MATERIALS PROCEDURE Issue Date: October 2000 Subject Code ... · Approved List for precast products...

NEW YORK STATE DEPARTMENT OF TRANSPORTATION MATERIALS BUREAU

ALBANY, NY 12232-0861

MATERIALS PROCEDURE

Materials Procedure No . : 00-01 M

Issue Date: October 2000 Subject Code : 7.42-2

SUBJECT: PROCEDURES FOR ACHIEVING AND MAINTAINING MANUFACTURER'S APPROVED LIST STATUS

Supersedes : APPROVED:

Robert L. Sack, Director, Materials Bureau

PRECAST CONCRETE

N/A

TABLE OF CONTENTS PAGE 1 .0 SCOPE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 .1 DEFINITION OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 .2 MANUFACTURER REQUIREMENTS . . . . . . . . . . . . . . . . . 4

1 .2 .1 Quality Control Policies And Procedures . . . . . . . . . . 4 1 .2.2 Plant, Production, Audit And Training Requirements . . 4 1 .2.3 Quality Control Plan Requirements . . . . . . . . . . . . . . 5 1 .2.4 Required QC Records . . . . . . . . . . . . . . . . . . . . . . . 5 1 .2.5 Calibration and Certification of Test Equipment . . . . . . 5

1 .3 GENERAL METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1 .3 .1 Obtaining Approved List Status . . . . . . . . . . . . . . . . 6 1 .3 .2 Initial Start-up and Routine Inspection . . . . . . . . . . . . 6 1 .3 .3 Maintaining Approved List Status . . . . . . . . . . . . . . . 7

1 .4 MONITOR CORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1 .4.1 Monitoring Process . . . . . . . . . . . . . . . . . . . . . . . . 9 1 .4.2 Annual Monitor Core Acceptance Limits . . . . . . . . . . 9 1 .4.3 Annual Monitor Core Frequency . . . . . . . . . . . . . . . 9 1 .4.4 Routine Evaluation of Monitor Core Test Results . . . . . 9 1 .4.5 Annual Evaluation of Monitor Core Test Results . . . . . 10

1 .5 PLANT MONITORING OF FINISHED PRODUCT . . . . . . . . 11 1 .6 JOB SITE EVALUATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 .7 SHOP DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

APPENDIX A : Precast Concrete Quality Control Plan Requirements . . Al APPENDIX B : Testing Facilities and Concrete Sampling and Testing

Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bl APPENDIX C: Sample Records and Documentation . . . . . . . . . . . . . Cl APPENDIX D : Precast Concrete Repair and Fabrication Discrepancy

Acceptance Procedure . . . . . . . . . . . . . . . . . . . . . . D1 APPENDIX E: Listing Of Precast Concrete Product Groups . . . . . . . El

of 11 MP : 00-01 M Date : October 2000

1.0 SCOPE

This Materials Procedure establishes the process for obtaining Approved List status as a manufacturer/supplier of various Department specified "wet cast" precast concrete products . Precast concrete products produced through a "dry cast" or zero slump process are excluded from this procedure . A listing of precast product groups that are manufactured in accordance with this procedure is shown in Appendix E. This procedure represents a joint effort between the Precast Concrete Industry and the Department in developing a program which provides the industry the ability to independently control their production, provide timely delivery of products, while at the same time assure the Department quality . Only "wet cast" precast concrete products produced by an Approved List manufacturer/supplier will be accepted for Department use . The procedure requires :

NPCA, or PCI facility certification Trained and certified quality control personnel NYSDOT approved manufacturer's quality control plan (QCP) . NYSDOT approval of an automated and recorded on or off-site PCC batch plant NYSDOT facility periodic unannounced inspections Achieving and maintaining Approved List Status Annual evaluation of monitor core test results Evaluation and Approval of shop drawings

1 .1

DEFINITION OF TERMS

1 .

ACI, G1 - An inspector that is certified by the American Concrete Institute as a Certified Concrete Field Testing Technician - Grade 1 .

2 .

APPROVED LIST - Identifies manufacturers' meeting the requirements of this procedure and specific precast concrete product groups they are approved to manufacture .

3 .

BATCH - Component materials : cement, aggregates, water and admixtures weighed to a pre-determined recipe and mixed to create a homogeneous mixture with uniform material properties throughout .

4 .

INSPECTION AUTHORITY - An office designated by the Materials Bureau as responsible for inspection control on behalf of the Department at specific manufacturing locations .

5 .

MANUFACTURER/SUPPLIER - A company engaged in the manufacture and supply of precast concrete units.

6 . MATERIALS BUREAU - A facility of the New York State Department of Transportation which may be contacted by mailing to:

Director, Materials Bureau, Bldg . 7A, Rm . 200, M.C. 0861 NYS Department of Transportation 1220 Washington Ave., Albany, NY

12232 or

Telephone (518) 457-5956


7 .

NPCA - National Precast Concrete Association .

8 .

NYSDOT - The New York State Department of Transportation which may also be referenced as Department .

9 .

PCA - Portland Cement Association

10. PCC - Portland Cement Concrete

11 . PCI - Precast/Prestressed Concrete Institute

12 . PA - Plan Administrator . Manufacturer/supplier's individual in charge of the overall precast operation with binding legal authority for the company .

13 . PIECE - A precast section, which together with other pieces complete a unit .

14 . QAM - Quality Assurance Manager . The Materials Bureau individual in charge of this program . The QAM shall be ACI Grade 1 certified and either satisfactorily completed the NPCA training program, Fundamentals of Quality Concrete for Precasters, or similar program approved by the Director, Materials Bureau. The QAM may be contacted by phoning the Materials Bureau, Field Engineering I office at (518) 457-5956.

15 . OAT. Level 1 - Quality Assurance Technician, Level 1 . Individual representing the NYSDOT in conducting periodic plant inspections . The QAT, Level 1 shall be ACI Grade 1 certified and either satisfactorily completed the NPCA training program, Fundamentals of Quality Concrete for Precasters, or similar program approved by the Director, Materials Bureau.

16 . OAT. Level 2 - Quality Assurance Technician, Level 2. Individual representing the NYSDOT and assisting with plant and product inspections . The QAT, Level 2 shall be ACI Grade 1 certified .

17 . QCP - Quality Control Plan . A manufacturer/supplier written plan that addresses all Department specification requirements and defines formal procedures and processes to assure compliance to Department specifications .

18 . OCT . Level 1 - Quality Control Technician, Level 1 . Manufacturer/supplier's individual responsible for the quality control system . The QCT, Level 1 shall be ACI Grade 1 certified and either satisfactorily completed the NPCA training program, Fundamentals of Quality Concrete for Precasters, or similar program approved by the Director, Materials Bureau .

19 . OCT, Level 2 - Quality Control Technician, Level 2. Manufacturer/supplier's individual responsible for performing concrete production tests for the manufacturer . Must be ACI Grade 1 certified .

20 . SOP - Standard Operating Procedure . A procedure that describes what is actually done in each area of the organization . The QCP shall contain separate SOPS for each component of the production process .

21 . UNIT - A completed precast concrete structure .

of 11 MP: 00-01 M Date : October 2000

1 .2

MANUFACTURER REQUIREMENTS

1.2.1 Quality Control Policies and Procedures . The manufacturer must have NYSDOT pertinent specifications and procedures, and a NYSDOT approved Quality Control Plan (QCP) readily available to managerial and supervisory employees . The manufacturer must provide adequate training to familiarize all production employees with the company's Quality Control (QC) procedures as they relate to their specific responsibilities . A Quality Control Technician, Level 1(QCT, Level 1) must be present on every work shift manufacturing precast products for the Department and shall monitor the QCP procedures and have authority to stop production if necessary .

Commentary: The ultimate success in achieving a quality product is heavily dependent upon the company's and employee's commitment and the employee's understanding of the company's QC procedures . In order to successfully implement and enforce compliance with the company's QCpolicies, a QCT, Level I shall report to the Plan Administrator (PA), who has the authority and knowledge to oversee and manage the overall plant operations .

1 .2.2 Plant, Production, Audit, and Training Requirements . The manufacturer must satisfy the following plant, production, audit, and training requirements to be on the NYSDOT Approved List for precast products and produce precast products for the Department .

1 .

Continuously maintain NPCA or PCI (Group C1) plant certification . 2 .

Supply concrete from a NYSDOT approved PCC batch plant . Either a manufacturer's batch plant or off-site ready-mix batch plant shall meet and be approved for compliance to Department Standard Specification Section 501-2.03 and 501-3 .02 including the requirements for automation and recordation .

3 .

Maintain a current NYSDOT approved QCP with SOPS for various components of the production operation meeting the requirements described in 1 .2 .3 and content and format shown in Appendix A.

4.

Have a QCT, Level 1 on site for every Department work shift . The QCT, Level 1, when not directly involved, may delegate QCT, Level 2s for the pre-pour inspection, all concrete placements, post-pour and final inspections prior to shipment . The QCT, Level 1 shall have ready access to and be familiar with and understand the latest company QCP, Department specifications, standards, and procedures .

5 .

Fabricate all products to Department Standard Sheets, or approved working drawings . 6 .

PA meetings . The PA shall conduct meetings with the QCT, Level 1 and 2s, and other designated QC personnel, periodically to review the plant's performance as it relates to QC procedures, discuss possible changes and implement any procedural changes . All written QCP procedural changes require Department review and approval .

7 .

PA Audit . The PA shall conduct an annual audit of the plant's QC procedures of all production personnel to assure compliance with this program .

8 .

Submit to periodic unannounced plant inspections by Department representatives . 9 .

Address deficiencies noted in the QAT and QAM reports and conduct subsequent follow-up meetings to assure compliance . The Department must be notified in writing of the deficiency corrective actions .

See section 1 .3 .3 Maintaining Approved List Status .

10 . Provide to the Department's QAM bi-weekly copies of the Manufacturer's Production Worksheet, shown in Appendix C, when actively producing for the Department .


11 . Provide to the Department's QAM in the'first quarter of the calender year a letter certifying that the QCP and all referenced plant, personnel and certifications are up to date and current, or a letter transmitting and updating the QCP as appropriate .

12 . Training . Provide necessary training to designated QCT Level 1 and 2, and production personnel .

1 .2.3

Quality Control Plan Requirements . The precast concrete manufacturer shall provide a quality control plan that addresses all Department specification requirements and establishes Standard Operating Procedures (SOP) that define the work to be done in each area of the organization to guide and assure compliance to Department specifications .

The plan shall be used for the manufacture of all Department precast products produced by the firm . If specific portions of the QC plan are used for specific products it must be clearly noted as such in the plan .

Two completed copies of control plans and amendments must be submitted to the QAM, who will provide one of the copies for review and comment to the Regional Materials Engineer, when serving as the Department's inspection authority for the precast manufacturer . The plan shall be updated as needed . All updates require QAM approval .

An annual audit of the plan by the PA shall be conducted and documented during the first quarter of each calendar year ; the results of the audit shall be forwarded to the Department's QAM including suggested QCP corrective action revisions with implementation dates .

The plan should be formatted, and as a minimum address the level of detail identified in Appendix A .

1 .2.4 Required QC Records . The following records should be retained for a minimum of seven years at a Department approved location .

l .

Employee's current ACI, PCI, NPCA certifications, and QC training records . 2 .

Copies of the plant's QCP, NYSDOT's Specifications, Standards, and other written procedures on file and readily available .

3 .

Proof of current plant PCI, or NPCA certification . 4 .

Materials Bureau batch plant approval letter . 5 .

Concrete mix design BR-155s. 6 .

Daily production records including : component material certifications, recorded batch weights, concrete test results as identified in Appendix B, major repairs, and shipping records . These records shall be kept for all units/lots produced for Department projects . These records shall be maintained in a manner that provides easy cross references to each day's production . See Appendix C Manufacturer's Production Worksheet .

7 .

Calibration and certification of test equipment as described in 1 .2.5 . 8 .

QAM inspection report along with the letter to the Department's QAM signed by the PA, that details the plant's response and follow-up to each specified corrective action point documented in the QAM's inspection report .

1 .2.5

Calibration and Certification of Test Equipment. All testing equipment must be in good repair, calibrated and certified as specified in AASHTO, ASTM, and the NYSDOT Standard Specifications and Test Methods, and Appendix B of this document.


1 .

Maintain calibration records of compression test equipment, air meters, thermometers, scales, and other related test equipment.

2 .

Any broken or malfunctioning equipment must be removed from service immediately and replaced with new or repaired/recalibrated equipment .

3 .

If an outside lab is used for concrete compressive strength tests, gradations, and other related tests, it must be Department evaluated and approved .

1 .3

GENERAL METHOD

1.3 .1

Obtaining Approved List Status

1 .3 .1 .1

Submission Letter . Applicants shall submit to the Director, Materials Bureau, a letter requesting that their manufacturing facility be considered for Approved List addition . The letter shall include the following :

1 . List of precast product groups intended to be manufactured for the Department. See Appendix E for list of product groups .

2 .

Submit a QCP in accordance with the requirements shown in Appendix A of this document. The manufacturer should plan well in advance of their intended production for the Department, a period of 30 days in receiving either Department comments and/or approval of the QCP should be expected .

1.3 .1.2

Initial Facility Inspection . Upon satisfactorily complying with the above and approval of the QCP, the manufacturer will be scheduled, whenever possible within two weeks, for an initial facility inspection. A Materials Bureau representative, and regional representative or inspection authority representative will conduct this inspection to check the facility for conformance to the manufacturer's submitted QCP. Upon completion, the inspection team will recommend one of the following:

1 . Approval as an Approved List precast concrete manufacturer . Upon satisfactory compliance to all of the above including facility inspections the QAM will provide to the manufacturer/supplier a letter notifying them of their acceptance as an Approved List Precast Concrete Manufacturer/Supplier . The QAM letter will be provided within 10 working days of the completion of the initial facility inspection .

2 . Non-Compliance as an Approved List precast concrete manufacturer . The QAM will provide to the manufacturer's designated PA a written report detailing the reasons for non-compliance. The QAM's report will be provided within 10 working days of the completion of the initial facility inspection. The manufacturer, upon successfully addressing the reasons for noncompliance in writing to the QAM, may request another facility inspection.

1 .3.2

Initial Start-up and Routine Inspections

1 .3.2.1

Initial Start-up Notification . The manufacturer must notify the QAM of the initial production of each different precast product being manufactured for the Department under this program for the first time and any time there is a lapse of 1 year or more in the production of an item. The QAM shall be notified 14 days prior to the anticipated start of production and shall be notified again 48 hours prior to the start of production to confirm the exact starting date . This notification is to provide the Department the opportunity to inspect the initial production of


different precast products . The manufacturer is not required to hold up production, provided ample notification is given to the Department, to accommodate this initial Department inspection .

1 .3 .2.2

Initial Production Inspection. The initial production QA inspection is to provide more frequent inspection as a manufacturer first begins production for the Department or recommences production for the Department after a non-production period of one year or more . The Department may repeat the initial production inspection for each product manufactured for the first time .

The Department's QAT, Level 1 will visit the facility to observe this initial production and the manufacturer's inspection, sampling and testing, record keeping and filing and shipping procedures to verify compliance to the QCP.

Upon a satisfactory review, including acceptable monitor core test results as described in 1 .4.2, the manufacturer will be allowed to certify products without Department direct oversight in accordance with the Routine Inspection Program described in 1 .3 .2.3 . Failure in any one or more of the requirements of this program may result in a continuation of the Initial Production Inspection, or removal from the Approved List .

1 .3 .2.3

Routine Inspection Program. This is a level of Department inspection used to provide the Department assurance that a manufacturer's certified production is in compliance with their submitted QCP and Department specifications and standards. The QAT, Level 1 will make periodic unannounced plant inspections . To assure accurate, consistent, and unbiased inspections QAT, Level 1's will be trained and rotated to accommodate repeat inspections from differing QAT, Level 1's . The QAT, Level 1 inspector will check the plant, materials sampling and testing procedures and records for compliance to the QCP and Department specifications and standards . The QAT, Level 1 inspection will address and report on items identified in the QAT, Level 1's Inspection Report shown in Appendix C .

Upon completion of the inspection and records review the QAT, Level 1 will conduct an exit interview with the PA and other applicable company representatives to discuss the findings of the routine inspection . The QAT, Level 1 will prepare and forward a report to the Department's QAM. The QAM will in turn prepare a written report for the manufacturer .

1 .3 .3 Maintaining Approved List Status

1 .3.3.1

QAM Inspection Reports . Upon receipt of the QAT, Level 1's inspection report the QAM will prepare a written report for the manufacturer outlining any recommendations and any corrective action points to be addressed by the manufacturer . The report will identify one of the following :

1 .3 .3 .2

Continued Acceptance As An Approved List Manufacturer .

If corrective actions are identified in the QAM report, they must be addressed by the manufacturer within 10 business days .

1 .3 .3 .3

Accelerated Inspection Program. The accelerated inspection program is to provide increased Department oversight for manufacturer's who have failed to consistently meet the requirements of the QCP and/or Department specifications


and standards. Specific violations will be identified and communicated to the company in the QAM written report .

The manufacturer has 10 business days to respond in writing to address corrective action for each violation . Failure to respond within the required time frame may result in the manufacturer's removal from the Approved List .

The accelerated inspection program can continue for a period of not greater than one year. Manufacturer's who do not return to the routine inspection program within one year will be recommended for removal from the Approved List .

Inspection frequency while on the accelerated program may vary from daily to not less than one per month. The manufacturer will continue on the accelerated inspection program until they have satisfactorily corrected all of the identified violations . The manufacturer must request in writing to the Department to be returned to the routine inspection program.

1.3.3 .4

Removal From The Approved List . Serious fraudulent infractions, such as : falsifying records, deliberate shipment of non-compliant product, or not taking corrective action for violations documented during the Accelerated Inspection Program will constitute grounds for removal of the precast concrete manufacturer from the Approved List under all precast product groups .

Continued repetitive problems with the manufacture of a product or products in a specific precast product group, such as the inability to : consistently achieve an acceptable architectural finish, maintain unit dimensions within specified tolerances, fabricate products without defects or handle products without damaging them will constitute grounds for removal of the precast concrete manufacturer from the Approved List under that precast product group .

The manufacturer will be notified in writing of the anticipated removal from the Approved List along with the reasons . An invitation will be given to meet with the Department's Materials Bureau to review the issues and determine the appropriateness of removing the company from the Approved List . The Materials Bureau will determine which Department Divisions should be represented at the meeting. Following the meeting the Department's decision will be final .

If removed from the Approved List for a product group, the manufacturer, immediately upon notification, will no longer be allowed to manufacture products listed in that group under this program . The acceptability of existing stock is subject to a manufacturer's ability to supply evidence of acceptability that can be confirmed through Department evaluation . Completion of incomplete and commenced projects is subject to continuous Department inspection . Department inspection will be provided without compensation for a period of up to 3 months . All appropriate engineering and inspection expenses incurred by the State, its consultants and inspection agencies beyond 3 months shall be deducted from any monies due the Contractor for the Department inspected precast items . To avoid this monetary deduction, the contractor may elect to have a currently Approved List Manufacturer complete the work.

The manufacturer may not apply for reinstatement to the Approved List until modifications to address the reasons for their removal have been made, documented, and demonstrated to the satisfaction of the Department for a minimum period of one month. At this time the manufacturer will be allowed to begin the re-approval process .


1 .4 MONITOR CORES

1.4.1 Monitoring Process. The Department will monitor the manufacturer's production of Department precast items by obtaining cores from selected precast products and testing the cores to assure that compressive strengths and air contents meet specification requirements . This is accomplished by the Department's representative randomly selecting a day's production and units/pieces of various precast concrete items manufactured for the Department for coring . Cores will be taken from these units/pieces at locations determined by the manufacturer . The cores should be taken from the mid point of the unit/piece whenever possible . The Department representative will witness the coring by the manufacturer and ship the cores to the Materials Bureau for testing . The cores, unless otherwise approved by the Department, shall be 100 mm in diameter and of a depth between 100 mm and 200 mm, with 200 mm being desirable .

The Department routinely returns monitor core test results to the manufacturer to assist in their evaluation of Department production . The manufacturer, upon receipt, shall list this data on their production worksheet shown in Appendix C. If results fall outside the specification limits, it is recommended that the manufacturer review the production operations to head off additional failures that could jeopardize their Approved List status .

The Department reserves the right to take cores from specific locations within a unit/piece where the quality is suspect . These cores may result in unit/piece rejection, but will not be used in computations to verify compliance with the annual monitor core acceptance limits .

1 .4.2 Annual Monitor Core Acceptance Limits. The manufacturer must have a minimum of 70 % of their annual monitor cores achieve the specified compressive strength and have air test results within the specification limits of 5 .0% to 9 .0% . Additionally, a minimum of 90% of the annual monitor cores must have compressive strengths of at least 85% of the specified compressive strength and an air content range of 4 .0% to 10 .0% .

1 .4.3 Annual Monitor Core Frequency . Monitor cores will be taken annually at the following minimum frequencies : The manufacturer shall notify the Department's QAM or the representative Regional Materials Engineer, as these production frequencies are achieved, for the coordination of locating and submitting cores to the Materials Bureau for testing .

"

First 500 m3 : 1 set of cores per 50 m' of production .

"

500 m' through 1 500 m3 : 1 set of cores per 100 m3 of production .

"

Greater than 1 500 m3 : 1 set of cores per 500 m3 of production .

Specification non-compliance may result in increased coring frequencies at the manufacturer's discretion . Manufacturers may increase the frequency of monitor coring at any time with the QAM's approval . This is appropriate when the acceptance levels fall below the minimum requirements and the manufacturer takes corrective action and uses the additional cores to raise the percentage back into the acceptable limits .

1.4.4 Routine Evaluation Of Monitor Core Test Results . All monitor core results will be evaluated by the Departments QAM . The QAM will determine whether the results are acceptable, are in substantial compliance or are unacceptable . The following definitions and actions apply :


1 . Acceptable - Test results that meet the specification requirements for the item under test are considered acceptable . The manufacture will be notified of the acceptable results . No further action by the manufacturer is required .

2 . Substantial Compliance - Test results that do not meet the specification requirements for the item under test but are considered to be in substantial compliance. Test results that are in substantial compliance will not, by themselves, be cause for rejection of the piece/unit represented by the cores. Typically monitor core test results are considered in substantial compliance when the following is met:

"

The compressive strength is less than the specification requirement but greater than or equal to 85 % of the specification requirement .

The air content is less than the specification minimum but greater than or equal to 3.0% OR greater than the specified maximum provided the companion compressive strength core meets specification requirements .

The manufacturer will be notified of the substantial compliance test results .

Occasional substantial compliance test results will require no further action by the manufacturer . When the QAM determines a significant number of substantial compliance test results have occurred the manufacturer will be asked to identify what is being done to resolve the problem . The manufacturer has 10 working days to respond .

3 . Unacceptable - Test results that do not meet the specification requirements for the item under test and do not meet the requirements for substantial compliance identified above are considered unacceptable . For cores having less than 3 .0% air, a microscopic examination will be completed to confirm the low air . The piece represented by unacceptable test results will be rejected. When this occurs the manufacturer will be notified and additional cores, representing units/pieces produced before and after the units/pieces in question will be required . Coring will continue until acceptable test results are obtained . These additional cores will not be used in computing the annual monitor core percent within limits . If test results are acceptable, no additional cores will be required beyond the normal monitoring frequency . When the QAM determines a significant number of unacceptable test results have occurred the manufacturer will be asked to identify what is being done to resolve the problem . The manufacturer has 10 working days to respond .

1.4.5

Annual Evaluation of Monitor Core Test Results . At the end of each year the core test results for both high pressure air content and compressive strength will be compared to the specification requirements and the limits described in 1 .4.2 . Manufacturers on the Approved List must meet the criteria of 1 .4.2 each calendar year to maintain a favorable status on the Approved List . At the completion of the QAM's evaluation of the monitor core results the manufacturer will be notified in writing as follows :

1.4.5.1

Complies With Section 1 .4.2 . The manufacturer will be notified that their monitor core test results meet the criteria in section 1 .4.2 . Monitor core frequencies for the new calendar year start again as described in section 1 .4.3 .

1 .4.5 .2

Does Not Comply With Section 1.4.2. The manufacturer will be notified that their monitor core test results do not meet the criteria in section 1 .4.2 and their Approved List status is in jeopardy .

Monitor core frequencies for the new calendar year will be accelerated to achieve one set of cores per day for the first 15 days of Department production .


If the section 1 .4.2 criteria is not met with the first 15 sets of cores the manufacturer is removed from the Approved List under all precast product groups .

If the section 1 .4 .2 criteria is met with the first 15 sets of cores the manufacturer remains on the Approved List and the monitor core frequency reverts back to the criteria described in section 1 .4.3 for the remainder of the calendar year . If at the end of the calendar year the manufacturer's core results again do not meet the criteria in section 1 .4.2 the manufacturer is removed from the Approved List . If at the end of the calendar year the manufacturer's core results do meet the criteria in section 1 .4.2 the manufacturer will not be in further jeopardy unless subsequent annual results again fail to meet the criteria in section 1 .4 .2 .

1 .5

PLANT MONITORING OF FINISHED PRODUCT. The Department will monitor the quality of finished precast pieces at the precast plant . The intent of this monitoring is to provide occasional inspection of structurally critical items such as large box culverts, retaining walls, etc . The QAM will determine the frequency of monitoring based on the type and quantity of units being produced and past performance of the precaster .

Evaluations will be performed by a QAT, Level 1 or 2 and will include the use of instruments to verify reinforcing spacing and concrete cover. The QAT, Level 1 or 2 will conduct an exit interview with the PA and other applicable company representatives to discuss the findings of the inspection . The QAT, Level 1 or 2 will then prepare an inspection report and forward it to the QAM for review . The QAM will in turn prepare a written report to the manufacturer as described in section 1 .3 .3 .

1 .6

JOB SITE EVALUATION.

Precast units shipped to the job site will be subject to evaluation by the Engineer In Charge (EIC) .

The EIC is responsible for acceptance of materials delivered to the job site and has the authority to reject units that are damaged or mis-fabricated to the extent that they can not be satisfactorily repaired or incorporated into the work. Problems identified by the EIC will be reported to the QAM. The QAM will investigate reported problems and determine if corrective actions are required by the manufacturer to prevent further occurrences of the problem.

If corrective actions are required the QAM and the manufacturer will proceed as detailed in section 1 .3 .3 .

1 .7

SHOP DRAWINGS . The manufacturer is required to prepare and submit shop drawings for some Department non-standard sheet precast concrete items for Department approval . These drawings are to be done in accordance with Department written policy including review and approval by the Department . For those drawings requiring Director, Materials Bureau approval, a manufacturer may request approval to prepare certified shop drawings . Separate approvals are required for different products (ie . barrier, box culverts, noise barrier, etc.) . Approval to certify drawings requires :

"

A licensed and registered New York State Professional Engineer that has successfully completed Department training .

"

History of successful shop drawings submissions . A manufacturer must have a minimum of five consecutive drawing submissions meeting the Department's standards with minimal to no revisions required .

Pre-approved manufacturer's will be allowed to produce and certify shop drawings without Department approval . The Department will monitor the certified drawings for overall compliance . Non-compliant drawings could result in the loss of certification approval .

APPENDIX A

PRECAST CONCRETE QUALITY CONTROL PLAN REQUIREMENTS

PRECAST CONCRETE CONTROL PLAN REQUIREMENTS

This identifies the general topics, production aspects, and format for developing a Quality Control Plan .

Commentaries are provided throughout Appendix A to identify detailed requirements and direction in completing a Quality Control Plan .

As a minimum the plan should include the following specific details :

A.

Title Page B .

Individual Qualifications and Responsibilities C. Training D .

Facility Components E.

Manufacturing Products F.

Standard Operating Procedures (SOP) for: Fl .

Component Materials Acceptance F2.

Mix Design F3 .

Shop drawings F4.

Pre-Pour Inspection F5 .

Pour Inspection F6. Curing F7. Cold Weather Manufacturing Procedures F8.

Stripping forms and post-pour inspection F9.

Handling and Storage of Items 1`10 . Repairs Fll . Final Inspection F12 . Shipping and Certification F13 . Monitor Cores F14. Internal Review

G. Documentation

A .

Title Page

1 .

Title page . Include title and address of the company, and facility location including the Materials Bureau's approved facility number if approved .

2 .

Number every page (page # of #) and include two initial/date lines on the bottom of each page .

3 .

Signature page . Include the facility name and location and signature and date lines for the Plan Administrator and Director, Materials Bureau.

Commentary: Include a statement similar to the following :

"This control plan outlines the process control for the production of precast concrete. All work, including sampling and testing procedures will be performed in accordance with Section 704-03 PRECAST CONCRETE GENERAL, of the specifications, other applicable precast specifications, Materials Methods, Materials Procedures and any additional procedures included in this Control Plan . "

B .

Individual Qualifications and Responsibilities . Provide a detailed organizational outline of the positions responsible for maintaining the quality control program. This information must include at a minimum the following :

A 1 of 7

June 12, 2000

"

Define QC program organization, including the title structure and organization chart . "

What inspection points, SOPS, are required and who is responsible for these inspections .

"

Which positions are ACI certified, level 1 . "

Which positions have received NPCA Fundamentals of Quality Concrete for Precasters training .

"

Name and/or title authorized to terminate production at the plant . "

Name and/or title authorized to make changes in mix designs . "

Name and/or title authorized to accept/reject precast pieces. "

Name and/or title authorized to sign shipping certifications . "

Name and/or title responsible to communicate with the resident Department inspectors .

"

Name and/or title having final responsibility and authority over all NYSDOT quality control and manufacturing activities .

"

Define typical communication methods used to maintain control across the various aspects of the QCP, such as regular meetings, attendees, etc .

Identify the firm's two primary QC/QA contacts, in the desired order, with the Department by name, address, telephone, beeper, fax numbers .

Identify the typical number of production shifts, the normal starting and ending time of each . Whenever the firm is in production for more than one shift describe the QCT Level 1 and 2 coverage of each shift.

C .

Training . Identify operating procedures to verify an individual's qualifications to perform the various SOPS identified in the QCP .

D.

Facility Components . Provide a description of the facility, including the following :

1 .

Concrete manufacturing capabilities : a .

Batch size of each mixer . b.

Concrete batching automation/recordation description . c . The number and capacity of cement and pozzolan silos . d . The number and capacity of aggregate bins . e .

The number and location of aggregate storage areas and the method used to maintain the identity of the aggregates .

f.

The number and capacity of admixture dispensers . g . Document the following:

i .

NPCA or PCI plant certification . ii

Provide the Department's assigned facility number.

Commentary : Annual batch plant approvals are required but these do not require resubmitting an amended QCP.

2.

Identify calibration frequencies of plant equipment including : a . Cement scales . b . Aggregate scales . c . Water scales/meters d . Admixture dispensers. e . Automation checks .

Commentary: Calibrations shall be done in accordance with Materials Method 9.1 .

A 2 of 7

June 12, 2000

3 .

Size and description of production facility as it relates to indoor versus outdoor exposure .

4 .

Size and description of laboratory facility . Identify equipment and frequency of calibration (as appropriate) and conformance to specific Department and national standards (ASTM, AASHTO etc.) . See Appendix B for more detail on equipment .

E.

Manufacturing Products . Identify all products by group intended to be manufactured for the Department . See Appendix E for listing of product groups .

F.

Standard Operating Procedures. Standard Operating Procedures (SOP) define the work to be done in each area of the production to guide and assure compliance to Department specifications . The SOPs should be structured by answering "What is the work to be done in this process or operation?" "How will the work be done?" and "What is necessary for the work to be done effectively?" The answers provide a basis to prepare SOPs for the following areas :

Fl . Component Materials Acceptance. Prepare SOP for receiving, handling, and storing materials including receipt, evaluation, and filing of certification when required to assure the quality of each of the materials used in concrete manufacturing . Indicate the basis of acceptance required for each material such as appearance on the Department's Approved List, manufacturers certification, Department BR, etc . The individuals required to provide assurance of these materials shall be identified by either name or title . 1 .

Portland Cement. 2 .

Fine and Coarse Aggregates . 3 . Admixtures . 4 .

Fly Ash. 5 . Water . 6 .

Steel Reinforcement (coated and uncoated) . 7 .

Lifting Devices. 8 . Chairs . 9 .

Form Oil . 10 .

Manhole Steps . 11 .

Frames and Grates . (Frames properly marked with Department "D" number) . 12 .

Curing Compounds. 13 .

Curing Covers . 14 .

Other miscellaneous items (coloring additives, etc .) .

F2. Mix Design. Prepare SOP and identify responsible individuals, by name or title to assure proper selection of mix design(s) by product . The SOPS should address methods for changing cement brand and type, and admixture changes in brands, types, and dosages .

Commentary: Separate mix designs documented on NYSDOT BR-155s shall be used for differing aggregate sources, cement and admixture type changes. New BR-155s for brand or manufacturer changes in cement and admixtures are at the precaster's discretion. Details should be included to document the method used to verify the concrete properties subsequent to changing material sources of any component(s) in the mix.

A 3 of 7

June 12, 2000

1 . Identify component material sources and the proportions of each along with a specific mix identification number .

2 . Identify slump, air content range, and 28 day compressive strength requirements of each mix.

3 . Identify mix adjustment procedures, (ie . fineness modulus and moisture content) .

F3.

Shop drawings. Prepare SOP and identify responsible individuals by name and title, and/or outside firms used to assure shop drawings accurately represent the contract documents .

F4.

Pre-pour inspection. Prepare SOP and identify responsible individuals by name and/or title to assure the conformance of the following minimum typical pre-pour activities :

1 . Use of approved shop drawings . 2 . Reinforcing cage including : (evidence of acceptability, size and grade, cage

stability, configuration, and concrete cover) . 3 . Forms.

a . Form quality, joint tightness, cleanliness with form release agent properly applied .

b . Dimension compliance . 4 . Embedded items, ie . lifting devices, threaded inserts, mechanical connectors, etc .

are properly placed . 5 . Blockouts and keyways are properly placed .

Commentary: The critical nature of products identified in Appendix E varies greatly from those contained in Group 1 to those in Group 5. The level of detail contained in the documentation of pre pour inspections should reflect the critical nature of the item being produced. The documentation for a pre pour inspection on a box culvert should contain much more detail as to what was checked than the documentation for a pre-pour inspection on a right of way marker. Special attention should be given to things that can not be readily verified from an evaluation of the finished product such as : reinforcing steel size, splice lengths, embedment depths, epoxy coating etc.

F5 .

Pour inspection . Prepare SOP and identify responsible individuals by name and/or title to assure the conformance of the following typical pour activities :

1 . Identify method of assuring proper mix design, including component materials are selected and properly batched .

2 . Identify method of batching and mixing concrete . 3 . Identify method of transporting concrete including distance from mixer to test

area and to pour area . 4 . Identify methods of sampling and all plastic concrete tests to be performed by

product such as : air, slump, unit weight, cylinders, and concrete temperature along with specific controls and acceptance limits with specific action requirements if a test falls outside these limits .

5 .

Identify handling, storage, and curing of test specimens . 6 . Identify method of depositing concrete into forms, including lift heights . 7 . Identify method of consolidating concrete . 8 . Identify finishing unformed surfaces . 9 . Identify hot weather precautions .

A 4 of 7

June 12, 2000

Commentary: Air content testing is required on individual batches unless the manufacturer demonstrates uniform air as described in Appendix B, #1 . Air Content.

If a manufacturer elects to discharge multiple individual pre mixed batches into a haul vehicle he must first demonstrate that individual batches have uniform air content as described in Appendix B. Pre mixed multiple batches discharged into a transit mix truck will be considered as an individual batch provided sampling and testing methods approved by the Director, Materials Bureau meet the criteria for concrete uniformity specified in Section 501-3.03B. Concrete Uniformity of the Standard Specifications. This testing is to be done by the manufacturer and witnessed by the Department.

In this situation, the truck mixer must meet the requirements of 501-2.04B.1 . Truck Mixer Requirements . The truck mixing RPMs and revolutions used to achieve uniform concrete will become the standard mixing procedure .

Multiple dry batches weighed separately and discharged into a truck mixer for complete mixing are considered individual batches . In this situation, the truck mixer and mixing procedures must meet the requirements of Section 501-3.03D. Transit Mixed Concrete .

F6.

Curing. Prepare SOP's for each curing method to be used and identify responsible individuals by name and/or title who determine what curing method will be used and who assure conformance to the requirements of the selected method . SOP's should include the following :

1 . Describe the use of curing enclosures or tarps . 2 . Describe procedures for the maintenance and verification of curing temperatures

during the curing period . 3 . Describe procedures for the continuation of curing, when necessary, after form

removal .

Commentary: Effective curing should begin as soon as casting is complete. Specific curing requirements are contained in the Standard Specifications, Section 704-03 Precast Concrete - General.

F7.

Cold Weather Manufacturing Procedures. Identify the firm's ability to produce when the outdoor temperatures are below freezing . Examples include :

1 .

Identify ability to heat water, what volume can be heated and what controls are in place for verification .

2 . Detail storage provisions of aggregate and provisions to prevent or remove ice and/or snow.

3 . Detail the location of the concrete mixing, the concrete pour and the provisions made to assure and document satisfactory temperatures throughout the curing phase .

4.

Detail the provisions made to assure the temperature of the forms .

Commentary: Requirements for cold weather concreting can be found in the Standard Specifications, Sections 501-3.02 Handling, Measuring and Batching Materials and 704-03 Precast Concrete - General.

A 5 of 7

June 12, 2000

F8 .

Stripping forms and post-pour inspection .

Prepare SOP and identify responsible individuals by name and/or title to assure the forms are stripped properly, (ie . minimum number of hours and/or minimum strength requirements) and actions if damage or non compliance results . The SOP should address the following typical post-pour inspections :

1 . Determine that the curing was properly applied and completed . 2 . Determine that the piece dimensions are within specification tolerances . 3 . Threaded inserts, mechanical connectors, blockouts, and keyways are properly

sized and located . 4 .

Finish is acceptable . 5 . Damage is documented and properly repaired . 6 . Lifting devices, frames, grates, manhole steps, etc . are of proper size, type and

location. 7 . Piece has proper identification markings . 8 . Cylinders are properly numbered and located with piece to simulate piece curing .

Commentary: The post pour inspection shall be completed in a timely manner to accommodate timely repairs and to avoid contract delays .

F9. Handling and storage . Prepare SOP and identify responsible individuals by name and/or title to assure pieces are properly handled and stored . Include the following :

1 .

Identify the method of determining when units can be lifted and moved, (cylinder breaks, etc .) .

2 .

Describe stacking procedures, use of dunnage, etc .

Commentary: A manufacturer may inventory products in a single stockpile that are manufactured for multiple Department projects including commercial or municipal projects provided all are manufactured to the same QCP and specifications . If specific portions of the QCP or specifications are not followed, then separate stockpiles are required .

F10 . Repairs . Prepare SOP and identify responsible individuals by name and/or title to assure repairs are properly documented and completed .

Commentary: Major repairs and non-compliant pieces shall either be rejected or considered for repair and acceptance in accordance with Appendix D.

F11. Final Inspection. Prepare SOP and identify responsible individuals by name and/or title to assure the final product is in total compliance to Department specifications and standards . The final inspection must address the following as a minimum:

1 . Cylinder results meet specified strength . 2 . Damage, if any, has been documented and properly repaired . 3 . Identification markings are permanent, complete and properly located .

Commentary: The final inspection shall be done at the time of loading and shipping to the project .

F12. Shipping and Certification . Prepare SOP and identify responsible individuals by name and/or title responsible for completing certification and authorizing shipment .

A 6 of 7

June 12, 2000

F13. Monitor Cores. Prepare SOP and identify responsible individuals by name and/or title to assure cores are properly selected and obtained .

F14. Internal Review.

Prepare SOP including frequency of reviews and identify responsible individuals by name and/or title to verify the firm's conformance to their QCP.

G.

Documentation . The quality control procedures throughout the manufacture and supply require documentation . This may be documentation that records an evaluation made, such as form evaluation, reinforcement placement, curing temperature, etc . It may also be documentation to provide the manufacturer assurance of the quality of a component of the finished product such as portland cement, aggregates, admixtures, reinforcement etc .

Commentary: It is imperative that the QC procedure includes who documents, where the information is recorded and filed, the detail to be included ft. specific dimensions recorded vs. the notation "OK"), who uses the recorded information and when the recorded documents are used . Copies of all documentation forms shall be submitted with the QC plan .

A 7 of 7

June 12, 2000

APPENDIX B

TESTING FACILITIES

AND

CONCRETE SAMPLING AND TESTING FREQUENCIES

Testing facilities shall consist of either of the following and the testing methods be done in accordance with NYSDOT Materials Method 9 .1 and 9 .2 unless modified herein:

1 .

An outside testing agency, approved by the Materials Bureau. or

2 .

In-house facility with testing equipment and methods approved by the Materials Bureau as follows :

a .

Sample splitter . The aggregate sample splitter shall be capable of splitting samples having a maximum particle size of 13 mm to 50 ruin .

b.

Large Scale. The scale shall have a minimum capacity of 14 kg with a maximum graduation of 0.005 kg .

c .

Small Scale . The scale shall have a minimum capacity of 1500 g with a maximum graduation of 0.1 g.

d .

Sample Drying Appliance . The appliance shall be either a stove or hot plate of sufficient size for rapidly drying aggregate samples .

e .

Coarse Aggregate Sieve Shaker . A power driven sieve shaker anchored to a firm base with a minimum clear sieve area of 0.21 m2 . The shaker shall impart a vertical, or lateral and vertical motion and be equipped with an automatic timing shut-off device and dust cover . When the shaker is located outside, it must be fully enclosed and weatherproof.

f.

Fine Aggregate Sieve Shaker .

A power driven sieve shaker independent of the coarse aggregate shaker, for 200 mm minimum diameter sieves . The shaker shall impart a vertical, or lateral and vertical motion and be equipped with an automatic timing shut-off device .

The shaker must be fully enclosed and weatherproof if operated outside an enclosed testing facility .

g .

Slump cone. (MM 9 .2) h.

Pressure air meter for determining air content of fresh concrete, calibrated weekly (ASTM C 231 & MM 9.2)

i .

Compression testing machine calibrated at least once a year . (ASTM E-4 & ASTM C-39)

j .

Cylinder molds in accordance with ASTM C 470 and prepared in accordance with MM 9 .2.

k .

Sulphur mortar and capping jig for compression specimens . (ASTM C-617) 1 .

Neoprene caps and extrusion rings ( NY Test Methods 301B-82 and 501-16P) m.

Shore "A" durometer for testing neoprene cap hardness . (ASTM D2240) n.

Thermometers/Temperature recorders . o .

Other Miscellaneous test equipment .

The required tests and frequencies are as follows per mix design :

l .

Air Content : To be determined on every batch . A reduced testing frequency of 1 per 5 batches with a minimum of 1 per day is allowed if a manufacturer's air test variation for five consecutive batches produced for Department work is less than f 1 .0% each side of a manufacturer's predetermined target, identified on the BR-155, between 6.0% and 8 .0% . When operating in the reduced testing frequency, an individual test outside the ±1 .0% range reverts the manufacturer back to testing every batch. To regain the reduced testing frequency, an additional five consecutive tests need to be within the 1 .0% range .

2 .

Slump : As defined in the QCP . 3 .

Unit weight : As defined in the QCP . 4 .

Cylinders for compression test : Minimum of 1 pair per 10 batches of a single mix and a minimum of 1 pair per day per mix. Additional pairs, per selected batch, are recommended to verify strength at a later date, if specified strength is not initially

B 1 of 2

June 12, 2000

achieved . 5 .

Gradation (coarse and fine aggregate) in accordance with MM 9 .1 including determination of fineness modulus : Minimum of 1 test per 300 m3 of combined concrete production including different mix designs, commercial, and Department production with a minimum test frequency of 1 test per day. A reduced testing frequency is allowed, subject to the approval of the QAM, up to once per week, when results are consistently at the mid range of the specification limits .

6 .

Coarse Aggregate Cleanness Test (MM 9 .1) . Conduct a coarse aggregate cleanness test any time a coarse aggregate appears dirty or if a coarse aggregate is within 0.2% of the maximum specification limit on the minus 751im material as determined in the coarse aggregate gradation test .

7 .

Aggregate Visual Identification Test (MM9.1) . To be determined in conjunction with the coarse and fine aggregate gradation test .

S .

Aggregate Moisture Content Determination . Fine Aggregate Moisture Content to be determined with the gradation test, or more frequently if visible signs indicate that aggregate moisture contents are variable . This would include a change in aggregate processing, after rainstorms, etc .

B 2 of 2

June 12, 2000

APPENDIX C

SAMPLE RECORDS AND DOCUMENTATION

"

Daily Production Work Sheet

Sample Precast Product Certification

QAT Inspection Report

SAMPLE

1 .

Identification of the Producer . Name of company and the address of its manufacturing facility . This can be letterhead .

2 .

Identification of the Material . Name of Item :

i.e . 706-04 Precast Concrete Drainage Units .

3 .

Identification of Shipment

CERTIFICATION

A .

Number of units & identity of individual pieces including : 1 .

Pay Item Number 2 .

Description of Item, i.e . (catch basin, drop inlet, etc .) . 3 .

Dates of manufacture & specific identification of individual pieces.

B .

DOT Contract Number

C.

Date of Shipment

4 .

Statement of Conformance. A definitive statement that the units contained in the shipment meet the requirements of the Department Specification under which it is to be used and that the materials used in the manufacture of the units meet the requirements of the Specifications .

5 .

Identification of Person Executing the Certification . The certification must be signed by a person, identified as being connected with the company, indicated by a statement or title of their position in the company . It is not necessary that such a signature be notarized . This person must inspect and approve all units being shipped .

6 .

A statement as to domesticity (or non-domesticity) of the steel and/or iron . Either :

Domestic - conforms to Standard Specification Section 110-10 and/or 110-11 . or :

Foreign - does not conform to Standard Specification Section 110-10 and/or 110-11 .

Note: A company's bill of lading modified to address the above would be an acceptable form of certification .

C 1 of 4

June 12, 2000

MANUFACTURER'S DOT PRODUCTION DAILY WORK SHEET

C 2 of 4

June 12, 2000

Ticket N Mix

Calender Item# Plastic Specified

Cylinder results Monitor Cores Date Invoice Piece I .D . or

Batch# I.D . Year

Cum. m' -

Description Air % Strength

Cyl. I Cyl. 2 Avg. Date of break H.P .A . Strength Date of Break of

shipment Contract No .

or Cert No.

QAT, LEVEL 1 INSPECTION REPORT Manufacturer's Location :

Inspector's Name : Date of inspection :

/

/-

C 3 of 4

June 12, 2000

Inspection Features to be compared to the approved QCP:

" Verify that the plant has a copy of NYSDOT's "Standard Specifications and Procedures" and an approved QCP on file and readily available .

" Evaluate methods of receiving, handling, storage, and sampling and testing of materials used in production including :

" Cement " Fine aggregate " Coarse aggregate " Lightweight aggregate " Admixtures " Reinforcement " Miscellaneous (lifting devices, studs, reinforcement chairs, etc.)

" Review concrete mix(s) used, method of identification, mix proportioning, admixtures, compressive strength, etc .

" Verify that the batch plant is Department approved . Evaluate hatching and mixing operations including : scale calibrations, automation, programed batching tolerances, mixing cycle, interlocks, and recordation .

" Evaluate quality of forms, including cleanliness, use of release agents, tightness, stability .

" Evaluate position of reinforcement and compliance to shop drawings .

" Evaluate concrete delivery, sampling, and testing .

" Evaluate methods of depositing concrete into forms, lift heights, consolidation methods, and finishing of exposed surfaces .

" Review hot weather and cold weather precautions

" Evaluate form stripping

" Evaluate concrete curing

" Evaluate concrete repair procedures and quality of completed repairs

" Evaluate storage and shipment of products

Note: Provide comments for strengths and weaknesses in each of the inspection features identified above .

C 4 of 4

June 12, 2000

" Review material and product record keeping including : " Raw material certifications " Working drawings " Concrete batching records " Aggregate test records (gradations, moisture content, cleanliness, etc.) " Concrete test reports (daily worksheets) " Product evaluations (pre-pour, post-pour, repair, final inspection reports)

" Test equipment calibration and certification records . Inspect testing equipment for damage and ensure all equipment is in good repair . If outside lab is used verify that it is Department approved .

" Interview the person(s) responsible for QC policies and procedures .

" Verify the QCT, Level 1 lines of authority .

" Determine the distribution of the QCP and its availability to employees .

" Review the distribution of QC training records .

APPENDIX D

PRECAST CONCRETE REPAIR

AND

FABRICATION DISCREPANCY

ACCEPTANCE PROCEDURE

A. DEFECT CATEGORIES AND REPAIR APPROVAL PROCESS

In the fabrication and handling of units occasionally a piece will be damaged or mis fabricated in some way which causes it to deviate from the specification or approved working drawing. When damage, defects or discrepancies are identified through post pour or final inspections the manufacturer must do the following :

Determine how the defect occurred . Decide whether corrective actions or changes in procedure are necessary to prevent reoccurrence . Changes in procedure must be documented by a revision of the QCP . Decide what category the defect falls into . Carry out the necessary actions to make the unit acceptable to the Department or re-fabricate the unit .

The following are typical defect categories and the necessary manufacturer's actions :

1 . Surface Defects - Surface defects are defined in 704-03 .

Surface defects which are not excessive do not require repair . When they are excessive and visible to view as defined in 704-03, 4. Non Repairable Defects the piece is unacceptable .

,

2. Minor Defects - Minor defects are defined in 704-03 . The manufacturer must repair minor defects in accordance with 704-03. Department involvement is not necessary .

Commentary. Minor defects should be repaired as soon as possible after being identified . Curing compound acts as a bond breaker and must be removed from any concrete surface that is to have repair material bonded to it .

3 . Major Defects - Major defects are defined in 704-03 . The repair of major defects requires Department approval . The manufacturer must prepare a "Precast Concrete Damage And Discrepancy Repair Request" each time a repair is requested . This form is on page D 3 of 3 . A complete description of the problem, the cause, and the proposed repair must be included . Detailed sketches showing dimensions for all defects and discrepancies should be attached on a separate sheet of paper. All unsound concrete must be removed from damaged areas before making sketches . The manufacturer must take photos of the damaged area after all unsound concrete has been removed and the area pre ared for re air and again after the repair is complete . Photos are to be retained with the approvedp"Precast Concrete Damage And Discrepancy Repair Request" form.

All spalls and honeycombed areas that are major defects should be repaired in accordance with section B . Concrete Repair Procedure For Precast Concrete Products on page D 2 of 3 . This can be requested by checking the appropriate box on the repair request form. Any modifications to this procedure, such as the use of anchor pins, must be clearly detailed . The repair request form with all attachments is mailed or faxed to the Materials Engineer in the project region.

The Materials Engineer in the project region reviews the request and checks the appropriate box indicating their approval or disapproval of the request . Reasons for not approving a request should be noted . Questions by the Materials Engineer regarding specific requests should be directed to the Materials Bureau Field Engineering I office . This can be done with a phone call (518-457-5956) or by faxing (518-457-8171) a copy of the request .

When the evaluation is complete the Materials Engineer signs and dates the request and returns one copy to the manufacturer .

The manufacturer takes photos and proceeds with repairs as necessary in accordance with the approved repair request . When repairs are not approved the unit must be re-fabricated . A copy of each completed repair request and photos must be maintained as part of the required QC records .

D 1 of 3

June 12, 2000

4. Non Repairable Defects - Non re airable defects are defined in 704-03 . Units with non repairable defects must be re-fabricate

5. Fabrication Discrepancies - The acceptance of units with fabrication discrepancies requires Department approval . Fabrication discrepancies include such things as out of tolerance dimensions, missing or miss located embedded items, improper curing, etc . The manufacturer must prepare a "Precast Concrete Damage And Discrepancy Repair Request" each time a repair or approval to accept-as-is is requested. The procedure described under 3) Major Defects above for preparing, processing and maintaining records of requests shall apply .

B. CONCRETE REPAIR PROCEDURE FOR PRECAST CONCRETE PRODUCTS

The following repair procedure is approved for use on precast concrete products . It shall be used to make concrete repairs which go beyond the scope of the specification . All such repairs require prior approval from the Materials Engineer in the project region .

1 .

All unsound concrete must be removed from the specified area down to sound concrete . All edges of the repair area shall be square cut a minimum of 10mm deep into the concrete to prevent feather edging of the repair material . The surface area shall be roughened to ensure a proper bond.

Please be advised that all exposed steel reinforcement must have all concrete removed from around it up to a distance of 25mm from the reinforcement before preceding any further .

2 .

The area to be repaired must be cleaned with water and surface dried .

3 .

A bonding agent must be applied to the area to be repaired in accordance with the manufacturer's instructions . This material must conform to our Specification 721-03, Epoxy Polysulfide Grout, and must have been sampled, tested, and accepted by the Materials Bureau.

The evidence of acceptability of this material consists of red and green tape seals, indicating the material has been sampled and accepted by the Department, affixed to the flaps of the carton that the material is supped in .

4 .

The area must be repaired with an approved Concrete Repair Material conforming to the requirements of 701-04, whose name appears on the Department's Approved List . The repair material shall be cured in accordance with the manufacturer's instructions . All repairs shall be done in an environment where the temperature will be above 10°C.

5 .

Finally, the finished repair must be sounded by applying a moderate blow to the repair area with a 450g hammer. To be acceptable, the finished repair must withstand the blow without any damage occurring and produce a sharp ring when struck indicating proper bonding of the repair .

6 .

In addition, all repairs which will be exposed to view after installation of the precast unit must be uniform in appearance . Repairs which are not similar in color and texture to the rest of the unit shall be cause for rejection .

D 2 of 3

June 12, 2000

PRECAST CONCRETE DAMAGE AND DISCREPANCY REPAIR REQUEST

Precast Manufacturer:, Contact Person Contract No: Approved Drawing No: Unit Identification (mark no./lot no./date of manu£) :

Materials Engineer (signature and date):

(completed by precast manufacturer)

Phone No: Region :

Precast Item: - Date Approved:

Date : Fax No :

Description Of Damage Or Discrepancy, The Cause And Proposed Repair (Include a sketch showing the location and dimensions of the defect, and all exposed reinforcing steel . All unsound concrete must be removed before dimensions are taken . Attach an additional sheet(s) for the sketch.) :

Request To Make Repairs In Accordance With The "Concrete Repair Procedure For Precast Concrete Products" Precast Manufacturer (signature and date) :

(completed by Materials Engineer)

Materials Engineer Approval And Comments (indicate acceptability of proposed repair and any comments on the procedure or instructions for verification of the repair by the manufacturer.) :

Repair Approved As Requested Repair Approved With Comments

O Repair Not Approved El Repair In Accordance With The "Concrete Repair Procedure For Precast Concrete Products" Comments :

D 3 of 3

June 12, 2000

APPENDIX E

LISTING OF PRECAST CONCRETE PRODUCT GROUPS

PRECAST PRODUCTS TO BE MANUFACTURED BY APPROVED LIST PRECASTERS

Precast products referencing Material Specification 704-03 PRECAST CONCRETE-GENERAL are to be manufactured in accordance with these procedures . Only Approved List Precast Manufacturers are allowed to manufacture precast products and only for those groups they are listed for in the Approved List .

Approved List precast product groups include :

El of 1

June 12, 2000

GROUP I GROUP2 GROUP3 GROUP4 GROUPS GROUP6

Box Culvert Drainage Units Median Banner Curb Drainage Outlet Architectural Headwalls Finishes (colored

concrete, fonn liner, Pull Boxes Retaining Wall Coping Right Of Way exposed aggregate,

Markers etc .)

Wet cast pipe Noise Wall Light Pole Bases

Guide Rail Anchor Blocks

Pipe End Sections

Miscellaneous precast products which reference 704-03 but are not listed above will be grouped by the Materials Bureau on a case by case basis .

MATERIALS PROCEDURE Issue Date: October 2000 Subject Code ... · Approved List for precast products...

Documents

Transcript of MATERIALS PROCEDURE Issue Date: October 2000 Subject Code ... · Approved List for precast products...