Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
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What is Qcast?
Audit and Certification
Demonstrates at Time of Audit
Plant is in compliance with ACPA
Guidelines
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Pipe
Box Culverts / 3 Sided Structures
Manholes
Engineered Precast
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Certifications by Category
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Participants Totals
200
180
160
140
SANITARY
MANHOLES
MANHOLES
SANITARY
120
100
80
60
STORM
PRECAST
BOX CULVERT
40
20
0
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
10
900
828
STORM
800
BOX CULVERT
700
PRECAST
600
MANHOLES
500
438
SANITARY
MANHOLES
400
300
200
136
182
167
100
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0
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Consistency
The name of the game in the
concrete industry
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Consistency
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Consistency
QCast will help you monitor your
products and procedures
Materials
Equipment
Procedures
Records
Final product
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Other Benefits?
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Recognition/Marketing
Government
Industry and Peers
Customer
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Standardize QC
Share the workload
Reduce confusion between plants
Simplify Reports to Management
Reputation
Reduce 2nds
Help you to catch potential issues
Customer Satisfaction
Customizable to your plant
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Company/Plant Manual
QCast made to fit your company
Industry defined but company
and plant specific!
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Industry Reputation
Consistency company to company
Rejects are the same to
everyone
Only the good stuff gets out
Contractors know what to expect
Concrete in Demand
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Industry specific
The program was built
specifically for the concrete
products industry
Program designed by industry
leaders
QCast built around all stages of
production
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Equipment Calibrations
Material Certifications
Test Documentation
Product and setup prepour
Curing, handling, storage, repair
Final postpour inspection
Records
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Non-Member
Single Certification - $8,600
Three Category Certification $10,800
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Documentation
Records! Records! Records!
Records show compliance
Refer to QCast Manual
Need two months
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Audit Day
Your going to be busy
Review documentation
Demonstrate knowledge
Set up and perform required tests
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Is it Cost Effective to be
Certified?
Experience tells us that ACPA QCast
pays for itself through:
Increased efficiency
Reduction of defective products
Reduction of field repairs
Increased sales through customer
satisfaction
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Once Certified
Manufacturer Shall:
Maintain the high standard of QCast.
Maintain product and material performance
documentation
Supply only certified products from a certified
plant to jobs requiring ACPA certified products
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Documentation
Filing System
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1.3 CURRENT
APPLICABLE ASTM
STANDARDS
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1.4
DOCUMENTATION OF
SPECIAL PROJECTS
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1.5 Q.C.
ORGANIZATIONAL
CHART
What goes in here?
Completed Q.C. Organizational Chart
Where can I get it?
From ACPA Certification Manual, Appendix A
Meet with key personnel involved with production,
quality and the Certification Program to delegate
responsibilities and fill in Chart.
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1.6 QUALITY
AUTHORITY/HOLD
PRODUCTION
POLICY
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1.7 Q.C.
PERSONNEL
TRAINING
RECORDS
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2.0
MATERIALS
What goes in here and where do I get it?
Files should be kept containing the following materials
certifications:
Cement Cement mill certs should be received from the cement
company once/mo. for each type of cement being used.
Aggregate A Certificate of Compliance (ASTM C33) should be
received once/yr. for each material from your aggregate supplier.
Aggregate Gradations Plant should have gradations for each
aggregate quarterly as per Pipe, Manhole and Precast Products
Certifications and monthly for Box Certification.
Fly Ash A test report should be supplied by the supplier once
per month.
Other Cementitious Material A certification should be supplied
by the supplier once/mo.
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2.0 MATERIALS
(Cont)
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3.0 CALIBRATIONS
What goes in here and where do I get it?
Documents showing the following calibrations at specified
frequency.
Concrete Batching Equipment
1/yr
Must be calibrated and certified by independent agency
Water Meter
1/yr.
In-house calibration using volumetrically calibrated 55 gallon
barrel or water weight works well.
Additive Dispensing Equipment
1/yr.
In-house volumetric calibration using graduated
cylinders works well. Get graduated cylinder from
house such as McMaster-Carr.
supply
3.0
CALIBRATIONS CONT.
Go-No-Go Gages
min. 1/yr
In-house or independent agency calibration with
micrometer or calibrated bars.
Laboratory Scales
1/yr.
In-house or independent calibration with certified test
weights.
Micrometers
1/yr.
In-house or independent calibration with certified
micrometer or calibration bars.
Vacuum Test Equipment
1/yr.
In-house or independent calibration with manometer
column height using a liquid with a verified specific
gravity or certified test gage.
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gravity or
4.0 CONCRETE
MIX DESIGNS
What goes in here?
A copy of all mix designs used in production.
4.1 Water either potable or meets ASTM C1602
Where do I get it?
Mixer man and production office should both have a copy
of mix designs.
What do I do with it?
Retain and update as changes are made.
Frequently verify that files mixes are actually those being
used in production.
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4.2
WATER/CEMENTIOUS
MATERIAL
CONFIRMATION
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4.3 CONCRETE
BATCH REPORTS
What goes in here?
Daily report of actual batch quantities for one batch of each mix
design used. If using ready-mix concrete should retain a batch
report for each load received.
SCC mixes require a written QC plan
Where do I get it?
Results should be received from plant mixer man or ready-mix
supplier. Electronic files ok as long as you can access them
easily.
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9.0 CONCRETE
TESTING
What goes in here?
Reports documenting slump/flow, temperature, air content,
unit weight, and absorption shall be kept on file.
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9.7 COMPRESSIVE
STRENGTH TESTING
What goes in here?
Reports documenting compressive strength tests for all
mixes used in production. Min. of 5 cylinders per week for
pipe tested in TEB otherwise 5 cylinders per day. Box
culverts min. of 2 additional cylinders per week for
stripping strength.
What do I do with it?
For tests done in-house will need to demonstrate cylinder
fabrication and concrete strength testing procedures
during audit.
Monitor strengths and ensure strength is adequate at
shipping ages per shipping policy.
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10.0 CURING
RECORDS
What goes in here?
Reports showing temperature cure cycle of products,
minimum one kiln per day/cycle.
Keep maximum temperatures below 160 F (71 C) with
max. rise 40 F/hr (25 C/hr).
Where do I get it?
Plants should have instruments to measure the cure cycle
of products, daily.
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12.0 PRODUCT
MARKING
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14.1 HANDLING
AND STORAGE
What goes in here?
Write a maximum stacking height policy for each class and
size of product.
Ensure that all products are handled to prevent damage.
All rejected materials must be clearly marked and
separated when able.
What do I do with it?
Use as a reference so Q.C personnel, shipping personnel
and ACPA Auditor can verify product compliance at the
time of shipping.
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14.2 SHIPPING
POLICY
What goes in here?
Write a Shipping Policy that corresponds with your current
shipping practices and how they relate to three-edge
bearing and concrete compression test results and
inspection criteria.
What do I do with it?
Use as a reference so Q.C personnel, shipping personnel
and ACPA Auditor can verify product compliance at the
time of shipping. Correlate with strength or TEB test
results.
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14.3 FINAL
INSPECTION
What goes in here?
Write a Final Inspection Policy that corresponds with your
actual practices. Identify persons responsible for the final
inspection in the policy.
Document final inspections to verify product compliance at
the time of shipping.
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5.4 GASKET
QUALITY
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1/300
- 36 and larger
1/100
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6.0 EQUIPMENT
& FORMS
What goes in here?
Inspection reports for all new and repaired equipment to
check dimensions and function.
Where do I get it?
Reports can be done in-house or by equipment supplier.
Plants should always verify critical measurements.
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7.0
REINFORCING
What goes in here?
Reinforcing design information for the production of all
Pipe, Manholes, Precast Products, or Boxes.
Where do I get it?
Designs can be done in-house or by a second party.
Standard drawings or job specific.
Must have: mesh style, diameter, length, steel area (design &
actual), location in wall, lap, bell reinforcing, and shear steel.
What do I do with it?
Retain on file and maintain at production fabrication
areas. Cage fabricators must be familiar with reinforcing
requirements.
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8.0 PRE-POUR
INSPECTIONS
What goes in here?
Reports documenting pre-pour inspections of reinforcing,
forms (visual and dimensions) and embedded items.
Measure a minimum of one cage at beginning of each
shift or any change.
Visually inspect each cage and form.
Initial shop drawings for check of embeds and blockouts.
Where do I get it?
Reports should be completed by Quality Control and
other plant personnel.
What do I do with it?
Retain on file for future reference.
Demonstrate inspection procedures during audit.
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11.0 POSTPOUR
INSPECTION
What goes in here?
Check a portion of each days production before and after
finishing/patching. Maintain a written repair procedure and list
acceptable repair materials.
Perform visual and dimensional checks on both barrel and joints.
Document 1 piece/size/shift.
Sanitary: Go/No Go gaging.
Where do I get it?
Sample forms can be found in the QCAST Appendix.
Demonstrate during audit.
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TESTING
(PIPE AND
MANHOLES)
What goes in here?
Proof of design and ongoing tests of pipe and manhole
showing that products are meeting standards for Water
Tightness, Three-Edge Bearing, and Joint Tests.
Monitor testing frequency with production.
Manhole Step Tests (v.6)
Where do I get it?
Most tests are ASTM Standards.
What do I do with it?
Use them to make sure your products are meeting all
applicable standards. Retain on file for future reference.
Demonstrate tests during audit.
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13.2 3-EDGE
BEARING TEST
What goes in here?
Test results at the frequency described in Section 13.2 of the
Certification Manual to minimum of 0.01 inch crack.
Annually, test a minimum of one pipe per size and class (60 or
smaller) to Ultimate Load.
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Class
Frequency
Class 5 and
Class 4 and
Class 5
Class 3 and
Class 4 and
All classes
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Appendix A:
Procedures and
Sample forms
Appendix B: Audit
Expectations.
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ACPA Certification
Checklist
Date of Previous
Calibrator
Calibration
Ind.
Ind. / In -house
* Additive Dispensing
____________
_____________
____________
_____________
Ind. / In-house
Date of Current
Year Calibration
Ind.
Ind.
____________
_____________
____________
_____________
____________
_____________
Ind. / In-house
____________
_____________
Laboratory Scales
Ind. / In-house
____________
_____________
Micrometer
Vacuum Test Equip
Air Test Equip.
Hydro Test Equip.
Ind. / In-house
Ind. / In-house
Ind. / In-house
____________
____________
Ind./ In-house
____________
In-house
_____________
_____________
_____________
____________
_____________
____________
_____________
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What happens
on Audit Day?
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Audit Day
DOCUMENTATION
The auditor will check your
documentation files for
completeness and content.
Audit Day:
Production Verification and
Testing (Highlights)
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REINFORCING
Have detailed reinforcing design in the fabrication
area.
Show how cages are measured.
Measured cages being used must meet specifications.
CONCRETE BATCHING
Batches proportioning must follow mix designs.
Show competence in batching.
FORMS
Inspect condition and cleanliness of forms.
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CURING
Plant personnel shall demonstrate curing
methods and retrieve results.
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Barrel/Box dimensions
Pipe/MH/Box joint inspection
Water tightness tests (sanitary)
Three-edge bearing tests
Off center hydrostatic joint test (sanitary)
Differential joint shear test (sanitary)
Storm sewer and culvert joint test
Compressive strength test
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Audit Day
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Product marking
Handling and storage
Repairs
Segregating of reject pieces
Final inspection
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Manholes
ASTM C478
Pre-pour each piece (wet-cast)
Sanitary manholes
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Precast
Standard and non-standard
products
ASTM or local specs control
Reinforcing drawings and
tolerances
Pre-pour min. one cage/shift/type
Post-pour critical
dimensions/blockouts
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Box Culvert
ASTM C1433/C1577 (C1504 3sided)
Monthly Gradations, air pot
calibrations 1/4ly, & w/c <=0.45
max.
Pre- and Post- product
inspections
Fit test
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SEE!
ITS EASY!
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