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Precast Plant Quality System Documentation Set

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This document is a basic quality manual specifically designed for precast concrete plants. This can be used as a blueprint for plants to design their quality system.

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Precast Plant Quality System Documentation Set

  1. 1. © Copyright 2007 by Sam Lines PRECAST PLANT QUALITY SYSTEM DOCUMENTATION SET by Sam J. Lines This document is an outline structure for developing a quality system in a precast concrete plant that addresses the minimum standards recognized in the industry. The outline is constructed using an outline of 12 separate volumes, each representing a unique set of documentation necessary for the verification of conformance. The set contains a written quality control manual, volume 1 of the set, which is intended to be modified to address specific procedures of each individual plant. The documentation set should be used as a blueprint in establishing a documented, plant specific, quality assurance system in a precast concrete plant. This product does not guarantee, either written or implied, the acceptance by any industry plant certification program.
  2. 2. © Copyright 2007 by Sam Lines Using This Document This document contains an outline with 12 main headings. Each heading is a volume. Each volume represents a set of documentation that is related to one another. Volume 1 is the quality control manual. A basic quality control manual has been written which can be used and modified by the user to add plant specific details. The remaining 11 volumes will be filled with documentation that either currently exists, or should exist in a precast concrete plant to show compliance to a quality system. Each volume of this documented system is to be contained in (1) three ring binder. The edge of the binder will be labeled with volume heading. The contents can be then separated into subsets using divider sheets. Different size binders will be needed in some instances to hold the volume of documents and records that may exist. This will vary from plant to plant. In most instances, a 1” binder will meet or exceed the volume requirements. The purpose for using 12 binders is so that they can be kept together in a library where anyone can see them. This accomplishes two goals. First of all, by being accessible, anyone can refer to the documentation when necessary. It also makes it easy to access when an auditor shows up to examine the system for compliance to a standard. And second, displaying the quality control system in this manner demonstrates to employees and visitors that the quality system is important and supported by management. A basic way of viewing a documented quality assurance system is to think say it, do it, and prove it. You need to say what you do, in other words, document the process. Then do what you say you are doing by following the written procedures. And finally you must prove it. The proof is in the records generated by the system to show evidence of continuous compliance. By following this format, developing a documented quality system can be done in less time, with less resources, allowing the precaster to do what they do best; make quality precast products.
  3. 3. © Copyright 2007 by Sam Lines 1. Precast Concrete Plant Quality Control Manual a. Management Quality Policy b. Company QC Organizational Chart c. Description of responsibilities for QC personnel d. Description of training requirements i. QC personnel ii. Production staff iii. Forklift operators iv. Batch plant operators v. Drivers e. Housekeeping Plan f. Production Procedures i. Pre pour inspection procedures ii. Post pour inspection procedures iii. Final inspection procedures iv. Curing procedures v. Product repair procedures vi. Nonconformance procedure vii. Mix qualification procedure viii. Raw material testing procedures ix. Equipment calibration procedures x. Product performance test procedures xi. Hot weather concreting procedure xii. Cold weather concreting procedure g. Minimum strength requirements i. Stripping ii. Shipping h. Product tolerances i. Quality control records – Sample of forms and documentation 2. Training Documentation Manual a. Quality Personnel i. Applicable ACI certifications ii. Concrete fundamentals and quality education b. Production Personnel i. Specific safety training ii. Vibrator training iii. Batch plant operator training c. QC Meetings d. Safety Toolbox Talks 3. Purchased Material Compliance Records a. Aggregate reports b. Cement / supplementary cementitious materials mill certificates c. Reinforcing mill certificates d. Certificates of compliance i. Admixtures ii. Sealants & connectors iii. Water
  4. 4. © Copyright 2007 by Sam Lines 4. Plant Equipment Records a. Forming (identification, annual inspection) b. Slings and lifting devices c. Batching tolerances d. Batch plant inspection criteria e. Calibration records f. Concrete mix formulas 5. Pre pour Inspection Log 6. Post Pour Inspection Log 7. Quality Inspection and Testing Log a. Daily checks log b. Concrete testing records c. Curing records 8. Final Inspection Log 9. Concrete Batch Reports 10. Product Specific Records a. Proof of conformance b. Stormwater concrete pipe requirements (when applicable) c. Round manhole component requirements (when applicable) d. Box culvert requirements (when applicable) e. Septic tank requirements (when applicable) 11. Standards Manual for Test Methods and Specifications a. ASTM b. AASHTO c. ANSI d. ISO 12. Plant Safety Manual a. Management commitment and employee involvement b. Hazardous communications program c. Confined space program d. Hearing conservation program e. Powered industrial truck program f. Control of hazardous energy program (lockout / tagout) g. Emergency response program h. Employee safety training program
  5. 5. © Copyright 2007 by Sam Lines PRECEAST CONCRETE PLANT QUALITY CONTROL MANUAL VOLUME 1 Issued <Month Date, Year>
  6. 6. © Copyright 2007 by Sam Lines Management Quality Policy <Company Name> is committed to providing quality products to our customers. To meet this objective, we will implement and follow the procedures detailed by this quality system manual. Our quality objectives are: • Customer satisfaction • On-time delivery • Zero defects • Continuous improvement The success of this quality management system is dependent on the support of top management and employee involvement. The president of <Company Name>, by placing his signature below, is demonstrating his support. Employees at all levels within the organization are charged with the responsibility of following this quality management system. _________________________ <Name of Company President> Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 2 of 21
  7. 7. © Copyright 2007 by Sam Lines Company QC Organizational Chart Designation of Responsibility for QC Personnel President • Has the ultimate responsibility for the Quality Management System • Responsible for dedicating resources to the quality department Manufacturing Manager • Responsible for following the production procedures Foremen • Responsible for verifying product requirements in process Human Resources Manager • Responsible for employee training Quality Manager • Responsible for the management of the Quality Management System Inspector • Responsible for in process and final inspections and testing Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 3 of 21 President Sales Manufacturing Controller HumanResources Quality InspectionForemen
  8. 8. © Copyright 2007 by Sam Lines Description of Training Requirements Quality Control Manager • ACI Field Testing Technician – Grade 1 • ACI Compression Testing Technician • ACI Aggregates Testing Technician • Concrete Production and Quality Training o NPCA: Production and Quality School; and/or o PCA: Concrete Principles and Practices; and/or o PCI: Level II Certification Quality Control Inspectors • ACI Field Testing Technician – Grade 1 Production Foremen • Concrete Production and Quality Training o NPCA: Production and Quality School; and/or o PCA: Concrete Principles and Practices • OSHA 10-hour Course Forklift Operators • Powered Industrial Truck Training and Certification Batch Plant Operator • Concrete Production and Quality Training o NPCA: Production and Quality School; and/or o PCA: Concrete Principles and Practices Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 4 of 21
  9. 9. © Copyright 2007 by Sam Lines ACI is the trademark for the American Concrete Institute NPCA is the trademark for the National Precast Concrete Association PCA is the trademark for the Portland Cement Association PCI is the trademark of the Precast/Prestressed Concrete Institute Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 5 of 21
  10. 10. © Copyright 2007 by Sam Lines Housekeeping Plan Safety is a priority. Good housekeeping is critical to eliminating slips, trips and falls. Each employee is responsible for picking up trash and debris and placing it in the proper container throughout the day. Any spill will be cleaned promptly. Tools and equipment will be put away when not in use. The use of extension cords and hoses will be kept to a minimum, and they will be stored when not in use. The quality manager will inspect the plant daily to make sure this policy is being followed. Acknowledgement that the housekeeping inspection is completed will be documented on the Daily Plant Inspection Form. Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 6 of 21
  11. 11. © Copyright 2007 by Sam Lines Production Procedures A. Pre-Pour Inspection Procedure A pre-pour inspection will be performed on each form prior to casting. As a minimum, the following items will be checked: o Form dimensions o Form tightness o Form cleanliness o Form release agent application o Positioning, size, and securing of reinforcement o Placement, securing, and location of embedded items o Placement, securing, and location of blockouts The record of the inspection will be made on the pre-pour inspection form for the date the product is to be cast. To identify that the pre-pour inspection is complete, and that the form is ready for casting, we will <explain the method used to identify that the form is ready>. Forms will not be cast until they have been inspected and approved. B. Post Pour Inspection Procedure A post pour inspection of each product will be performed. As a minimum, the following items will be included in the inspection: o The evidence of any damage such as spalls or cracks o Excessive bugholes or honeycombing o The dimensions of the product and cast in items are within tolerance o Exposed reinforcing o Assembly of any components to the casting o Permanent identification of the product as required The results of the inspection will be recorded on a post pour inspection form for the date the product was cast. Any defects noted are to be repaired and re- inspected before the product passes inspection. Any product which cannot be repaired, or does not conform to the required specifications will be permanently identified as nonconforming. All castings that are approved will be designated with a distinct mark that identifies the casting as accepted. C. Final Inspection Procedure Before shipment, all products will be inspected to assure that the product conforms to requirements and is properly identified. Shipments containing more than 5 units of the same product will have 1 product for every 10 shipped inspected. If a defect is found, 2 additional products will be inspected. If a defect is found in either of those products, all remaining product will be inspected. Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 7 of 21
  12. 12. © Copyright 2007 by Sam Lines Any defects noted are to be repaired and re-inspected before the product passes inspection. Any product which cannot be repaired, or does not conform to the required specifications will be permanently identified as nonconforming. Only products which pass inspection will be shipped unless the purchaser is notified and agrees to accept the product with the nonconformance. The final inspection, including any nonconformances or customer acceptance of a defect, will be recorded on the final inspection form. D. Curing Procedures Procedure The typical curing process for all products is by non-mechanical means. Castings will be protected from moisture loss after pouring and prior to stripping. For concrete with a temperature above 55° F, the form will be covered with a plastic sheet of no less than 6 mils thick. Alternative curing methods such as a curing membrane may be used when applied at a rate not exceeding 200 SF per gallon. Heat Curing (only when used) – Accelerated curing by heat or steam may be performed. When it is done, concrete will not be subjected to hot air or steam until after a minimum of 30 minutes or after the initial set of the concrete. The casting will be protected against moisture loss by covering or the addition of steam when using an accelerated method. The concrete curing temperature will be monitored and will not exceed 150° F. The rise in temperature will be limited to a maximum of 40° per hour. Records for accelerated curing processes, if used, will be kept and include the following information: o Time of initial set (ASTM C403) o Ambient curing temperature measured a minimum of once per week o Inspection of cured products for evidence of plastic shrinkage cracking and documentation of any damage found E. Product Repair Procedure A qualified person will determine whether the defect is minor or major in nature. If the defect will not impair the function or expected life of the product, then the defect will be considered minor, all other defects will be considered major. Defects will be repaired according to the following process: Minor Defects – To repair a honeycomb area or spalling, any loose debris will be removed and the area surrounding will be cut away. The mating surface will be dampened. <enter the type of repair mortar used> will be used to patch the area. The material will be used in accordance with the manufacturers recommended procedures. Major Defects – Major defects that affect the function or life of the product will not be repaired. The casting will be scrapped or re-classified if it meets another specification. Products with defects that are considered major will be clearly designated. All defects will be documented on the inspection records. Any repairs made will be re-inspected before the casting is approved. The re-classification or rejection of any product with a major defect will be documented. Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 8 of 21
  13. 13. © Copyright 2007 by Sam Lines F. Mix Qualification Procedure Standard slump concrete will be proportioned by a volumetric method by a qualified individual. Each recipe will be proportioned, documented and labeled for identification. The nominal compressive strength will be designed to exceed the required minimum compressive strength by either one standard deviation (when a minimum of 20 test samples are available) or 1,200 psi. Changes in the mix design will be documented. When Self-Consolidating Concrete (SCC) is used, the qualification process will involve the SCC admixture manufacture. SCC will be tested daily at the beginning of the pouring operation. A specified range for the spread of the SCC will be determined for each design used. The mix will be considered to be within specification when two consecutive tests for spread fall within the specified range. The air content, maximum water-to-cement ratio and minimum compressive strength will be as specified by the customer’s requirements. G. Raw Material Testing Procedure All raw materials will be tested by the supplier, and shipped with a certificate of conformance or mill certificate. H. Equipment Calibration Procedure A listing of all equipment used to measure the materials used in making or testing the concrete will be listed and calibrated at least annually. The list will include, but not be limited to, the following: o Weight Scales o Admixture dosing equipment / meters o Moisture sensing equipment o Air entrainment meter o Compressive test machine o Thermometers o Rule or tape measure I. Product Performance Test Procedure Proof of Conformance to Specifications – When required, conformance to specification will be by design calculations or by performance testing. Performance testing will be verified by an independent expert or by a licensed professional engineer. o Stormwater Concrete Pipe – The following inspections will be performed on the applicable stormwater concrete pipe produced.  Reinforcing Steel – A minimum of three cages from each production day, but not less than 3%, will be inspected for compliance to requirements. The cage will be verified with the design, the type of reinforcing used will be verified, and the Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 9 of 21
  14. 14. © Copyright 2007 by Sam Lines connection method will be checked. These inspections will be documented and kept on file for a minimum of three years.  Three-edge Bearing Testing – When conformance is required, this test will be conducted per ASTM C497. Unless a greater frequency is specified, the three-edge bearing test will be conducted on each size pipe a minimum of once per year, or as shown on the following chart, which ever is greater: Pipe size / Diameter (inches) Test Frequency 12 through 15 1 in 800 18 through 36 1 in 400 42 through 60 1 in 200 66 and over As specified The results from this testing will be documented and maintained at the plant for a minimum of three years.  Absorption testing – Absorption testing will be conducted per ASTM C497 a minimum of once per year on the mix design with the lowest amount of cementitious material. The results from this testing will be documented and maintained at the plant for a minimum of three years.  Dimensional Checks – The dimensions of pipe will be checked periodically to verify conformance to specification. A minimum frequency of three pipes per day, or 3% of production per day will be sampled. The results from this inspection will be documented and maintained at the plant for a minimum of three years.  Joint Design and Testing – Joints will be designed and verified per ASTM C443, ASTM C990, or as required by the customer’s specification. Leakage testing by either hydrostatic or vacuum testing will be conducted on the gasketed connections annually, or when the joint or gasket material changes. The results from this testing will be documented and maintained at the plant for a minimum of three years. o Round Manholes – The following inspections will be performed on the applicable round manholes produced:  Reinforcing Steel – A minimum of three cages from each production day, but not less than 3%, will be inspected for compliance to requirements. The cage will be verified with the design, the type of reinforcing used will be verified, and the connection method will be checked. These inspections will be documented and kept on file for a minimum of three years.  Flat Slab Tops – Flat slab tops will be verified by design calculations or by proof testing. A licensed professional engineer or an independent expert will verify the results of proof testing. The design will conform to ASTM C478.  Absorption testing – Absorption testing will be conducted per ASTM C497 a minimum of once per year on the mix design with Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 10 of 21
  15. 15. © Copyright 2007 by Sam Lines the lowest amount of cementitious material. The results from this testing will be documented and maintained at the plant for a minimum of three years.  Step Testing – A test of the steps will be conducted a minimum of once per year in accordance with the requirements of ASTM C497. The testing will meet the requirements of ASTM C478.  Dimensional Checks – The dimensions of pipe will be checked periodically to verify conformance to specification. A minimum frequency of three pipes per day, or 3% of production per day will be sampled. The results from this inspection will be documented and maintained at the plant for a minimum of three years.  Sanitary Manhole Vacuum Testing – When required, vacuum testing will be performed according to ASTM C1244. The results from this inspection will be documented and maintained at the plant for a minimum of three years.  Joint Design and Testing – Joints will be designed and verified per ASTM C443, ASTM C990, or as required by the customer’s specification. Leakage testing by either hydrostatic or vacuum testing will be conducted on the gasketed connections annually, or when the joint or gasket material changes. The results from this testing will be documented and maintained at the plant for a minimum of three years. o Box Culvert – The following inspections will be performed on applicable box culverts produced:  Absorption testing – Absorption testing will be conducted per ASTM C497 a minimum of once per year on the mix design with the lowest amount of cementitious material. The results from this testing will be documented and maintained at the plant for a minimum of three years.  Joint Design and Testing – Joints will be designed and verified per ASTM C443, ASTM C990, or as required by the customer’s specification. Leakage testing by either hydrostatic or vacuum testing will be conducted on the gasketed connections annually, or when the joint or gasket material changes. The results from this testing will be documented and maintained at the plant for a minimum of three years.  Pre-pour Inspection – Critical form dimensions, including the top, bottom, and wall thicknesses will be included in the pre-pour inspections. A minimum of one box culvert produced in each form per day will be verified. The cage will be verified with the design, the type of reinforcing used will be verified, and the connection method will be checked. These inspections will be documented and kept on file for a minimum of three years. o Septic Tanks - The following inspections will be performed on applicable septic tanks produced: Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 11 of 21
  16. 16. © Copyright 2007 by Sam Lines  Structural Proof of Design – Proof of design will be performed by either calculations or by proof testing. Design calculation will be stamped by a licensed professional engineer. Performance testing will be verified by an independent expert or by a licensed professional engineer.  Watertightness Testing – Septic tanks will be verified for water tightness according to the applicable section of ASTM C1227 or the requirements of local authority with jurisdiction, whichever is more stringent. A minimum of one septic tank produced from each form will be tested at least once per year unless a greater frequency is required by the customer. The results from this testing will be documented and maintained at the plant for a minimum of three years. J. Hot Weather Concreting Procedure It is preferred that the fresh plastic concrete temperature be no greater than 90° F. When the fresh temperature of the concrete reaches 87° F, the batch plant operator will be notified. The concrete temperature will then be monitored for each batch by the batch plant operator. Also, if the fresh temperature reaches 87° F, the aggregate stockpiles will be saturated with water 15 minutes ever 1 hour between 6 am and 6 pm. If the fresh concrete temperature reaches 90° F, the batch plant operator will take additional steps to cool the concrete. Ice will be substituted in equal volume for water. The ice will be added into the mixer and the mix water will be reduced accordingly. The batch number and the amount of ice added will be recorded. Ice can be added to replace no more than 75% of the mix water. All ice must be completely dissolved before mixing is complete. If the addition of ice and increase in sprinkling aggregates does not reduce the fresh mix temperature to below 90° F, then concrete production will be discontinued. K. Cold Weather Concreting Procedure It is preferred that the fresh plastic concrete temperature be no less than 50F. When the fresh temperature of the concrete reaches 55° F, the batch plant operator will be notified. The concrete temperature will then be monitored for each batch by the batch plant operator. If the fresh concrete temperature falls below 50° F, the concrete production will be discontinued. Since a significant amount of aggregate can be stored indoors, the aggregate temperature will increase in storage. Therefore, after additional storage time, concrete production may be resumed once the combined temperature of the aggregates and cement exceeds 40° F. Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 12 of 21
  17. 17. © Copyright 2007 by Sam Lines Minimum Strength Requirements A. Stripping Strength The plant will need to provide the requirements for minimum strip strength for the products produced. The minimum strengths can be the same, or differ for the type of product, or lifting equipment. B. Shipping Strength The plant will need to document the required minimum shipping strength for the products produced. The minimum strengths can be the same, or differ for the type of product, or lifting equipment. Applicable standards should be consulted before determining this requirement. C. 28 Day Strength The plant will need to document the required minimum 28 day strength for the products produced. This can be the same or different for each type of product. Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 13 of 21
  18. 18. © Copyright 2007 by Sam Lines Product Tolerances Bugholes, chips, voids, and honeycombing 3/8" maximum depth Maximum size joint gap 3/8” Length, width, height, and diameter (inside): 0 to 5 ft +/- 1/4” 5 to 10 ft +/- 3/8” 10 and over +/- 1/2" Squareness (determined by inside diagonal dims.): 0 to 10 ft 1/2” 10 and over 3/4" Wall thickness +3/8”, -1/8” Top and bottom slab thickness +1/2”, -1/8” Standard Weight Concrete: Minimum cement content 564 lbs. Maximum w/cm ratio .45 Slump w/ water reducing admixture 4 1/2” min.,6 1/2” max. Spread (SCC only) 22” to 28” Air content 5%, + 2%, - 1% Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 14 of 21
  19. 19. © Copyright 2007 by Sam Lines Quality Control Records • Prepour Inspection Form • Post Pour Inspection Form • Final Inspection Form • Daily Plant Inspection Form • Concrete Testing Form • Concrete Mix Design Form • Vacuum Testing Form Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 15 of 21
  20. 20. © Copyright 2007 by Sam Lines Prepour Inspection Form Product or Job: ____________________________________ Inspection Date: Mon Tue Wed Thu Fri Sat Form Condition Form Cleanliness Form Joints Release Agent / Retarder Design Length (ft/in) Set Up Length (ft/in) Design Width (ft/in) Set Up Width (ft/in) Design Depth (ft/in) Set Up Depth (ft/in) Blockouts Squareness End and Edge Details Reinforcing Steel Reinforcing Size Reinforcing Spacing Reinforcing Rustification Cast-in Items Lifting Devices Comments:__________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ Inspector: ___________________________________________ Date: __________________ QC Supervisor: _______________________________________ Date: __________________ Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 16 of 21
  21. 21. © Copyright 2007 by Sam Lines Post Pour Inspection Form Product or Job: ____________________________________ Casting Date: Inspection Date: Mon Tue Wed Thu Fri Sat Stripping Strength (psi) Casting Finish Coating Finish (if applicable) Cast Length (ft/in) Cast Width (ft/in) Cast Depth (ft/in) Cracks or Spalls Squareness Honeycombing / Bugholes Bowing / Camber Exposed reinforcement Embedment Item Locations Openings and Blockouts Lifting Devices Markings Comments:__________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ Inspector: ___________________________________________ Date: __________________ QC Supervisor: _______________________________________ Date: __________________ Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 17 of 21
  22. 22. © Copyright 2007 by Sam Lines Final Inspection Form Final Inspection Date: ____________________________________ Product or Job: ____________________________________ Number of Units: ____________________________________ Casting / Unit Type: ____________________________________ Casting Pour Date: ____________________________________ ____ Post Pour Inspection Compete? Yes or No ____ Check product and compare it to the order ____ Check product markings for correct information ____ Check to make sure manufacture name or trademark is visible ____ Check for cracks, spalls, or damage ____ Check installed components ____ Check accessories and compare to the order ____ Make sure concrete strength exceeds minimum requirement for shipment Inspector: ___________________________________________ Date: __________________ QC Supervisor: _______________________________________ Date: __________________ Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 18 of 21
  23. 23. © Copyright 2007 by Sam Lines Daily Plant Inspection Form Monday  Check here if Holiday or Plant is Not in Operation Date: __________ Testing Performed By: _________________________________Slump: __________ Temperature: __________ Air Content: __________Yards of concrete produced on this day: _________ Housekeeping Inspection Performed By: _________________________________ Storage Area Inspection Performed By: _________________________________ Tuesday  Check here if Holiday or Plant is Not in Operation Date: __________ Testing Performed By: _________________________________Slump: __________ Temperature: __________ Air Content: __________Yards of concrete produced on this day: _________ Housekeeping Inspection Performed By: _________________________________ Storage Area Inspection Performed By: _________________________________ Wednesday  Check here if Holiday or Plant is Not in Operation Date: __________ Testing Performed By: _________________________________Slump: __________ Temperature: __________ Air Content: __________Yards of concrete produced on this day: _________ Housekeeping Inspection Performed By: _________________________________ Storage Area Inspection Performed By: _________________________________ Thursday  Check here if Holiday or Plant is Not in Operation Date: __________ Testing Performed By: _________________________________Slump: __________ Temperature: __________ Air Content: __________Yards of concrete produced on this day: _________ Housekeeping Inspection Performed By: _________________________________ Storage Area Inspection Performed By: _________________________________ Friday  Check here if Holiday or Plant is Not in Operation Date: __________ Testing Performed By: _________________________________Slump: __________ Temperature: __________ Air Content: __________Yards of concrete produced on this day: _________ Housekeeping Inspection Performed By: _________________________________ Storage Area Inspection Performed By: _________________________________ Saturday  Check here if Holiday or Plant is Not in Operation Date: __________ Testing Performed By: _________________________________Slump: __________ Temperature: __________ Air Content: __________Yards of concrete produced on this day: _________ Housekeeping Inspection Performed By: _________________________________ Storage Area Inspection Performed By: _________________________________ Weekly Tests: Unit Weight Tests: __________ __________ __________ __________ Cylinders Made On: __________ __________ __________ __________ Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 19 of 21
  24. 24. © Copyright 2007 by Sam Lines Concrete Testing Form Date of Pour: ________________ Mix Design/Formula Number: ________________ Batch Number: ________________ Specimen ID Number: ________________ Mix Proportions: Cement: ________________ Fly Ash - Class ____ : ________________ Slag / Other Pozzolans: ________________ Course Aggregate: ________________ Fine Aggregate: ________________ Water: ________________ Air Entraining Admixture: ________________ Water Reducing Admixture: ________________ Set Accelerating Admixture: ________________ Other: ________________: ________________ Test Results: Slump/Spread: ________ VSI: ________ Temperature: ________ Unit Weight: ________ Air Content: ________ Yield: ________ Stripping Cylinder Compressive Strength: ___________ psi @ _____ days. 7 Day Cylinder Compressive Strength: ____________ psi 7 Day Cylinder Compressive Strength: ____________ psi Average 7 day Compressive Strength: ____________ psi 28 Day Cylinder Compressive Strength: ____________ psi 28 Day Cylinder Compressive Strength: ____________ psi Average 28 day Compressive Strength: ____________ psi Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 20 of 21
  25. 25. © Copyright 2007 by Sam Lines Concrete Mix Design Form Formula Number: ______________ Plant: _______________ Formula Name: ____________________________________________________________ Design Compressive Strength: _________________ PSI @ 28 days Water-to-cement Ratio: __________ Design Air Content: __________ % Design Unit Weight, Batched: ___________ PCF Coarse Aggregate Ratio: __________ Cement (type ___ ): ________________ LBS. from __________________________________ Fly Ash: ________________ LBS. (Fly Ash % = _________ ) from ______________________ Water: _________________ LBS. ______________ GAL. Coarse Aggregate: _____________ LBS. (SSD) (Type: ______________________________ ) Sand: _______________ LBS. (SSD) (Type: _____________________________________ ) Air Entrainment Admixture: ___________ OZ. (Name: _______________________________ ) Water Reducing Admixture: __________ OZ (Name: ________________________________ ) Set Accelerating Admixture: __________ OZ (Name: ________________________________ ) Notes: ____________________________________________________________________ Mix Design Approval: _________________________________________________________ Production Manager Date _________________________________________________________ Quality Manager Date Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 21 of 21
  26. 26. © Copyright 2007 by Sam Lines Vacuum Testing Form Date Tested: __________________ Location of Test: __________________ Equipment/Product Tested: __________________ Product Serial # __________________ ____________________________________________________________________________ TEST SPECIFICATIONS Test Requested By: _________________________________ Test Performed By: _________________________________ Test Witnessed By: _________________________________ Description of Test: _________________________________ Product Tested To: _________________________________ Additional Comments: ______________________________________________ ______________________________________________ Hg reading: Start: _________” End: _________” Time: _____ Min. (Allow the tank to stabilize before beginning the timed test. Refer to the latest edition of ASTM C 1227 for requirements. For safety of testing personnel, do not exceed 7” Hg. A calibrated gauge with a scale of 0 to -10 inches of mercury (maximum) with a ±1% accuracy should be used.) Pass _________ Fail __________ Signature: _______________________________________________ Issue Date: <Month Date, Year> Volume 1: QUALITY CONTROL MANUAL Approved by: ___________________________________ Page 22 of 21
  27. 27. © Copyright 2007 by Sam Lines About the author Sam Lines has over 15 years of experience in the precast concrete industry. He has held positions in Engineering, Quality Assurance, Health and Safety, and Sales. While employed at a large precast concrete plant in Indiana, Sam was instrumental in leading a multi-facility operation to ISO 9001 Certification, as well as NPCA Plant Certification and certification by four State Departments of Transportation. Sam studied Industrial Engineering at Purdue University and holds a Bachelor of Science Degree in Management from Indiana Wesleyan University. He is an active member of the American Society of Testing and Materials (ASTM), and the National Precast Concrete Association (NPCA) where he participates in several committees. He is also a member of the American Concrete Institute (ACI), and the American Society for Quality (ASQ). Sam is employed by Concrete Sealants, Inc. in Tipp City, Ohio. Concrete Sealants manufactures and distributes products which are widely used in the precast concrete industry.

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