQC 3.2: Airform ...................................................................................................................................... 19

QAQC 3.2.1: Dome Layout ......................................................................................................................... 19

QAQC 3.2.2: Airform Inflation - Air Form Fabric Quality ............................................................................. 20

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QAQC 3.2.3: Airform Inflation - Pressure .................................................................................................... 20

QAQC 3.3: Polyurethane Foam Process .................................................................................................... 22

QAQC 3.3.1: Polyurethane Foam Process - Primer Application ................................................................ 22

QAQC 3.3.2: Polyurethane Foam Process - Application ............................................................................ 24

QAQC 3.4: Pre-Mat Steel ............................................................................................................................ 26

QAQC 3.4.1: Pre-Mat Steel - Sticker Placement ........................................................................................ 26

QAQC 3.4.2: Pre-Mat Rebar Placement .................................................................................................... 27

QAQC 3.4.3: Depth Gauge Installation ...................................................................................................... 28

QAQC 3.4.4: Mounter Wire Placement ....................................................................................................... 29

QAQC 3.5: Dome Shell ............................................................................................................................... 30

QAQC 3.5.1: Shotcrete - Materials ............................................................................................................. 30

QAQC 3.5.2: Shotcrete Placement ............................................................................................................ 31

QAQC 3.5.3: Embedment of Pre-Mat Steel with Shotcrete ....................................................................... 32

QAQC 3.5.4: Shotcrete Surface Preparation .............................................................................................. 33

QAQC 3.5.5: Structural Rebar Placement .................................................................................................. 34

QAQC 3.5.6: Shotcrete Placement and Structural Steel Embedment ........................................................ 35

QAQC 3.5.7: Final Shell Completion ......................................................................................................... 36

QAQC 4.0: Tunnel Construction ................................................................................................................. 38

QAQC 4.1: Precast Sections....................................................................................................................... 38

QAQC 4.1.1: Precast Forms ....................................................................................................................... 38

QAQC 4.1.2: Precast Sections - Rebar & Embed Placement .................................................................... 39

QAQC 4.1.3: Precast Sections - Concrete Placement and Curing ............................................................. 40

QAQC 4.2: Invert ......................................................................................................................................... 41

QAQC 4.2.1: Invert Steel ............................................................................................................................ 41

QAQC 4.2.2: Invert Concrete ...................................................................................................................... 42

QAQC 4.3: Tunnel Placement & Finishing .................................................................................................. 43

QAQC 4.3.1: Placing Precast Sections ....................................................................................................... 43

QAQC 4.3.2: Closure Pour.......................................................................................................................... 44

QAQC 4.3.3: Hopper Concrete Walls ......................................................................................................... 45

QAQC 4.3.4: Waterproofing ........................................................................................................................ 46

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QAQC 5.0: Additional Dome Elements ...................................................................................................... 47

QAQC 5.1: Curbs & Piers .......................................................................................................................... 47

QAQC 5.1.1: Curbs & Piers - Rebar .......................................................................................................... 47

QAQC 5.1.2: Curbs & Piers - Forms .......................................................................................................... 48

QAQC 5.1.3: Curbs & Piers - Concrete ..................................................................................................... 49

QAQC 5.2: Entryway .................................................................................................................................. 50

QAQC 5.2.1: Entryway - Rebar .................................................................................................................. 50

QAQC 5.2.2: Entryway - Forms ................................................................................................................. 50

QAQC 5.2.3: Entryway - Concrete ............................................................................................................. 51

QAQC 5.3: Floor Construction ................................................................................................................... 52

QAQC 5.3.1: Floor Construction - Rebar ................................................................................................... 52

QAQC 5.3.2: Floor Construction - Concrete .............................................................................................. 53

QAQC 5.4: Post Tensioning ....................................................................................................................... 50

QAQC 5.4.1: PT Ducts ............................................................................................................................... 50

QAQC 5.4.2: PT Anchorage....................................................................................................................... 50

QAQC 6.0: Steel ......................................................................................................................................... 52

QAQC 6.1: Bulkhead Doors ....................................................................................................................... 57

QAQC 6.1.1: Door Fabrication/Installation ................................................................................................. 57

Sample Forms ............................................................................................................................................. 57

Revisions ..................................................................................................................................................... 92

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List of Forms

Number Title Rev. Date

F-0SR1 Shipment Receiving Log 09/30/15

F-1E1 Earthwork - Excavation 09/30/15

F-1E2 Earthwork - Backfill 09/30/15

F-1E3 Earthwork - Compaction 09/30/15

F-1P1 Precast Pile Placement 09/30/15

F-1P2 Aggregate Pier Placement 10/21/15

F-2C1 Concrete Pour Card 10/12/15

F-2C2 Concrete Pour Inspection 10/12/15

F-2CW1 Cold Weather Log 09/30/15

F-2F1 Forms Checklist 10/12/15

F-2R1 Rebar Checklist-Concrete 10/12/15

F-3AI1 Airform Inflation Checklist 09/30/15

F-3DG1 Depth Gauge Installation QC Log 10/12/15

F-3DP1 Dome Profile 10/14/15

F-3P1 Primer Placement 10/12/15

F-3P2 Primer Application Checklist 10/14/15

F-3P3 Primer Adhesion Testing Log 09/30/15

F-3PF1 Polyurethane Foam Placement 10/12/15

F-3PF2 Polyurethane Foam Application Checklist 10/12/15

F-3PF3 Polyurethane Foam Log & Inspection 09/30/15

F-3PF4 Polyurethane Foam Adhesion Testing Log 09/30/15

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F-3R1 Rebar Placement-Dome 10/12/15

F-3R2 Rebar Checklist-Dome 10/19/15

F-3S1 Shotcrete Placement 10/12/15

F-3S2 Shotcrete Pour Card 10/12/15

F-3ST1 Sticker Placement 10/15/15

F-3ST2 Sticker Pull Test 09/30/15

F-3T1 Temperature, Relative Humidity & Dew Point Log 09/30/15

F-4PC1 Precast Tunnel QAQC 10/12/15

F-4PC2 Precast Placement Checklist 10/12/15

F-4W1 Waterproofing Checklist 10/12/15

F-5PT1 PT Duct Checklist 10/19/15

F-5PT2 PT Anchorage Checklist 10/19/15

F-6D1 Door Installation Checklist 10/19/15

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QAQC Quality Assurance / Quality Control Overview

Purpose

Dome Technology recognizes the importance of documenting its methods for ensuring quality dome

construction. Therefore, Dome Technology provides the following Plan as an overview of its Quality

Assurance/Quality Control (QAQC) policy. This Plan is instituted throughout our company.

The intent of the QAQC Plan is to ensure the quality of Dome Technology’s construction not only meets all

contract specifications but also allows its employees to walk away from a completed job feeling proud of

their work and leaves the client with the assurance that the work performed is something of which they can

also be proud. Ensuring quality by following this Plan also enhances employee safety by reducing the risks

associated with construction errors.

Construction of each project is based on the contract documents approved for that project. The Project

Manager is responsible to establish, with the Project Construction Superintendent, site specific

requirements for critical construction points such as construction air pressure, air pressure variances, phase

adjustments, scope of work, construction schedules, etc. Modification of these requirements must be

cleared through the Project Manager and the Project Construction Superintendent.

Construction activities associated with this Project are to be completed under this quality program. Only

controlled products & materials are accepted when delivered to Dome Technology. All construction phases

are to be built with skilled craftsmen following approved drawings using proper tools, materials and

equipment. Inspections, reports and tests are to be completed as outlined in this Plan to document the

construction is proper and meets Project requirements. Periodically, the processes are refined based on

identified quality problems, test data, inspection results, audits, and Dome Technology’s general

satisfaction with the quality of the Project.

Scope

This Plan applies to all Work performed by Dome Technology on the Project.

Referenced Documents

• Contract Documents

• Applicable Standards, Codes & Specifications

• QAQC Forms

Responsibilities

Quality Assurance & Quality Control on construction sites remain the responsibility of the Project

Construction Superintendent with the oversight of a Project Manager. On an as needed basis, projects may

also have the assistance of an onsite QAQC Manager. When an onsite QAQC Manager is assigned, the

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QAQC Manager is responsible for verifying compliance with this QAQC Plan and signing the required

QAQC reports. Where a QAQC Manager is not assigned, the Project Construction Superintendent is

responsible for performing all QAQC responsibilities.

Organizational Chart (Project Specific)

Dome Technology

Shotcrete Foreman

Dome Technology

Project Manager

(not on site full time)

__________________

Dome Technology

Project Superintendent

(on site full time)

__________________

General Contractor/

Onsite Representative

Owner/Customer

or Client

Dome Technology

QAQC Manager

(If assigned)

Dome Technology

Rebar Foreman

Dome Technology

Dome Building Team

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QAQC 1.0: Civil/Foundation Work

QAQC 1.1: Earth Work

QAQC 1.1.1: Excavation

Potential Quality Concern: Removal of hazardous materials; Hidden works & utilities; Over

excavation

Quality Control Measure: Excavated soil is to either be placed in an onsite temporary

staging area or loaded directly into trucks and transported to the

disposal facility. Prior to commencing the excavation, the owner

is responsible for identifying and confirming the location of buried

utilities and indicating the presence of hazardous materials on

site.

Quality Assurance Procedure: Confirmation from the owner is to be obtained for locating the

staging area and/or disposal locations for all excavated soils. The

locations of all underground utilities are to be marked and areas

of conflict or hazard are to be addressed with owner. All

excavated material is to be logged; an excavation form is filled out

daily and is to include planning information, truck numbers, ticket

numbers, load sizes and disposal and/or staging locations.

Acceptable Tolerance: The excavation is to be kept to a minimum while meeting the

dimensions & specifications of the construction documents and

adhering to required safety protocols.

Related Documents: F-1E1 (Earthwork-Excavation)

QAQC 1.1.2: Backfill

Potential Quality Concern: Backfill that does not meet the engineering specifications; poor

compaction.

Quality Control Measure: All backfill is to meet the required material specifications. The fill

is placed in lifts as specified in the approved plans. Soil is to be

compacted to meet the criteria of the construction documents.

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Compaction is to be completed with equipment suitable for the

soil type.

Quality Assurance Procedure: Test data & relevant documentation is to be obtained to

demonstrate that the fill material meets the design criteria.

Density testing is to be administered per the project general

structural notes and is to be in accordance with ASTM D1556.

Records are kept for all fill brought on site and each compaction

test performed.

Acceptable Tolerance: Backfill is to be placed and compacted to meet the project

specifications as given in the construction documents and as

noted in the project general structural notes.

Related Documents: F-1E2 (Earthwork-Backfill)

F-1E3 (Earthwork-Compaction)

QAQC 1.2: Piles/Piers

QAQC 1.2.1: Precast Piles

Potential Quality Concern: Incorrect strength, size or position, improper hammer; damaged

piles; piles placed out of plumb.

Quality Control Measure: Piles are to be transported and lifted with an appropriate bridle or

sling attached at pick points. Piles are to be rejected if they are

damaged and removed & replaced. A proper hammer is to be

used and in good working condition. Pile heads must be properly

protected and the pile should be held in vertical and horizontal

alignment when driving. Correct pile placement must be verified

with the approved design documents. Starter holes are not to be

drilled unless otherwise specified in the contract documents. All

pile splices are to be inspected and meet the requirements of the

contract documents. Adjacent piles must be measured for heave

and meet the design criteria. All damaged piles, or piles that do

not meet the quality control or tolerance criteria must be replaced

or corrected in accordance with the design professional

recommendations.

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Quality Assurance Procedure: The placement of all piles is to be documented. Piles are to be

given an identification # and a daily checklist (F-1P1) is to be

completed to verify the quality control procedures are followed.

The locations of all underground utilities are to be marked and

areas of conflict are to be addressed with owner. Pile design

strength and dimensions along with the transport method and

time of placement are to be included in the placement checklist.

Location and plumb for each pile placed are to be verified and

approved.

Acceptable Tolerance: Piles less than 60’-0” long are not to be splice unless noted

otherwise. Piles are to be cut to +/-1” of the design elevation and

cut level without damage. Adjacent Piles must be measured for

heave and re-driven if heaving is > 0.5” unless otherwise specified

in the contract documents. Driving stresses are not to exceed

85% of the pile design compressive strength.

Related Documents: F-1P1 (Precast Pile Placement)

QAQC 1.2.2: Aggregate Piers

Potential Quality Concern: Incorrect strength, size or position, damaged piers or cave-ins;

improperly protected piers

Quality Control Measure: The owner should be contacted to identify the locations of any

obstructions and utilities that is to be removed or relocated as

required before drilling the aggregate piers. A modulus test is to

be performed and the adequacy of the bearing strength of the

piers confirmed on a sample pier before placing the piers

generally. The location of each pile is to be surveyed and marked

and the center of each pier should meet the placement tolerance

defined in this plan. Drill depths are to be measured and must

meet the design specifications. Lift thicknesses are not to exceed

24” and the tamping of the aggregate should be done in using the

same method as the successful test pier. Relative density of the

aggregate piers is to be measured periodically and meet the

design specifications. Piers are to be rejected if they are

damaged, if soil caves into the drilled hole or if the piers are

otherwise not meeting the quality control criteria or tolerances

while being placed. The aggregate is to be removed & replaced

in piers that are rejected. Completed piers are to be properly

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protected, a drainage plan is to be put in place to prevent water

from ponding over the piers.

Quality Assurance Procedure: Verification of the modulus test pier must be recorded. The

placement of all piers is to be documented. Aggregate Piers

placed are to be recorded and a daily checklist (F-1P2) is to be

completed to verify the quality control inspection has been

completed and the correct procedures are followed. The

locations of all underground utilities are to be marked and areas

of conflict are to be addressed with owner. Pier design bearing

strengths, depths and diameters along with the time of placement

are to be included in the placement checklist.

Acceptable Tolerance: Aggregate lifts are not to exceed 24” unless otherwise specified

in the contract documents. Drill depths are to be within 3” (75mm)

or deeper than the specified design depths. The center of the

drilled piles must be placed within 4” of the designated position.

Unless otherwise specified, the relative density of the aggregate

lifts must test to be 15 blows minimum per 1.75” of penetration

using a Dynamic Cone Penetrometer in accordance with the

procedures of ASTM STP-399.

Related Documents: F-1P2 (Aggregate Pier Placement)

Rev: 2 10/21/15 13 of 93


QAQC 2.0: Materials & Equipment QC

QAQC 2.1: Materials QC

QAQC 2.1.1: Concrete

Potential Quality Concern: Mix, temperature, slump, air content or w/c ratio that do not meet

the design specifications; Old concrete; Insufficient compressive

strength

Quality Control Measure: The Construction Superintendent or QAQC Manager reviews

the batch information for each load. Concrete that does not meet

the design criteria or is not applied within the specified time

frame is to be turned away. If a truck is rejected, the reason for

refusing the truck is to be documented. Concrete is to be tested

using standard cylinders or as specified in the contract

documents. A test sample is to be obtained the greater of once

a day or every 150 yards (110 m3) per ACI 301 section 1.6.3.2d.

The compressive strength is accepted based on the criteria of

ACI 301 section 1.6.6.1. The Engineer of Record is to be

notified of the placement of any concrete that does not meet the

compressive strength requirements. Recommendations

provided by the Engineer are to be followed and all required

corrective actions must be taken.

Quality Assurance Procedure: Temperature, slump and air content are to be verified and

documented for each truck tested. Water may be added at the

site; however, the water to cement ratio and slump must fall

within the design parameters. A pour card is to be filled out each

day prior to placing concrete and an inspection report is to be

filled out to document the pour. Test reports are to be reviewed

by the Construction Superintendent or the QAQC Manager who

verifies that the design strength is reached. Concrete test data

is to be recorded and saved. Cylinder break inconsistencies are

to be examined by the Project Manager and corroborated by the

testing agency.

Acceptable Tolerance: Concrete must meet the mix design requirements for slump,

temperature & air content. Concrete must be poured within 90

Rev: 2 10/21/15 14 of 93


minutes of leaving the batch plant unless specified otherwise in

the contract documents. If the truck time extends beyond 90

minutes the slump & temperature may be retested per ACI 301

section 4.3.2.2 to ensure the concrete meets the design

requirements; otherwise, the truck is to be sent away. Concrete

is to meet the design strength in 28 days.

Related Documents: F-2C1 (Concrete Pour Card)

F-2C2 (Concrete Pour Inspection)

F-2CW1 (Cold Weather Log)

Concrete Testing Log

Concrete Batch Tickets

QAQC 2.1.2: Steel Reinforcement

Potential Quality Concern: Proper steel amounts, sizes, types & grades; Delivery of

damaged reinforcement

Quality Control Measure: The project Construction Superintendent or QAQC Manager

receive the steel reinforcement and embeds on site

accompanied by a mill certification. The mill cert is to be

reviewed to ensure the steel meets the specifications for quality,

type, size and grade. All steel reinforcement is to be deformed

and plain carbon steel bar in accordance with ASTM A615

unless otherwise specified in the contract documents. The steel

is to be physically assessed and inspected for rust, flaking,

excess bend damage or deleterious materials such as dirt or

grease. Steel reinforcement delivered to the site that is

damaged or does not meet the design specifications and is not

of high quality is to be rejected.

Quality Assurance Procedure: The mill certifications and delivery tickets for the reinforcing

steel are saved on site. A report detailing the size, condition

and quantity is to be completed. Details for what caused the

materials to be rejected are to be recorded for any steel

reinforcement which is deemed to be unacceptable. A rebar

checklist is to be completed each day rebar is placed and is to

verify that the bar has been inspected and meets the criteria of

this QAQC Plan.

Rev: 2 10/21/15 15 of 93


Acceptable Tolerance: Steel reinforcement must meet the design specifications. The

Project Superintendent or QAQC Manager reviews the mill

certificates and rejects any bar that does not meet the approved

specifications.

Related Documents: F-2R1 (Rebar Checklist-Concrete)

QAQC 2.2: Equipment QC

QAQC 2.2.1: Formwork

Potential Quality Concern: Incorrectly placed or out of tolerance; damaged or missing

bracing; bonding to concrete

Quality Control Measure: Forms are to be fully assembled. They are measured for

correct tolerances and inspected for any structural damage. A

form-release agent that does not bond or effect concrete

surfaces is to be used. Bracing and fasteners are to be

inspected by the Construction Superintendent or QAQC

Manager and verified to meet the loading criteria of ACI 347

section 2.2.

Quality Assurance Procedure: The project Construction Superintendent or QAQC manager

verifies the dimensions of the fully assembled forms prior to

concrete being delivered. A report is to be completed each

day formwork is placed and is to verify that the QAQC Plan is

being followed and document the type of forms and form-

release agent being used.

Acceptable Tolerance:

Related Documents:

Formwork is to meet the tolerance requirements for finished concrete of ACI 117 unless otherwise specified in the contract documents.

F-2F1 (Forms Checklist)

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QAQC 3.0: Dome Construction

QAQC 3.1: Ringbeam

QAQC 3.1.1: Ringbeam - Lean Fill

Potential Quality Concern: Poor concrete quality, Improper curing techniques,

Unacceptable subgrade preparation; Cold joints

Quality Control Measure: Before placing lean fill, the subgrade is verified to have met the

design specifications. The lean fill concrete is placed by or under

the direction of a qualified concrete foreman. Prior to pouring

concrete, excavations are to be cleaned from all loose material

and standing water is to be removed. Although lean fill is

generally specified with a low compressive strength, the design

strength is to be verified with the contract documents. The

acceptance of the concrete loads at the job site is to follow the

requirements of section 2.1.1 of this Plan. The rate of concrete

delivered to the site must be adequate to prevent cold joints

from forming; all construction joints must be as detailed or

approved by the Engineer of Record. Curing materials are to be

staged on hand. Cold or hot weather plans for concrete

placement must be followed as required.

Quality Assurance Procedure: Concrete quality is to be assured per the requirements of

section 2.1.1 of this Plan. The Project Construction

Superintendent or QAQC Manager inspects and documents

lean fill placement. A concrete pour card is to be filled out each

day prior to pouring concrete. An inspection report is filled out

to document the pour and ensure the quality control measures

are being implemented.

Acceptable Tolerance: Concrete quality tolerances are to be in accordance with section

2.1.1 of this Plan. Acceptable curing is to meet the criteria given

in ACI 308.

Rev: 2 10/21/15 17 of 93



QAQC 3.1.2: Ringbeam - Rebar

Potential Quality Concern: Incorrect size or quantity of rebar; Incorrect rebar placement;

missing dowels, anchors or ties

Quality Control Measure: The placement of the ringbeam steel reinforcement is

designated by the structural engineer and is to be placed as

specified on the approved construction drawings. The

placement of the steel in the ringbeam is done under the

direction of the project Construction Superintendent. Proper

placement of dowels, anchors and ties are verified and

documented as the steel is placed.

Quality Assurance Procedure: The steel is inspected and documented in accordance with the

requirements of section 2.1.2 of this Plan. A quality control

checklist is completed for the rebar placed within the ringbeam

formwork. This QAQC report is to note the required rebar

spacing, splice lengths and coverage. The form also includes

a record of the dowels and anchors placed.

Acceptable Tolerance: Rebar quality tolerances are to be in accordance with section

2.1.2 of this Plan. Rebar placement within the ringbeam is to

meet the coverage & spacing tolerances specified in ACI 117

section 2.2 unless otherwise specified in the contract

documents.


QAQC 3.1.3: Ringbeam - Forms

Potential Quality Concern: Forms located incorrectly, Damaged or warped materials;

inadequate or missing bracing

Quality Control Measure: The form quality control measures of section 2.2.1 of this Plan

are to be followed. The coordinates for the center of the dome is

to be clearly marked. The forms are assembled and then

Rev: 2 10/21/15 18 of 93


measured from dome center to verify correct dimensions &

placement. Forms are to be inspected for damage and must be

clean from deleterious materials. Bracing, clamps & fasteners

are to be inspected by the Construction Superintendent or

QAQC Manager. ¾” chamfer strip is to be used on exposed

corners unless otherwise specified in the contract documents.


inspects the fully assembled formwork prior to delivery of

concrete. A checklist is to be completed to document that the

quality control measures for the erection and securing of the

ringbeam forms are being followed.

Acceptable Tolerance: Formwork tolerances are to be in accordance with section 2.2.1

of this Plan. The drop lip of the Ringbeam may vary by +/- ½”

(13 mm) from the radius of the dome. The top of the Ringbeam

may vary +/- ½” (13 mm) from the design elevation.

Related Documents: F-2F1 (Forms Checklist)

QAQC 3.1.4: Ringbeam - Concrete

Potential Quality Concern: Poor concrete quality; Unacceptable subgrade preparation;

improper curing techniques or consolidation, Cold joints;

Inadequate finishing

Quality Control Measure: The acceptance of the concrete loads at the job site is to follow

the requirements of section 2.1.1 of this Plan. The concrete is

to be placed under the direction of an experienced foreman.

Consolidation equipment is to be in good working condition and

is to be staged on hand prior to pouring concrete. The concrete

is to be vibrated to ensure proper consolidation around

reinforcement and embeds and prevent honeycombing in

corners or against forms. The rate of concrete delivered to the

site must be adequate to prevent cold joints from forming; all

construction joints must be as detailed or approved by the

Engineer of Record. Curing materials are also to be staged.

Cold or hot weather plans for concrete placement must be

followed as required.

Rev: 2 10/21/15 19 of 93


Quality Assurance Procedure: Concrete quality is to be assured following the requirements of

section 2.1.1 of this Plan. The Project Construction

Superintendent or QAQC Manager inspects and documents the

ringbeam concrete placement. A concrete pour card is to be

filled out each day prior to pouring concrete. An inspection

report is filled out to document the pour and ensure the quality

control measures are being implemented. Concrete placement

is also recorded and the location of each load is documented.


2.1.1 of this Plan. Acceptable curing is to meet the criteria given

in ACI 308. Acceptable finish is as required by the contract

documents.



QAQC 3.2: Airform

QAQC 3.2.1: Dome Layout

Dome Technology utilizes a specific dome layout comprised of zones and quadrants which are used in our

QAQC documentation. This layout helps to organize our communication when reporting on placement of

materials during the construction of each dome.

Each dome plan is separated into four quadrants: A, B, C, & D. QUAD A is the first quadrant to the left of

the air lock entry on each dome. The other quadrants are designated clockwise from the air lock; B, C, &

D respectively.

QUAD A

QUAD B QUAD C

QUAD D

Rev: 2 10/21/15 20 of 93


The vertical profile of the dome is divided into zones. The distance of each zone is approximately 20’-0” (6

meters). As the dome shell is constructed, the zone heights are based on the vertical lengths of the steel

reinforcement placed along the arc. The zone designation is not a vertical elevation notation; the zone

heights vary depending on the lap splices that are required for the vertical bars. Please refer to the figures

above for clarification on the dome layout.

QAQC 3.2.2: Airform Inflation – Airform Fabric Quality

Potential Quality Concern: Unacceptable air form fabric quality & safety margin; Ensure

proper airform fabric specifications for each project

Quality Control Measure: The airform manufacturer evaluates the anticipated dome

airform stresses and submits a request to order the proper

airform fabric based on the contract document specifications.

Quality Assurance Procedure: Dome Technology’s Project Manager reviews the fabric

request. Upon approval, the Project Manager orders the correct

airform for the Project.

Acceptable Tolerance: Dome Technology does not accept undersized, light weight or

poorly constructed airforms. Proper airforms are to be made of

high quality fabrics which are verified by testing to meet the

project specifications.

Related Documents: Air Form Engineering Report (provided by others)

QAQC 3.2.3: Airform Inflation - Pressure

Potential Quality Concern: Proper shape and volume of dome

Quality Control Measure: Airform construction pressure is critical for each dome. Dome

Technology determines the proper air pressure for each dome

and document the approved working pressure.

In determining airform pressures, Dome Technology takes into

account the dome size, the radius of curvature, the expected

temperatures during construction, the strength of the fabric, and

the thicknesses and locations of shotcrete placement. Dome

Technology balances the air pressure tension with the fabric

Rev: 2 10/21/15 21 of 93


strength. Air support of materials and the air pressure are also

balanced to keep both within an acceptable safety margin.

Dome Technology installs a continuous pressure reading device

at the air lock location on the dome. Each dome built has a

construction pressure level specified. It is the Project

Construction Superintendent’s responsibility to calibrate the

pressure gauge and set the pressure of the dome at the

appropriate construction pressure. The Project Superintendent

is responsible for daily maintenance of the inflators, motors,

engines, fans, pressure control box, etc. The pressure reading

is taken and is documented daily during each work period or

shift.

Quality Assurance Procedure: The dome air pressure is reported by the Construction

Superintendent or QAQC Manager each day. The dome air

pressure is tracked by the Project Manager from the daily

project reports and evaluated along with the temperature and

relative humidity for each job. This information is tabulated at

Dome Technology’s corporate office and is available for review

by management.

Acceptable Tolerance: Pressure readings are to be documented daily. The construction

air pressure must be maintained within a 1/4" (6 mm) tolerance

to specified pressures.

A monolithic dome air form cannot be fabricated to duplicate

exact design, shape, or size specifications. Some of the air form

fabrication variables that control actual shape and size are:

fabric stretch, inconsistencies in raw material characteristics,

slight differences in fabrication, temperature variations after

inflation, and slight distortions from the weight of the initial thin

layers of sprayed shotcrete, etc.

The height of the fabric form is to be within 3% of the total design

height measured at the center of the building, per ACI 334.3R-

05. This same percentage difference in the radius of curvature,

perpendicular to the design profile, may occur anywhere in the

dome.

When the inflated airform does not meet the 3% tolerance, the

shape must be reviewed by the structural engineer for possible

design changes. The project design engineers and architects

must allow for these tolerances by including flexibility in the

Rev: 2 10/21/15 22 of 93


design of the interior and exterior connections. These space

allowances must be made so the airform tolerances do not

become critical construction problems. Final connection designs

required for attachment to the dome, interior or exterior, are to

utilize actual measurement from the inflated dome after the pre-

mat steel is embedded. This stage of the dome construction

process provides a relatively stable dome with dimensions that

remain fairly consistent through final dome completion.

When specific or tight tolerances are required in the size and

shape of the dome, they must be specified by the customer and

agreed upon by Dome Technology prior to construction. The

tolerances are to be verified and approved by the customer

when the airform is inflated.

Related Documents: F-3DP1 (Dome Profile)

3.3: Polyurethane Foam Process

QAQC 3.3.1: Polyurethane Foam Process - Primer Application

Quality Control Measure: Proper adhesion, thickness, quality and finish

Potential Quality Concern:

1. Primer Adhesion:

Ensure the air form is clean and dry prior to spraying primer.

Ensure the paint pump is in good working condition. Ensure

proper curing conditions exist; note that as the temperature

cools, the primer may take longer to cure.

2. Primer Thickness: The primer should be sprayed on the air form at the rates

specified by the manufacturer.

3. Primer Quality: The primer must be stored properly and mixed thoroughly to

ensure the chemicals are the correct ratio throughout the barrel.

Primer must be applied under the direction of an experienced

technician.

4. Primer Finish: The primer surface should be uniform with minimal runs.

Quality Assurance Procedure:

Rev: 2 10/21/15 23 of 93


1. Primer Adhesion: The temperature, humidity and dew point are to be recorded

daily on form F-3T1. The airform is to be cleaned and inspected

to ensure it is free from dirt and is dry prior to applying primer.

After the primer has been applied and has cured, the adhesion

is to be tested prior to applying foam throughout the dome.

Every 10,000 ft2 (929 m2), four locations minimum, a ¼” (6 mm)

thick layer of foam is sprayed over a minimum area of 2’-0”

square (0.2 square meters). The adhesion is then tested and

verified following Dome Technology’s current means and

methods for primer adhesion testing. The results of the primer

adhesion test are to be recorded on form F-3P3.

2. Primer Thickness: A dye is added to the primer to improve the visibility which

allows the technicians to better observe the cured primer on the

air form. Total primer application rates may be verified by taking

the overall surface area of the air form and dividing by the

volume of primer used. Spot checks are to be performed by an

experienced technician to verify that the primer thickness meets

the design specifications. Daily logs are to be kept to record the

location and amount of primer sprayed and the design

application rates and thicknesses.

3. Primer Quality: The primer is mixed for at least ten minutes prior to use. Primer

is to be remixed if allowed to settle, such as overnight. The

primer is stored above 45° Fahrenheit (7.2° Celsius) per the

manufacturer’s recommendations. The primer application is

inspected by the Project Superintendent, QAQC Manager or

Foam Supervisor and a daily quality checklist is to be

completed.

4. Primer Finish: The primer is to be inspected after it is applied. Cured primer

should be tacky to the touch and running should be minimized.


1. Primer Adhesion:

The minimum adhesive strength of the primer must be 2.8 psi

(0.020 MPa). The results of site testing must confirm that the

adhesive strength meets the design requirements. Additional

primer is to be applied and retested in areas that do not meet

this minimum criteria.

Rev: 2 10/21/15 24 of 93


2. Primer Thickness:

At least 90% of spot checks must meet the minimum plan

thickness. Application rates must be within 10% of the design

rates.

3. Primer Quality: Dome Technology does not accept placement of poor quality

primer on the dome. If a section of primer does not meet the

design specifications, it is to be removed and reapplied.

4. Primer Finish: Primer is to be covered with polyurethane foam; therefore, the

surface texture is not an issue if other primer criteria are met.

Related Documents: F-3P1 (Primer Placement)

F-3P2 (Primer Application Checklist)

F-3P3 (Primer Adhesion)

F-3T1 (Temp, Relative Humidity & Dew Point Log)

QAQC 3.3.2: Polyurethane Foam Process - Application

Quality Control Measure: Proper adhesion, thickness, quality and texture


1. Foam Adhesion:

The air form must be clean, dry and the primer properly cured

prior to spraying foam. Ensure the foam gun is in good working

condition. Temperatures and dew points inside the dome must

meet the quality control specifications.

2. Foam Thickness: The foam must be sprayed in uniform layers at specified

thicknesses. Uneven or irregular application of foam is to be

avoided.

3. Foam Quality: The foam equipment and foam machines must be in good working

condition to ensure the foam chemicals are delivered to the spray

tip at the correct ratio, pressure and temperature. Foam must be

applied under the direction of qualified technicians.

4. Foam Finish: Foam overspray must be cleaned between each layer applied.

Foam texture is to be inspected for proper adhesion between

layers; a smooth to orange peel texture is verified.

Rev: 2 10/21/15 25 of 93



1. Foam Adhesion:

Temperature, Relative Humidity and Dew Points are to be

recorded daily on form F-3T1. The first layer of foam is to be quite

thin, especially if the skin temperature is low. After the first layer

is applied it should be allowed to set, cure and bond to the

skin/primer before additional layers are sprayed. This takes

longer in cold weather. Once all the foam has been applied and

has cured, the foam adhesion is to be tested prior to hanging

premat throughout the dome. Every 10,000 ft2 (929 m2), four

locations minimum, a sticker is to be cored and tension tested to

verify the adhesion between the foam layers. Dome Technology’s

current means and methods for foam adhesion testing is to be

used. The results of the foam adhesion test results are to be

recorded on form F-3PF4.

2. Foam Thickness: Foam placement and thicknesses are recorded daily. Foam

thickness is to be measured with a depth probe. The probe is

pushed into the foam on the air form and the depth is measured.

Care must be taken not to penetrate the air form when using the

probe.

3. Foam Quality: Foam barrels are stored at the manufacturers recommended

temperatures and are mixed prior to use. A sample of foam is to

be sprayed each day and inspected for quality in structure and

mix ratio prior to applying foam on the substrate. A daily log is

kept and foam chemical ratios, amounts, pressures and

temperatures are recorded. The foam application is inspected by

the project Construction Superintendent, QAQC Manager or

Foam Supervisor and a daily application checklist is completed.

Any foam placed that shows the characteristics of an off-ratio mix

is to be examined in detail. Wherever off-ratio foam is determined

to have been applied, it is removed and replaced.

4. Foam Finish: The Construction Superintendent or QAQC Manager ensures that

foam overspray is cleaned prior to applying an additional layer.

When properly prepared, the surface texture of the foam is

beneficial to adhesion when applying a subsequent layer of foam

or shotcrete.


Rev: 2 10/21/15 26 of 93


1. Foam Adhesion: Foam is only be applied when the Dew Point is measured to be

5° F (2.8° C) above the ambient temperature recorded inside of

the dome. The minimum adhesive strength of the foam core must

be 2.8 psi (0.020 MPa). The results of site testing must confirm

that the adhesive strength meets this design requirement. Foam

is to be repaired and retested in areas that do not meet this

minimum criteria.

2. Foam Thickness: The minimum total thickness of foam on an air form is 1¼” (32

mm). The tolerance for foam thickness is ±½" (13 mm). There is

to be at least ¾” (19 mm) in place prior to placing the stickers.

Sufficient foam must cover the stickers to lock them in place;

approximately ½” (13 mm). When thicker insulation is specified,

the additional foam should be applied prior to placing the stickers.

3. Foam Quality: Dome Technology does not accept placement of off-ratio foam on

the dome; off-ratio foam is to be removed and replaced.

4. Foam finish: All foam is to be covered with shotcrete; therefore, the surface

texture is not an issue if all foam QAQC criteria are met. The final

foam surface should be smooth enough both horizontally and

vertically to ensure the pre-mat rebar can be placed next to the

surface of the foam without being held away by undulating foam.

Related documents: F-3PF1 (Polyurethane Foam Placement)

F-3PF2 (Polyurethane Foam Application Checklist)

F-3PF3 (Poly Foam Log & Inspection)

F-3PF4 (Polyurethane Foam Adhesion)

F-3T1 (Temp, Relative Humidity & Dew Point Log)

QAQC 3.4: Pre-Mat Steel

QAQC 3.4.1: Pre-Mat Steel - Sticker Placement

Potential quality concern:

Incorrect sticker spacing; Improper leveling & spacing;

Inadequate tensile strength

Rev: 2 10/21/15 27 of 93


Quality Control Measure: The specifications for sticker placement are generated by the

Project Manager and Construction Superintendent. Sticker pull

testing is to be performed and documented to verify that the

design strength is achieved prior to hanging premat steel. When

performing the test, a sticker should be pulled to 50 lb (23 kg)

and held for 2 seconds. The sticker test should be performed

every 900 ft2 (81 m2) or every 30’-0” (9 meters) in each direction.

Quality Assurance Procedure: Sticker placement is recorded daily on form F-ST1. The sticker

placement is to be inspected by the Project Construction

Superintendent or the QAQC Manager. If a sticker fails the pull

test, an adjacent sticker is to be pulled and must pass or the

area is deemed deficient. Areas that are found to be deficient

in tensile strength are marked and additional foam is to be

applied. The area is retested until the strength requirements

have been satisfied.

Acceptable tolerance: Although it is essential that the correct number of sticker rows

be placed and that rows are placed level horizontally, the

vertical spacing of the rows can vary up to 20%. The horizontal

spacing of sticker columns may vary up to 12" (30 cm). 100%

of the areas tested must meet the specified tensile strength.

Related Documents: F-3ST1 (Sticker Placement Summary)

F-3ST2 (Sticker Pull Test)

QAQC 3.4.2: Pre-Mat Rebar Placement

Potential Quality Concern: Proper placement; Proper laps and splice ties; Proper

attachment to stickers; Sufficient intersection ties

Quality Control Measure: Rebar is to be inspected and documented following the

procedures of section 1.2.2 of this Plan. Pre-mat rebar

placement is to be specified by the Project Manager. Pre-mat

rebar is tied to the stickers horizontally. Vertical pre-mat bars

are to be tied to the horizontal bars at 100% of the intersections.

Lap lengths are to be in accordance with the minimums

specified in the contract documents. Lapping bars are to be

placed in contact to one another and wire tied at each end of

each splice.

Rev: 2 10/21/15 28 of 93


Quality Assurance Procedure: The pre-mat bar placement is to be inspected by the Project

Construction Superintendent or QAQC Manager who verifies

proper laps, splices, staggering, ties and placement. The daily

placement of bars is documented & a rebar checklist is

completed to verify that the pre-mat rebar has been placed

according to the quality control measures specified in this Plan.

Acceptable tolerance: Pre-mat rebar spacing, laps, splices and ties are to be within

20% of the specified dimensions.

Related Documents: F-3R1 (Rebar Placement-Dome)

F-3R2 (Rebar Checklist-Dome)

QAQC 3.4.3: Depth Gauge Installation

Potential Quality Concern: Proper gauge lengths & placement

Quality Control Measure: Depth gauges are used to verify final shotcrete thicknesses

throughout the dome. Depth gauges are also used to monitor

intermediate thicknesses for proper rebar placement &

shotcrete embedment. The design thickness of the concrete

varies throughout the dome shell in accordance with the

contract documents. Varying lengths of depth gauges are made

to correspond with these thicknesses. Depth gauges are placed

at the location of transitions in dome shell thickness as they are

specified in the contract documents. They are also placed at

equivalent distances throughout the dome. Vertical spacing of

depth gauges is not to exceed 6'-0” (1.8 meters); horizontal

spacing is not to exceed 12'-0” (3.6 meters).

Quality Assurance Procedure: The Construction Superintendent or QA Manager inspects and

verifies that gauges of the proper length are in place at the

correct locations prior to spraying the pre-mat shotcrete. The

placement of each gauge is to be documented in a depth gauge

QC log. Depth gauges are to be inspected as rebar and

shotcrete are placed to ensure proper placement and

embedment throughout the construction process.

Acceptable tolerance: When change in thickness is denoted, the depth gauge should

be placed within +6" (15 cm) of the change location; otherwise

Rev: 2 10/21/15 29 of 93


the spacing of depth gauges can vary up to 2-3 feet (60-90 cm).

Gauge depths may vary by ¼” (6 mm), gauges that are not

within this tolerance must be replaced.

Related Documents: F-3DG1 (Depth Gauge Installation QC Log)

F-3R2 (Rebar Placement-Dome)

F-3S1 (Shotcrete Placement)

QAQC 3.4.4: Mounter Wire Placement

Potential Quality Concern: Proper placement; Verification of strength to support structural

mats of rebar.

Quality Control Measure: Mounter wires are attached to the pre-mat rebar as well as

intermediate mats of steel to support consecutive mats. The

size and placement of these wires is to be determined by Project

Manager and the Project Construction Superintendent and are

placed as required to support the consecutive mats. The wires

must be in the correct position and be of adequate size and

quantity to support the required mounting bars, steel mats, and

additional steel specified around entry ways and openings.

Quality Assurance Procedure: Upon completion of the placement of the mat of steel, and prior

to applying additional shotcrete, the project Construction

Superintendent or QAQC Manager inspects the placement of

the mounting wires for proper installation. A daily rebar checklist

is to be completed and is to include a verification that the

mounter bars have been properly placed and the quality control

measures of this Plan are followed.

Acceptable tolerance: Quantity and placement is to be within 90% of the specified

spacing.

Related Documents: F-3R2 (Rebar Checklist-Dome)

Project Manager Summary Report: Mounter Wire

Rev: 2 10/21/15 30 of 93


QAQC 3.5: Dome Shell

QAQC 3.5.1: Shotcrete - Materials

Potential Quality Concern: Poor shotcrete quality; insufficient strength; pumping problems

Quality Control Measure:

The Construction Superintendent or QAQC Manager reviews

the batch information and follows the criteria for accepting or

rejecting the load per section 2.1.1 of this Plan. A local supplier

is to provide quality shotcrete to the project by using a shotcrete

mix design that complies with Dome Technology’s standard

design, modified as agreed upon to meet project specifications.

The basic mix design includes approximately 900 pounds of

cement powder per cubic yard (534 kg/m3). 100 pounds (45 kg)

of fly ash may be substituted for an equivalent weight of cement;

fly ash used must be in accordance with ASTM C 168. The

aggregate used in the approved shotcrete is to be

predominantly 1/4" (6mm) minus concrete sand. A range of

water-to-cement ratio is specified to provide a mix typically with

a 4-6 inch (10-15cm) slump. The slump may be adjusted in the

field to ensure the shotcrete is easily pumped; however, care is

to be taken to confirm the slump and water-to-cement ratio fall

within the range given in the design specifications.

Concrete cylinders are to be prepared from a random batch for

each 50 cubic yards (40 cubic meters) delivered, but not less

than one set each production day. The compressive strength

is to be tested by an independent testing agency. At minimum,

7 & 28 day tests should be performed and a 56 day hold cylinder

should be cast. The Engineer of Record is to be notified of the

placement of any shotcrete that does not meet the compressive

strength requirements. Recommendations provided by the

engineer are to be followed and all required corrective actions

must be taken.


The criteria for accepting a load of shotcrete follows the quality

assurance procedure of section 2.1.1 of this Plan. A preliminary

batch of the shotcrete mix should be tested for strength and sent

through the pump to test the workability.

Rev: 2 10/21/15 31 of 93


Independent lab results for the cylinder breaks are to be

provided to the project Construction Superintendent or Project

Manager for review and to verify that the design strength is met.

Shotcrete test data is to be recorded and saved. At the

beginning of the job, extra cylinders to be tested for 3 day

strength may be made at the request of the Project Manager.

The 3-day breaks are reviewed against potential break curves

to confirm strength and shotcrete quality; thereby allowing early

adjustments to be made to the mix as necessary.

Acceptable Tolerance: Shotcrete must be workable and easy to pump and is to achieve

the design strength at 28 days. The compressive strength must

be verified by an independent lab. Acceptable shotcrete is to

follow the tolerances of section 2.1.1 of this Plan.

Related Documents: Concrete Testing Log

Concrete Batch Tickets

QAQC 3.5.2: Shotcrete Placement

Potential Quality Concern: Safe load limits of shotcrete placement during all construction

phases; maintain proper thickness & weight distribution

Quality Control Measure: The Project Manager and project Construction Superintendent

determine the order, the timing, and rate of thickness with which

the shotcrete is placed. A daily log is kept identifying the

shotcrete placement by specific zones and quadrants as well as

the thickness and time of application.

Quality Assurance Procedure: The project Construction Superintendent directs how the

shotcrete is applied to the zones and directs the crew day to day

as to where shotcrete is to be applied. The amount of shotcrete

applied and the zones sprayed is to be reported and verified.

The nozzlemen confirm the thickness of the shotcrete each day.

The Construction Superintendent or QAQC manager verifies

that the shotcrete is applied evenly to maintain a proper weight

distribution.

Rev: 2 10/21/15 32 of 93


Acceptable Tolerance: Although, shotcrete structures are not required to meet the

tolerance specifications of cast-in-place structures, the

thickness tolerance for Dome Technology’s thin shelled dome

construction is to meet or exceed the specifications of ACI 334.3

section 4.18. Unless otherwise specified in the contract

documents, the tolerance of dome walls 12” (30 cm) and thinner

are to be the lesser of +25% to -10% and 2" (5 cm) of the

specified thickness. Walls thicker than 12” (30 cm) are to

maintain a tolerance of +15% to -5%.

Related Documents: F-3S1 (Shotcrete Placement)

QAQC 3.5.3: Embedment of Pre-Mat Steel with Shotcrete


Proper embedment of rebar; Air pressure control; Proper weight

distribution

Quality Control Measure: The embedment of pre-mat steel is a critical phase in dome

construction, the locations, thicknesses and sequence of

shotcrete placement are directed by the Project Manager and

Construction Superintendent. Although the pre-mat rebar is not

considered structural steel, it gives the structure an initial

rigidity. Great care must be taken to properly embed the bars

using the placement techniques specified in ACI 506.2. Pre-mat

rebar is to be embedded with thin layers of shotcrete that are

inspected daily.

Quality Assurance Procedure: Shotcrete is to be placed by or under the direct supervision of a

Dome Technology certified nozzleman. The shotcrete

nozzlemen controls the quality of the shotcrete application. The

nozzlemen are trained to regulate embedment thicknesses and

adjust shotcrete techniques as necessary to best meet the

requirements of each dome area. The procedures for applying

shotcrete given in ACI 506 “Guide to Shotcrete” are to be

followed.

The project Construction Superintendent or QAQC Manager

inspects the pre-mat embedment with the shotcrete foreman

throughout the dome. The shotcrete is to be inspected for

Rev: 2 10/21/15 33 of 93


noticeable voids as the pre-mat is embedded. Shotcrete

determined to contain voids is to be removed and replaced prior

to the next application in the same area. Thickness of

embedment is determined by the pre-mat bar thickness minus

the clear distance for the structural steel specified in the design

drawings. Depth gauges are to be checked and recorded daily

to verify the shotcrete thickness. A pour card checklist is to be

completed each day by the Construction Superintendent or

QAQC manager who verifies that the shotcrete has been

applied in accordance with the QAQC Plan.

Acceptable Tolerance: Shotcrete embedding pre-mat rebar is to be within 20% of the

specified thickness.


F-3S2 (Shotcrete Pour Card)

QAQC 3.5.4: Shotcrete Surface Preparation

Potential Quality Concern: Cleaning of overspray and rebound; verify SSD conditions;

Removal of laitance, sand pockets, dust and debris

Quality Control Measure: Prior to applying a consecutive layer of shotcrete, the shell is to

be inspected for the build-up of overspray, rebound, laitance,

sand pockets, dust and/or debris by the Construction

Superintendent or the QAQC Manager. The dome shell is

cleaned as required and shotcrete overspray, rebound, sand

pockets and laitance are removed from all areas where

additional shotcrete layers are to be applied. A blow pipe is to

be used to remove overspray as the shotcrete is placed. The

shell is also to be inspected daily to ensure that the surface is in

a surface saturated dry (SSD) condition prior to applying

additional shotcrete.

Quality Assurance Procedure: Rebound generally accumulates at the connection of the dome

shell and the dome footing. Typically the removal is completed

by blowing the materials away with an air lance as the shotcrete

is applied. However, additional roughening and chipping may be

needed if excessive overspray, sand pockets or laitance is

observed. If excessive surface evaporation has taken place

Rev: 2 10/21/15 34 of 93


between the shooting of successive layers, water should be

applied to the surface to ensure an SSD condition prior to

applying additional shotcrete. The adequacy of the surface

preparation is to be signed off on daily on the shotcrete pour

card by the Construction Superintendent or QAQC Manager.

Acceptable Tolerance: The surface preparation is to meet the requirements of ACI

506.2 section 3.3.2.

Related Documents: F-3S2 (Shotcrete Pour Card)

QAQC 3.5.5: Structural Rebar Placement

Potential Quality Concern: Proper steel placement; correct splice lengths & staggered

splices; appropriate size & grade of steel

Quality Control Measure: Acceptance of steel reinforcement to be used in the dome shell

is to follow the requirements of section 2.1.2 of this Plan. The

placement of the structural steel reinforcement is designated by

the structural engineer and specified on the building plans. The

attachment of the steel to the dome shell is performed under the

direction of the project Construction Superintendent. The

Superintendent directs placement to ensure proper weight

distribution and oversees attachment procedures to ensure safe

steel placement. The placement locations & amounts of steel

placed are recorded daily. The Construction Superintendent or

QAQC Manager is responsible for inspecting the placement of

the steel, verifying that bar size and splice locations are correct,

measuring and documenting spacing and splice lengths and

ensuring the approved plans are being followed. The depth

gauges are inspected daily to ensure the reinforcement is

placed at the correct embedment. Where multiple mats of steel

are specified, spacing between mats are also measured and

verified.

Quality Assurance Procedure: The project Construction Superintendent or QAQC Manager

receive the steel reinforcement on site accompanied by a mill

certification. The mill cert is to be reviewed to ensure the steel

meets the requirements for quality, type, size and grade. The

steel is physically assessed and inspected for visual

Rev: 2 10/21/15 35 of 93


conformance to the standards, noting rust, flaking, excess bend

damage, etc. that would cause rejection of the materials. If the

quality of the shipped steel is not acceptable details are to be

reported for why the materials are rejected. A quality control

checklist is to be completed for the rebar placed in the dome

shell. This QAQC form is to note the required rebar spacing &

splice lengths and, upon inspecting the rebar, is to be signed to

verify that the steel placement is in accordance with the plans.

Daily placement of the rebar is recorded and is to include the

locations and quantities of the reinforcement placed.

Acceptable Tolerance: Rebar placement is to meet the tolerances specified in ACI 117

section 2.2 unless otherwise specified in the contract

documents. Where 50% or more of the splices are placed in

the same location, the splice length is to be increased by a factor

of 1.3.

Steel reinforcement and embeds must meet the design criteria.

The Project Construction Manager or QAQC Manager reviews

the mill certs and rejects any steel that does not meet the

approved specifications.

Related Documents: F-3R1 (Rebar Placement-Dome)

F-3R2 (Rebar Checklist-Dome)

QAQC 3.5.6: Shotcrete Placement and Structural Steel Embedment

Potential Quality Concern: Proper embedment of rebar; Correct placement techniques;

Proper weight distribution;

Quality Control Measure: The daily placement of shotcrete including the location and

thickness is directed day to day by the Project Construction

Superintendent. As the shotcrete is applied, great care is taken

to properly embed the bars using the placement techniques

specified in ACI 506.2. Thicknesses and application rates are

monitored and recorded to verify that the shotcrete is evenly

distributed. The Construction Superintendent or QAQC

Manager inspects the work done daily and verifies that the

shotcrete quality is in accordance with the QAQC Plan. If

Rev: 2 10/21/15 36 of 93


acceptable quality is not achieved, remedial action must be

taken to ensure proper embedment.

Quality Assurance Procedure: Shotcrete is placed by or under the direct supervision of a Dome

Technology certified nozzleman. The shotcrete nozzlemen

control the quality of the shotcrete application. The nozzlemen

regulate embedment thicknesses and adjust shotcrete

techniques as necessary to best meet the requirements of each

dome area. The procedures for applying shotcrete given in ACI

506 “Guide to Shotcrete” are to be followed.

The project Construction Superintendent or QAQC Manager

inspect the embedment of the structural reinforcement

throughout the dome. The shotcrete is inspected for noticeable

voids as the bar is embedded. Shotcrete determined to contain

voids or excessive shadowing or sand pockets are to be

removed and replaced prior to the next application in the same

area. Thickness of embedment is determined by measuring the

depth gauges which are inspected daily. A pour card checklist

is to be completed each day by the Construction Superintendent

or QAQC manager who verifies that the shotcrete has been

applied in accordance with the QAQC Plan.

Acceptable Tolerance: The tolerance for steel embedment is per ACI 117 or as

otherwise specified in the approved construction drawings.

Embedment is measured against the depth gauges. This

tolerance applies to dimensions between mats of steel as well

as clear distances. Tolerances for the total thickness of finished

shotcrete are to be in accordance with section 3.5.2 “Shotcrete

Placement”.


F-3S2 (Shotcrete Pour Card)

QAQC 3.5.7: Final Shell Completion

Potential Quality Concern: Correct wall thickness & rebar cover; Acceptable finish

Quality Control Measure: Upon completion of the dome shell the Construction

Superintendent or QAQC Manager is to verify that the wall

thicknesses and rebar cover are within the design tolerances.

Rev: 2 10/21/15 37 of 93


The depth gauge locations are to be inspected and the walls

between the gauges examined to ensure that a consistent wall

thickness has been achieved and the finish is in accordance

with the contract specifications.

Quality Assurance Procedure: Upon approving the quality of the finished shell, a walk through

with the General Contractor or Owner’s Onsite Representative

is to take place. The walk through serves as a final inspection

of the work performed and the shell finish. A substantial

completion form is to be signed by the General Contractor or

Owner’s Representative and any deficiencies or items that are

found in need of completion prior to final approval are to be

listed.

Acceptable Tolerance: Finish tolerances are to be in accordance with the contract

specifications and verified and signed off on by General

Contractor or Customer’s Representative in a substantial

completion form.

Related Documents: Notice of Substantial Completion

Rev: 2 10/21/15 38 of 93


QAQC 4.0: Tunnel Construction

QAQC 4.1: Precast Sections

QAQC 4.1.1: Precast Forms

Potential Quality Concern: Acceptable form tolerances; damaged bracing or work platforms;

broken welds or additional damage; bonding to concrete.

Quality Control Measure: Form placement is to be in accordance with section 2.2.1 of this

Plan. The precast forms are to be measured for correct tolerances

and inspected for any structural damage prior to pouring concrete.

All fasteners, clamps and braces must also be inspected and be

in good working condition prior to each pour. A form-release

agent that does not bond or affect precast concrete surfaces is to

be used. Block-outs are to be placed as specified.


verifies the dimensions of the fully assembled precast forms prior

to concrete being delivered. A form-release agent is to be used

and documented to prevent bonding of concrete surfaces. A

precast report is completed each day during this phase of

construction and serves to verify that the quality control measures

in this Plan have been followed. Block-outs, as specified in the

approved drawings, are to be documented and referenced in the

precast report.

Acceptable Tolerance: The distance at the base of the tunnel may vary by +/- ¼” (6 mm).

The overall height of the tunnel may vary by +/- ¼” (6 mm).

Related Documents: F-4PC1 (Pre-Cast Tunnel Section QA)

Rev: 2 10/21/15 39 of 93


QAQC 4.1.2: Precast Sections - Rebar & Embed Placement

Potential Quality Concern: Incorrect size or quantity of rebar; rebar incorrectly placed within

the form, missing dogbones or embeds.

Quality Control Measure: Acceptance of steel reinforcement to be used in the dome shell

is to follow the requirements of section 2.1.2 of this Plan. The

placement of the steel reinforcement is designated by the

structural engineer and is to be placed as specified in the

approved construction drawings. The rebar is placed in the

precast forms under the direction of the project Construction

Superintendent. Dogbones or embeds are to be cast into the

sections for picking as designated by the construction

documents.


receive embeds, if applicable, on site accompanied by a mill

certification. The mill cert is to be reviewed to ensure the steel

meets the requirements for quality, type, size and grade. A

quality control checklist is completed for the rebar placed within

the precast forms. This QAQC form is to note the required rebar

spacing, splice lengths and coverage and is to document the

placement of any embeds that are specified.

Acceptable Tolerance: When the number of bars per section is specified, the spacing

of the steel is not as critical as having the correct amount of steel

in place. Although equivalent spacing is preferred, it may vary

by up to 25%. The concrete cover of the rebar is to meet the

tolerances specified in ACI 117 section 2.2.2 unless otherwise

specified in the contract documents.

Where 50% or more of the splices are placed in the same

location, the splice lengths are to be increased by a factor of 1.3

unless otherwise specified in the contract documents.


The project Construction Manager or QAQC Manager reviews

the mill certificates and rejects any steel that does not meet the

approved specifications.


Rev: 2 10/21/15 40 of 93


F-4PC1 (Pre-Cast Tunnel Section QA)

QAQC 4.1.3: Precast Sections - Concrete Placement and Curing

Potential Quality Concern: Poor concrete quality; bad consolidation; improper curing

techniques or time.

Quality Control Measure: Concrete quality is to be verified in accordance with section

2.1.1 of this Plan. The precast concrete is placed by or under

the direction of a qualified concrete foreman. Vibrators are

staged on hand prior to the pour. The concrete is vibrated as it

is poured in a manner which properly consolidates it around the

rebar and prevents honeycombing in corners, on form walls and

around blockouts. Curing materials are also on hand to provide

proper curing. Hot or cold weather plans are to be developed

as applicable and followed throughout the curing process.

Quality Assurance Procedure: Proper vibration techniques are used to consolidate the

concrete following the recommendations given in ACI 309.

Concrete curing meets the specifications of ACI 308. The

project Construction Manager or QAQC Manager inspects and

documents the precast concrete placement. A concrete pour

card is to be filled out each day prior to pouring concrete.


2.1.1 of this Plan. Acceptable curing follows the criteria given in

ACI 308 & consolidation the criteria of ACI 309.


F-4PC1 (Pre-Cast Tunnel Section QA)


Rev: 2 10/21/15 41 of 93


QAQC 4.2: Invert

QAQC 4.2.1: Invert Steel

Potential Quality Concern: Incorrect size or quantity of rebar placed; rebar incorrectly

placed within the formwork; missing dowels, embeds or

anchors

Quality Control Measure: Acceptance of steel reinforcement is to follow the requirements

of section 2.1.2 of this Plan. The placement of the rebar is


specified in the approved construction drawings. The rebar is

placed within the invert formwork under the direction of the

project Construction Superintendent.

Quality Assurance Procedure: Proper placement of dowels, embeds and anchors are verified

and documented as the steel is placed. A quality control

checklist is completed for the rebar placed within the invert

formwork. This QAQC form is to note the required rebar

spacing, splice lengths and coverage.

Acceptable Tolerance: Rebar placement is to meet the clearance & tolerances

specified in ACI 117 section 2.2 unless otherwise specified in

the contract documents.


location, the splice length is to be increased by a factor of 1.3



The Project Construction Superintendent or QAQC Manager

reviews the mill certificates and rejects any steel that does not

meet the approved specifications.


Rev: 2 10/21/15 42 of 93


QAQC 4.2.2: Invert Concrete


techniques or time; improper finishing


2.1.1 of this Plan. Invert formwork is to meet the requirements

of section 2.2.1 of this Plan. The concrete is placed by or under

the direction of a qualified concrete foreman. Vibrators &

finishing tools are staged on hand prior to the pour. The

concrete is vibrated as it is poured in a manner which properly

consolidates around the rebar and prevents honeycombing in

corners and on formwork walls. Finishing work uses proper

techniques and is done in a timely manner to meet the project

specifications. Curing materials are also on hand to provide

proper curing. Hot or cold weather plans are to be developed

as applicable and followed throughout the curing process which

is to last 7 days unless otherwise specified in the contract

documents.

Quality Assurance Procedure: Daily inspection and QAQC forms are to be completed to ensure

the construction plans are followed. Proper vibration techniques

are used to consolidate the concrete following the

recommendations given in ACI 309. Concrete curing meets the

specifications of ACI 308. The Project Construction Manager or

QAQC Manager inspects and documents invert concrete

placement. A concrete pour card is filled out each day prior to

pouring concrete and a concrete pour inspection is completed

to document the pour. The placement of embeds, anchors &

dowels are to be inspected and documented. Invert elevations

are verified and are to meet the acceptable tolerances.

Acceptable Tolerance: Concrete quality must be in accordance with section 2.1.1 &

formwork the criteria of 2.2.1 of this Plan. Acceptable curing

follows the criteria given in ACI 308 & consolidation the criteria

of ACI 309. Invert finish elevations are to meet the tolerances

given in ACI 117.


Rev: 2 10/21/15 43 of 93





QAQC 4.3: Tunnel Placement & Finishing

QAQC 4.3.1: Placing Precast Sections

Potential Quality Concern: Damaging the sections during transport and setting; placing the

hopper sections in the wrong location; damaging the invert

dowels

Quality Control Measure: When using a crane to set the forms, the dogbones are to be

utilized to lift the sections. The pick points are to be approved

by the design engineer. A tagline is used to keep the section

under control as it is moved into place and a spotter assists in

directing each section into its final position. When using a forklift

to set the sections, the forks are to be covered with a material

that does not scrape, chip, or damage the underside of the

sections. A spotter is similarly used to guide the forklift as the

sections are placed.

Quality Assurance Procedure: Equipment operators verify that all safeguards are in place on

their equipment prior to moving a tunnel section. A quality

checklist for the placement of the precast is filled out each day

sections are placed. The precast number and position are to be

recorded. Job specific training is given to the crew outlining the

sequencing and importance of quality control while placing the

precast sections. The tunnel invert is marked prior to setting the

sections to ensure placement precision.

Acceptable Tolerance: Precast sections may vary in their placement by +/- ½” (13

mm).

Related Documents: F-4PC2 (Precast Placement Checklist)

Rev: 2 10/21/15 44 of 93


QAQC 4.3.2: Closure Pour

Potential Quality Concern: Poor concrete quality; bad consolidation, especially under

precast section legs; improper curing techniques or time


2.1.1 of this Plan. Closure pour formwork is to meet the

requirements of section 2.2.1 of this Plan. The concrete is

placed by or under the direction of a qualified concrete foreman.

Vibrators & finishing tools are to be staged on hand prior to the

pour. Great care is to be taken to vibrate the concrete

underneath the precast legs to completely consolidate the

concrete in and around the precast hooks and invert dowels.

Curing materials are also to be on hand to provide proper curing.

Hot or cold weather plans are to be developed as applicable and

followed throughout the curing process which lasts 7 days

unless otherwise specified in the contract documents. Daily

inspection and QAQC forms are completed to ensure the

construction plans are followed.

Quality Assurance Procedure: Proper vibration techniques are used to consolidate the


Concrete curing is to meet the specifications of ACI 308. The

project Construction Manager or QAQC Manager inspects the

concrete and formwork placement for the closure pour. A

concrete pour card is to be filled out each day prior to pouring

concrete and a concrete pour inspection is to be completed to

document the pour.

Acceptable Tolerance: Acceptable curing follows the criteria given in ACI 308 &

consolidation the criteria of ACI 309. Concrete quality must be

in accordance with section 2.1.1 & formwork the criteria of 2.2.1

of this Plan.



F-2C3 (Concrete Testing QA)


Rev: 2 10/21/15 45 of 93


QAQC 4.3.3: Hopper Concrete Walls


techniques or time; Incorrect dimensions or out of plumb

Quality Control Measure: Concrete quality is to be verified in accordance with section 2.1.1

of this Plan. Prior to pouring concrete, the wall elevations,

dimensions & plumbness are to be verified and must meet the

acceptable tolerances; formwork is to meet the requirements of

section 2.2.1 of this Plan. The concrete is placed by or under the

direction of a qualified concrete foreman. Vibrators & finishing

tools are staged on hand prior to the pour. The concrete is

vibrated as it is poured in a manner which properly embeds the

rebar and attains satisfactory consolidation. Particular attention is

to be paid to dimensions & plumbness to ensure that the

manufactured hoppers fit as specified. Curing materials are also

staged on hand to provide proper curing. Hot or cold weather

plans are developed as applicable and followed throughout the

curing process which lasts 7 days unless otherwise specified in

the contract documents. Daily inspection and QAQC forms are to

be completed to ensure the construction plans are followed.

Quality Assurance Procedure: Proper vibration techniques are to be used to consolidate the


Concrete curing is to meet the specifications of ACI 308. The

project Construction Manager or QAQC Manager is to inspect and

document the concrete placement for these walls. A concrete

pour card is to be filled out each day prior to pouring concrete and

a concrete pour inspection is to be completed to document the

pour.

Acceptable Tolerance: Concrete quality must be in accordance with section 2.1.1 &

formwork the criteria of 2.2.1 of this Plan. Acceptable curing is to

follow the criteria given in ACI 308 & consolidation the criteria of

ACI 309. The finish dimensions of the hopper concrete walls are

to meet the tolerances given in ACI 117.



Rev: 2 10/21/15 46 of 93




QAQC 4.3.4: Waterproofing

Potential Quality Concern: Damaged, missing, or incorrectly installed waterproofing

elements

Quality Control Measure:

The crew installing the waterproofing is to undergo job specific

training to understand the sequencing and quality expectations

for placing the waterproofing. During application, the

waterproofing application is inspected to ensure that it is installed

correctly and meets industry standards and the manufacturer’s

recommendations. Any waterproofing that is damaged during

construction is to be documented and repaired; all corrective

actions are to be recorded.

Quality Assurance Procedure: The project Construction Manager or QAQC Manager is to

inspect and report on daily waterproofing placement. A

waterproofing checklist is completed and notes any defects or

damage observed during placement. The checklist is also used

to document that the waterproofing has been installed per the

approved recommendations.

Acceptable Tolerance: Material tolerances for application & thickness are to follow the

manufacturer’s recommendations; Overlapping of layers may be

+/- 1” (25 mm) or as otherwise recommended by the

manufacturer.

Related Documents: F-4W1 (Waterproofing Checklist)

Rev: 2 10/21/15 47 of 93


QAQC 5.0: Additional Dome Elements

QAQC 5.1: Curbs & Piers

QAQC 5.1.1: Curbs & Piers - Rebar

Potential Quality Concern: Incorrect size or quantity of rebar placed; rebar incorrectly placed

within the formwork; missing dowels, embeds or anchors

Quality control procedure: Acceptance of steel reinforcement is to follow the requirements




placed within the formwork under the direction of the project

Construction Superintendent. All embeds & anchors are to be

inspected and the placement verified with the construction

drawings. Extra care should be used when placing dowels

through the dome shell when constructing curbs and piers at the

apex of the dome. The dowels may be placed before access to

the apex is opened or approved for construction.


receive embeds & anchors and review the mill certifications for

dimensions, steel grade & quality. Proper placement of dowels,

embeds and anchors are verified and documented as the steel is

placed. A quality control checklist is completed for the rebar

placed within the formwork of the curbs or piers. This QAQC form

is to note the required rebar spacing, splice lengths and coverage

and is to list the dowels, embeds, anchors and ties placed. The

spacing and splice lengths are also to be listed and verified.

Acceptable Tolerance: Rebar placement is to meet the clearance & tolerances specified

in ACI 117 section 2.2 unless otherwise specified in the contract

documents.




Rev: 2 10/21/15 48 of 93


Steel reinforcement, anchors & embeds must meet the design

criteria. The Project Construction Superintendent or QAQC

Manager reviews the mill certificates and rejects any steel that

does not meet the approved specifications.


F-3R1 (Rebar Placement-Dome)

QAQC 5.1.2: Curbs & Piers - Forms

Potential Quality Concern: Acceptable form tolerances; damaged bracing or work platforms;

broken welds or additional damage; bonding to concrete.

Quality Control Procedure: Form placement is to be in accordance with section 2.2.1 of this

Plan. The curb and pier forms are to be measured for correct

tolerances and inspected for any structural damage prior to

pouring concrete. All fasteners, clamps and braces must also be

inspected and be in good working condition prior pouring

concrete. A form-release agent that does not bond or affect

precast concrete surfaces is to be used. Block-outs are to be

placed as specified. Forms are assembled and measured for

correct location. When placing formwork at the apex of the dome,

formwork is to be inspected for proper fit along the curvature of

the dome.



concrete being delivered. A form-release agent is to be used and

documented to prevent bonding of concrete surfaces. A daily

report is completed as formwork is placed and is to verify that the

quality control measures in this Plan are being followed. Block-

outs, as specified in the approved drawings, are to be

documented and referenced in the report. When placing

formwork at the top of the dome, top of wall elevations must be

confirmed with the construction drawings. Changes made to the

elevations of curbs and piers must be approved by the Engineer

of Record.

Acceptable Tolerance: The top of the Curbs/Piers may vary +/- ¼” (6 mm) from design.


Rev: 2 10/21/15 49 of 93


QAQC 5.1.3: Curbs & Piers - Concrete


techniques or time; improper finishing

Quality control procedure: Concrete quality is to be verified in accordance with section 2.1.1

of this Plan. The concrete is placed by or under the direction of

a qualified concrete foreman. Vibrators & finishing tools are

staged on hand prior to the pour. The concrete is vibrated as it is

poured in a manner which properly consolidates around the rebar

and prevents honeycombing in corners and on formwork walls.

Finishing work uses proper techniques and is done in a timely

manner to meet the project specifications. Curing materials are

also on hand to provide proper curing. Hot or cold weather plans

are to be developed as applicable and followed throughout the

curing process which is to last 7 days unless otherwise specified

in the contract documents.

Quality Assurance Procedure: Proper vibration techniques are used to consolidate the concrete

following the recommendations given in ACI 309. Concrete

curing meets the specifications of ACI 308. The Project

Construction Manager or QAQC Manager inspects and

documents the curb and pier concrete placement. A concrete

pour card is filled out each day prior to pouring concrete and a

concrete pour inspection is completed to document the pour. The

placement of embeds, anchors & dowels are to be inspected and

documented. Top of pier/curb elevations are verified and are to

meet the acceptable tolerances.

Acceptable Tolerance: Concrete quality must be in a accordance with section 2.1.1.

Acceptable curing follows the criteria given in ACI 308 &

consolidation the criteria of ACI 309. Curb & pier dimensions are

to meet the tolerances given in ACI 117.




Rev: 2 10/21/15 50 of 93


QAQC 5.2: Entryway

QAQC 5.2.1: Entryway - Rebar

Potential Quality Concern: Incorrect size or quantity of rebar placed; rebar incorrectly placed

within the formwork; missing dowels





placed within the entry formwork under the direction of the project

Construction Superintendent.

Quality Assurance Procedure: Proper placement of dowels is verified and documented as the

steel is placed. A quality control checklist is completed for the

rebar placed within the entry formwork. This QAQC form is to

note the required rebar spacing, splice lengths and coverage.


Rebar placement is to meet the clearance & tolerances specified


documents.





QAQC 5.2.2: Entryway - Forms

Potential Quality Concern: Acceptable form tolerances; damaged bracing or forms; bonding

to concrete.

Quality control procedure: Form placement is to be in accordance with section 2.2.1 of this

Plan. The entryway forms are to be measured for correct

tolerances and inspected for any structural damage prior to

pouring concrete. All fasteners, clamps and braces must also be

inspected and be in good working condition prior pouring

concrete. When the entryway is poured in multiple lifts, formwork

on the first lift may remain in place to facilitate the placement of

Rev: 2 10/21/15 51 of 93


the formwork of the second lift and extra care must be used when

inspecting multiple lifts for plumb. A form-release agent that does

not bond or affect precast concrete surfaces is to be used. Forms

are assembled and measured for correct location. When placing

formwork along the dome shell, formwork is to be inspected for

proper fit along the curvature of the dome.



concrete being delivered. A form-release agent is to be used and

documented to prevent bonding of concrete surfaces. A daily

report is completed as formwork is placed and is to verify that the

quality control measures in this Plan are being followed. Top of

wall elevations are to be confirmed to be in accordance with the

construction drawings.

Acceptable Tolerance: The Entryway dimensions may vary +/- 1” (25 mm) from design.


QAQC 5.2.3: Entryway - Concrete


techniques or time; improper finishing; Proper construction joints.

Quality control procedure: Concrete quality is to be verified in accordance with section 2.1.1

of this Plan. The concrete is placed by or under the direction of

a qualified concrete foreman. Vibrators & finishing tools are

staged on hand prior to the pour. When pouring walls over 6’-0”

(1.8 meters) care is taken during concrete placement to prevent

aggregate segregation by dropping the concrete. The concrete

is vibrated as it is poured in a manner which properly consolidates

around the rebar and prevents honeycombing in corners and on

formwork walls. Construction joints must be placed per plan or

be approved by the Engineer of Record. Finishing work uses

proper techniques and is done in a timely manner to meet the

project specifications. Curing materials are also on hand to

provide proper curing. Hot or cold weather plans are to be

developed as applicable and followed throughout the curing

process which is to last 7 days unless otherwise specified in the

contract documents.

Rev: 2 10/21/15 52 of 93


Quality Assurance Procedure: Daily inspection and QAQC forms are to be completed to ensure

the construction plans are followed. Proper vibration techniques

are used to consolidate the concrete following the

recommendations given in ACI 309. Concrete curing meets the

specifications of ACI 308. The Project Construction Manager or

QAQC Manager inspects and documents entryway concrete

placement. A concrete pour card is filled out each day prior to

pouring concrete and a concrete pour inspection is completed to

document the pour. The placement of dowels is to be inspected

and documented.


Concrete quality must be in accordance with section 2.1.1.

Acceptable curing follows the criteria given in ACI 308 &

consolidation the criteria of ACI 309. Entryway finish elevations &

dimensions are to meet the tolerances given in ACI 117.




QAQC 5.3: Floor Construction

QAQC 5.3.1: Floor Construction - Rebar


Incorrect size or quantity of rebar placed; rebar incorrectly placed;

missing dowels and embeds or anchors; proper construction

joints





placed under the direction of the project Construction

Superintendent. Proper lap splices are placed and verified.

Termination of bar or proper laps at contraction joints and/or

construction joints are placed per plan and verified.

Quality Assurance Procedure: Proper placement of dowels & embeds are verified and

documented as the steel is placed. A quality control checklist is

Rev: 2 10/21/15 53 of 93


completed for the rebar placed. This QAQC form is to note the

required rebar spacing, splice lengths and coverage required.

Acceptable Tolerance: Rebar placement is to meet the clearance & tolerances specified


documents.





QAQC 5.3.2: Floor Construction - Concrete


Poor concrete quality; bad consolidation; improper curing techniques

or time; placement of joints; improper finishing

Quality control procedure: Concrete quality is to be verified in accordance with section 2.1.1 of

this Plan. The concrete is placed by or under the direction of a qualified

concrete foreman. Joints are placed as specified in the approved

drawings. Vibrators & finishing tools are staged on hand prior to the

pour. The concrete is vibrated as it is poured in a manner which

properly consolidates around the rebar and prevents honeycombing in

corners and on formwork walls. Finishing work uses proper techniques

and is done in a timely manner to meet the project specifications.

Curing materials are also on hand to provide proper curing. Hot or cold

weather plans are to be developed as applicable and followed

throughout the curing process which is to last 7 days unless otherwise

specified in the contract documents.

Quality Assurance Procedure: Daily inspection and QAQC forms are to be completed to ensure the

construction plans are followed. Proper vibration techniques are used

to consolidate the concrete following the recommendations given in

ACI 309R. Concrete curing meets the specifications of ACI 308R. The

Project Construction Manager or QAQC Manager inspects and

documents the floor slab concrete placement. A concrete pour card is

filled out each day prior to pouring concrete and a concrete pour

inspection is completed to document the pour. The placement of

embeds are to be inspected and documented. Floor elevations are

verified and are to meet the acceptable tolerances.

Rev: 2 10/21/15 54 of 93


Acceptable Tolerance: Concrete quality must be in accordance with section 2.1.1 & formwork

the criteria of 2.2.1 of this Plan. Acceptable curing follows the criteria

given in ACI 308R & consolidation the criteria of ACI 309R. Floor slab

finish elevations are to meet the tolerances given in ACI 117.




QAQC 5.4: Post Tensioning

QAQC 5.4.1: PT Ducts


Incorrect size or placement; Insecurely fastened or improperly

connected

Quality control procedure: The placement of the PT ducts is designated by the structural

engineer and is to be placed as specified in the approved

construction drawings. The PT ducts are placed under the

direction of the Project Construction Superintendent who is

responsible for training the crew on proper installation. Ducts are

to be inspected and accepted then properly stored before

installation. The center of the ducts are to be placed at the correct

elevations and must be placed in a smooth shape with no kinks

or severe irregularities. Inspections are made to ensure there are

no conflicts with the duct placement and steel reinforcement,

utilities or blockouts. Duct joints must be properly connected at

all joints and any crack or hole must be sealed to prevent the

intrusion of concrete. Ducts must be securely fastened to prevent

movement when shotcrete is applied or concrete poured. Ducts

are to be capped at the end to prevent contaminants from

entering prior to grouting.

Quality Assurance Procedure: Proper placement of PT ducts are verified and documented as

the steel is placed. The number of ducts placed is to be recorded

and proper placement is to be verified. A quality control checklist

(F-5PT1) is completed each day for the ducts placed. This form

will serve to verify that all the required quality control procedures

are followed.

Rev: 2 10/21/15 55 of 93


Acceptable Tolerance: The duct specified in the contract documents is to be used. Ducts

are to be semi-rigid and must bend without crimping or flattening.

Placement of ducts are as indicated in the approved drawings.

Tolerances for duct placement are to meet the requirements of

ACI 117 section 2.2.6.1 unless otherwise specified in the contract

documents.

Related Documents: F-5PT1 (PT Duct Checklist)

QAQC 5.4.2: PT Anchorage


Poor anchorage quality; Improper confinement steel; Incorrect blockout

or bearing plate sizes or positions

Quality control procedure: PT anchorage quality is to be verified in accordance with this Plan. The

PT anchorage is placed under the direction of the Project Construction

Superintendent. Anchorage assemblies are inspected and approved

to meet the requirements for design and quality when received on site.

Plates, wedges and spirals must be free from rust, corrosion, grease

or other contaminants. Confinement steel is to be correctly sized and

spaced and be concentric to the trumpets. Blockouts and bearing plate

size and position are to meet the design requirements. Bearing plates

are to be placed perpendicular to the PT strands. Al anchorage support

is to be securely fastened to prevent movement during the placement

of concrete. Congestion of steel around the anchorage is to be

minimized to allow proper consolidation of concrete in the compression

block.

Quality Assurance Procedure: Inspections and a QAQC checklist (F-5PT2) are to be completed daily

to ensure the construction plans are followed. The Project Construction

Manager or QAQC Manager inspects and documents the adequacy of

the PT anchorage placement. Special instructions, confinement steel

& bearing plate sizes and blockout dimensions are documented and

confirmed. All additional reinforcement required in the compression

block is verified and documented on form F-2R1. Formwork, including

anchorage blockouts, are verified and recorded on form F-2F1.

Acceptable Tolerance: Steel reinforcement quality must be in accordance with section 2.1.2 &

formwork the criteria of 2.2.1 of this Plan. Bearing Plate placement

Rev: 2 10/21/15 56 of 93


tolerances are to meet the requirements of ACI 117 section 2.2.9



F-2R1 (Rebar Checklist-Concrete))

F-5PT2 (PT Anchorage Checklist)

Rev: 2 10/21/15 57 of 93


QAQC 6.0: Steel

QAQC 6.1: Bulkhead Doors

QAQC 6.1.1: Door Fabrication/Installation

Potential Quality Concern: Door located incorrectly, incorrect steel grade or members,

poor welds, poor galvanization or paint

Quality control procedure: All steel used is to be inspected upon receipt and verified for

quality, type & grade. Steel is to be fabricated according to the

specifications contained in the approved structural drawings &

shop drawings. Welding procedures, electrodes and welder

qualifications are to conform to the “Code for Welding in Building

Construction”, American Welding Society (AWS) and the AISC

“Specifications for the Design, Fabrication and Erection of

Structural Buildings”. Galvanizing/Paint is applied according to

the requirements specified in the contract documents. The door

is to be properly prepped for shipment to minimize damage to

the doors. Once received onsite the door location is to be

verified and the doors are to be installed per the approved

specifications.

Quality Assurance Procedure: Prior to fabrication, the steel members are to be verified and

documented. During fabrication dimensions, welds, paint quality

and thicknesses are to be documented and verified to meet the

design specifications. Shipping preparations must be signed off

on prior to shipping the doors to the job site.

Acceptable Tolerance: Tolerances are per the approved structural drawings.

Related Documents: F-6D1 (Door Installation Checklist)

Rev: 2 10/21/15 58 of 93


Sample Forms

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Rev: 2 10/21/15 90 of 93


Rev: 2 10/21/15 91 of 93


Rev: 2 10/21/15 92 of 93


Revisions

June 2014: Issued as Rev A for initial review and comment

August 2014: Issued as Rev B for review and comment

September 2014: Issued as Rev 0

May 2015: Issued as Rev 1; Revisions to foam testing methods & added updated forms

October 2015: Issued Rev 2; Complete revision of QAQC form/report templates; added sections for

pile/pier foundations & concrete post tensioning