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Qcast and How it

Benefits Your Plant


Matt Childs, PE
American Concrete Pipe Association
Randy Wahlen, PE
Oldcastle Precast
www.concrete-pipe.org

www.concrete-pipe.org

QCast and How it Can


Benefit Your Plant,
Company, Industry,
Products, People, and
Customers

www.concrete-pipe.org

What is Qcast?
Audit and Certification
Demonstrates at Time of Audit
Plant is in compliance with ACPA
Guidelines

Operations and Procedures are in


place to facilitate continued
compliance
www.concrete-pipe.org

The goal of the QCast Program


Assist you in making the best products
possible

All the time.

www.concrete-pipe.org

What Products are Covered by


Qcast?

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What Products are Covered by QCast?

Pipe
Box Culverts / 3 Sided Structures
Manholes
Engineered Precast

100+ plants are QCast Certified


www.concrete-pipe.org

www.concrete-pipe.org

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Certifications by Category

10

Participants Totals
200
180
160
140

SANITARY
MANHOLES
MANHOLES
SANITARY

120
100
80
60

STORM
PRECAST
BOX CULVERT

40
20
0

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

10

Total Audits Since


Inception
SANITARY

900
828

STORM

800

BOX CULVERT

700

PRECAST

600

MANHOLES

500

438

SANITARY
MANHOLES

400

300

200

136

182
167

100
23
0

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12

Why Join Qcast?


Betterment of the Industry

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A rising tide lifts all boats

14

Consistency
The name of the game in the
concrete industry

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Consistency

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Consistency
QCast will help you monitor your
products and procedures

Materials
Equipment
Procedures
Records
Final product

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Other Benefits?

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18

Tap into industry


knowledge
The Manufacturing Committee
Federal, State, Customer, and
Manufacturers have all had input

www.concrete-pipe.org

19

Recognition/Marketing
Government
Industry and Peers
Customer

www.concrete-pipe.org

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How can Qcast Benefit Your


Company?
22

Standardize QC
Share the workload
Reduce confusion between plants
Simplify Reports to Management
Reputation
Reduce 2nds
Help you to catch potential issues
Customer Satisfaction
Customizable to your plant

www.concrete-pipe.org

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Company/Plant Manual
QCast made to fit your company
Industry defined but company
and plant specific!

www.concrete-pipe.org

24

Industry Reputation
Consistency company to company
Rejects are the same to
everyone
Only the good stuff gets out
Contractors know what to expect
Concrete in Demand
www.concrete-pipe.org

25

Industry specific
The program was built
specifically for the concrete
products industry
Program designed by industry
leaders
QCast built around all stages of
production
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26

How Can QCast Benefit


Your Product?

Equipment Calibrations
Material Certifications
Test Documentation
Product and setup prepour
Curing, handling, storage, repair
Final postpour inspection
Records

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How Can QCast Benefit


Your People
Training
Direction
Pride

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28

What is the QCast Process?


Complete application/contract with
ACPA
Pay the initial fees

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29

ACPA QCast Annual Fees


ACPA Member
Single Certification - $4,300
Three Category Certification $5,400

Non-Member
Single Certification - $8,600
Three Category Certification $10,800

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30

How Long Does it Take to


Become Certified?
Apply for Qcast
An Audit is Scheduled (1 to 3
months)
Start with the ACPA QCast Manual
Update your Plant QC Manual
Update your Filing System
Manage your Documentation
Update your Processes
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Documentation
Records! Records! Records!
Records show compliance
Refer to QCast Manual
Need two months

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32

How Often Are Inspections


Performed?
There is an unannounced Annual
Inspection to renew the certification
once the initial audit is made.

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33

Who Performs the Inspections?


An independent engineering firm
performs the audit
In the United States, Wiss Janney
Elstner is the auditor

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34

What is Required to Pass an


Inspection?

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What Should a Plant Expect


During an Inspection?
Audit starts first thing in the morning
Appoint a plant representative to
assist the auditor
Auditor will review:
Normal Operations
Quality Control Testing
Quality Control Documentation

Auditor will provide immediate


feedback
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Audit Day
Your going to be busy
Review documentation
Demonstrate knowledge
Set up and perform required tests

Remember, the program cannot


fall apart because your tied up
with the auditor.
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37

You do Not Have to do it


Alone
You have support!
Network

ACPA offers a Certification


School
Training in many different aspects
Prepares you for QCast
Meets program requirements
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What Topics are Covered?

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39

ACPA QCast Manual


Certification Bylaws
Section I Common Program
Requirements
Section II Concrete Pipe
Section III Manhole
Section IV Precast Products
Section V Box Culvert and Threesided Structures
Appendix A: Procedures and Sample
forms
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ACPA QCAST MANUAL


PROGRAM REQUIREMENTS
1.0 Quality Control Documents
2.0 Raw Materials
3.0 Calibration
4.0 Mix Designs
5.0 Joint Design Drawings and Testing
6.0 Forms and Joint Forming Equipment
7.0 Reinforcing
8.0 Pre-Pour Inspection
9.0 Concrete Testing
10.0 Curing
11.0 Post-Pour Inspection and Repairs
12.0 Product Marking
13.0 Product Testing
14.0 Storage, Handling, Shipping and Final
Inspection

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What is The Best Way to Prepare


for Inspection and to Become
Certified?

www.concrete-pipe.org

42

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43

What is you have more than one


Plant?
Purpose is to insure quality at each
plant
If a company has more than one
plant, each plant must apply for
certification and receive a separate
inspection

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44

How Difficult is it to Pass an


Inspection?
If you have a QC program, you are
already are doing many things that
will help you.
You may have to adjust the
frequency of testing or commitment
to documentation

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45

What is the Best Indicator that a


Plant will likely pass and
inspection?
Managements commitment to quality
is a necessity
Without this commitment, most QC
programs will likely fail

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46

Is it Cost Effective to be
Certified?
Experience tells us that ACPA QCast
pays for itself through:

Increased efficiency
Reduction of defective products
Reduction of field repairs
Increased sales through customer
satisfaction

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Once Certified
Manufacturer Shall:
Maintain the high standard of QCast.
Maintain product and material performance
documentation
Supply only certified products from a certified
plant to jobs requiring ACPA certified products

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Certification process can


seem overwhelming.

Break the program down into


many smaller parts.

1.5 Q.C. Organizational


Chart
1.4 Documentation of
Special Projects
1.3 ASTM Standards
1.2 ACPA Concrete
Pipe, Manhole and
Precast Product
1.1 Plant Quality
Control Manual

Documentation
Filing System

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Documentation files - previous 3


years plus year-to-date.
For new applicants, a minimum of
two months of documentation.
.

1.1 PLANT QUALITY


CONTROL MANUAL

What goes in here?


Plants/Company Quality Control Manual
Where do I get it?
Plant/Company Quality Control Director
What do I do with it?
Evaluate program to make sure it meets or
exceeds all ACPA requirements.

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1.2 ACPA QCAST


CERTIFICATION
MANUAL
What goes in here?
Current version of ACPA Concrete Pipe, Manhole and
Precast Products Plant Certification Manual

Where do I get it?


American Concrete Pipe Association
www.concretepipe.org

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1.3 CURRENT
APPLICABLE ASTM
STANDARDS

What goes in here?


ASTM Standards. A list of required standards can be found
in ACPA QCAST manual.

Where do I get them?


A book containing all required ASTM
Standards on concrete pipe may be
purchased from the ACPA. All other
recommended ASTM Standards may be
purchased from ASTM. (www.astm.org)

53

1.4
DOCUMENTATION OF
SPECIAL PROJECTS

What goes in here?


Any special projects specifications that exceed minimum
ACPA requirements or have different test methods or
criteria.
Note: if no special projects exist, it may be of value to
insert a sheet of paper dated to the current year that says
No special project specifications for the 20XX year-todate.

Where do I get it?


From your Project Specifications.

54

1.5 Q.C.
ORGANIZATIONAL
CHART
What goes in here?
Completed Q.C. Organizational Chart
Where can I get it?
From ACPA Certification Manual, Appendix A
Meet with key personnel involved with production,
quality and the Certification Program to delegate
responsibilities and fill in Chart.

Update annually and whenever changes in staff


responsibilities occur.

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1.6 QUALITY
AUTHORITY/HOLD
PRODUCTION
POLICY

What goes in here?


Authority of personnel to correct and/stop production
when quality issues arise and to reject products not
meeting requirements.

Where do I get it?


Plant/company quality director and approved by the
company president.
Once policy is written it should be shared with the
entire plant.

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1.7 Q.C.
PERSONNEL
TRAINING
RECORDS

What goes in here?


ACI, DOT or other quality training certifications.
In-house quality meeting minutes.

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2.0
MATERIALS
What goes in here and where do I get it?
Files should be kept containing the following materials
certifications:
Cement Cement mill certs should be received from the cement
company once/mo. for each type of cement being used.
Aggregate A Certificate of Compliance (ASTM C33) should be
received once/yr. for each material from your aggregate supplier.
Aggregate Gradations Plant should have gradations for each
aggregate quarterly as per Pipe, Manhole and Precast Products
Certifications and monthly for Box Certification.
Fly Ash A test report should be supplied by the supplier once
per month.
Other Cementitious Material A certification should be supplied
by the supplier once/mo.

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2.0 MATERIALS
(Cont)

Additives Cert. should be supplied by the additive


supplier once/yr. for each material.
Reinforcing Mill certs should be supplied by the
supplier once/mo. for each type of product.
Gasket Material Certification should be supplied by the
manufacturer once per year for each type of gasket.
Joint Sealant Certification should be supplied by the
manufacturer once per year for each type of sealant.
Pipe to Manhole Seals Cert. should be supplied by the
manufacturer once per year for each type of gasket.
What do I do with it?
Certifications should be kept on file for future inspections.

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3.0 CALIBRATIONS
What goes in here and where do I get it?
Documents showing the following calibrations at specified
frequency.
Concrete Batching Equipment
1/yr
Must be calibrated and certified by independent agency
Water Meter
1/yr.
In-house calibration using volumetrically calibrated 55 gallon
barrel or water weight works well.
Additive Dispensing Equipment
1/yr.
In-house volumetric calibration using graduated
cylinders works well. Get graduated cylinder from
house such as McMaster-Carr.

supply

Concrete Compression Tester


1/yr.
Must be calibrated and certified by independent agency.

3.0
CALIBRATIONS CONT.

3-Edge Bearing Tester


1/yr.
Must be calibrated and certified by independent agency.

Go-No-Go Gages
min. 1/yr
In-house or independent agency calibration with
micrometer or calibrated bars.
Laboratory Scales
1/yr.
In-house or independent calibration with certified test
weights.
Micrometers
1/yr.
In-house or independent calibration with certified
micrometer or calibration bars.
Vacuum Test Equipment
1/yr.
In-house or independent calibration with manometer
column height using a liquid with a verified specific
gravity or certified test gage.

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3.0 CALIBRATIONS CONT.


Pipe Air Test Equipment
1/yr.
In-house or independent calibration with manometer
column height using a liquid with a verified specific
certified test gage.

gravity or

Hydro Test Equipment


1/yr.
In-house or independent calibration with certified test gage.
Air Content (PCC) Test Equipment min. 1/yr 1/mo. Box
In-house calibration allowed.

What do I do with it?


Retain in file for documentation.

4.0 CONCRETE
MIX DESIGNS
What goes in here?
A copy of all mix designs used in production.
4.1 Water either potable or meets ASTM C1602
Where do I get it?
Mixer man and production office should both have a copy
of mix designs.
What do I do with it?
Retain and update as changes are made.
Frequently verify that files mixes are actually those being
used in production.

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4.2
WATER/CEMENTIOUS
MATERIAL
CONFIRMATION

What goes in here?


Confirmation of the w/c ratio for each mix design should
be done once per month for Pipe, Manhole and Precast
Products and weekly for Box Culverts and Three-sided
structures. No mix design should have a w/c ratio higher
than 0.50 for pipe, manhole and precast and 0.45 for Box
and Three-sided structures.
Where do I get it?
Tests should be done at least monthly by QC personnel.
What do I do with it?
File for documentation of compliance and use results to
track changes in mix components.

65

4.3 CONCRETE
BATCH REPORTS
What goes in here?
Daily report of actual batch quantities for one batch of each mix
design used. If using ready-mix concrete should retain a batch
report for each load received.
SCC mixes require a written QC plan
Where do I get it?
Results should be received from plant mixer man or ready-mix
supplier. Electronic files ok as long as you can access them
easily.

66

9.0 CONCRETE
TESTING
What goes in here?
Reports documenting slump/flow, temperature, air content,
unit weight, and absorption shall be kept on file.

Where do I get it?


Reports should be completed by Quality Control, other
plant personnel or other outside testing agencies.

Need to demonstrate concrete testing procedures during


audit.

67

9.7 COMPRESSIVE
STRENGTH TESTING
What goes in here?
Reports documenting compressive strength tests for all
mixes used in production. Min. of 5 cylinders per week for
pipe tested in TEB otherwise 5 cylinders per day. Box
culverts min. of 2 additional cylinders per week for
stripping strength.
What do I do with it?
For tests done in-house will need to demonstrate cylinder
fabrication and concrete strength testing procedures
during audit.
Monitor strengths and ensure strength is adequate at
shipping ages per shipping policy.

68

10.0 CURING
RECORDS
What goes in here?
Reports showing temperature cure cycle of products,
minimum one kiln per day/cycle.
Keep maximum temperatures below 160 F (71 C) with
max. rise 40 F/hr (25 C/hr).
Where do I get it?
Plants should have instruments to measure the cure cycle
of products, daily.

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12.0 PRODUCT
MARKING

No files needed but must understand the minimum


requirements of ASTM or local standards for marking your
products.
Periodically check your products to make sure that they
are properly marked.

Auditor will inspect your products to ensure that they are


properly and legibly marked.

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14.1 HANDLING
AND STORAGE
What goes in here?
Write a maximum stacking height policy for each class and
size of product.
Ensure that all products are handled to prevent damage.
All rejected materials must be clearly marked and
separated when able.
What do I do with it?
Use as a reference so Q.C personnel, shipping personnel
and ACPA Auditor can verify product compliance at the
time of shipping.

71

14.2 SHIPPING
POLICY
What goes in here?
Write a Shipping Policy that corresponds with your current
shipping practices and how they relate to three-edge
bearing and concrete compression test results and
inspection criteria.
What do I do with it?
Use as a reference so Q.C personnel, shipping personnel
and ACPA Auditor can verify product compliance at the
time of shipping. Correlate with strength or TEB test
results.

72

14.3 FINAL
INSPECTION
What goes in here?
Write a Final Inspection Policy that corresponds with your
actual practices. Identify persons responsible for the final
inspection in the policy.
Document final inspections to verify product compliance at
the time of shipping.

73

ACPA QCAST MANUAL


Section II Concrete Pipe Requirements
Section III Manhole Requirements
Section IV Buried Precast Products
Requirements
Section V Box Culvert and Three-sided
Structures
Requirements

74

5.1, 5.2, 5.3


JOINT DESIGN
DRAWINGS

What goes in here?


Detailed drawings of joints used for gasketed and non-gasketed
pipe, manholes, precast and boxes. Include tolerances.
(See sample form in Appendix)
Sanitary Pipe include design calculations and Go/No Go gaging
system including gasket compression figures.

Where do I get it?


Check with both equipment and gasket suppliers.
What do I do with it?
Retain in file.
Sanitary - Demonstrate proper use of Go/No Go gaging during
audit.

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5.4 GASKET
QUALITY

77

What goes in here?


Critical dimensions of gaskets (pipe, MH, box, others).
Reports of gasket tests per frequency in QCAST manual
- less 36

1/300

- 36 and larger

1/100

Where do I get it?


Check with equipment and gasket suppliers.

What do I do with it?


Demonstrate gasket QC tests during audit and compare results
with acceptable dimensions.

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6.0 EQUIPMENT
& FORMS
What goes in here?
Inspection reports for all new and repaired equipment to
check dimensions and function.
Where do I get it?
Reports can be done in-house or by equipment supplier.
Plants should always verify critical measurements.

81

6.2 PIPE AND


MANHOLE HEADER/PALLET/RING
INSPECTION
What goes in here?
Incoming Inspection Reports for all Headers/Pallets/Truing Rings for
gasketed pipe and manholes.
Annual inspection of gasket sealing surfaces for sanitary products.
Sample forms in Appendix A of the Certification Manual.

What do I do with it?


Verify compliance with established tolerance to insure joint integrity. File
for future reference.
NOTE: Good idea store your original, detailed Incoming Inspection
Reports separately from annual QC data.
Sanitary Audit: demonstrate procedures for measuring joint formers.

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7.0
REINFORCING
What goes in here?
Reinforcing design information for the production of all
Pipe, Manholes, Precast Products, or Boxes.
Where do I get it?
Designs can be done in-house or by a second party.
Standard drawings or job specific.
Must have: mesh style, diameter, length, steel area (design &
actual), location in wall, lap, bell reinforcing, and shear steel.
What do I do with it?
Retain on file and maintain at production fabrication
areas. Cage fabricators must be familiar with reinforcing
requirements.

85

8.0 PRE-POUR
INSPECTIONS
What goes in here?
Reports documenting pre-pour inspections of reinforcing,
forms (visual and dimensions) and embedded items.
Measure a minimum of one cage at beginning of each
shift or any change.
Visually inspect each cage and form.
Initial shop drawings for check of embeds and blockouts.
Where do I get it?
Reports should be completed by Quality Control and
other plant personnel.
What do I do with it?
Retain on file for future reference.
Demonstrate inspection procedures during audit.

86

11.0 POSTPOUR
INSPECTION
What goes in here?
Check a portion of each days production before and after
finishing/patching. Maintain a written repair procedure and list
acceptable repair materials.
Perform visual and dimensional checks on both barrel and joints.
Document 1 piece/size/shift.
Sanitary: Go/No Go gaging.
Where do I get it?
Sample forms can be found in the QCAST Appendix.
Demonstrate during audit.

87

TESTING
(PIPE AND
MANHOLES)
What goes in here?
Proof of design and ongoing tests of pipe and manhole
showing that products are meeting standards for Water
Tightness, Three-Edge Bearing, and Joint Tests.
Monitor testing frequency with production.
Manhole Step Tests (v.6)
Where do I get it?
Most tests are ASTM Standards.
What do I do with it?
Use them to make sure your products are meeting all
applicable standards. Retain on file for future reference.
Demonstrate tests during audit.

88

13.2 3-EDGE
BEARING TEST
What goes in here?
Test results at the frequency described in Section 13.2 of the
Certification Manual to minimum of 0.01 inch crack.
Annually, test a minimum of one pipe per size and class (60 or
smaller) to Ultimate Load.

Where do I get it?


ASTM C 497 and QCAST manual.
What do I do with it?
Retain on file for future reference.
NOTE: Production records should be used to verify test
frequencies. Pipe tested only to the formation of the 0.01 in.
crack meeting test requirements should be accepted for use.

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90

T.E.B. TEST FREQUENCIES (Min.)


Pipe
Size
12-15
18-36
18-36
42-60
42-60
66 and
larger

Class

Frequency

Class 5 and
Class 4 and
Class 5
Class 3 and
Class 4 and
All classes

below 1/1000 pcs


below 1/800 pcs
1/400 pcs
below 1/400 pcs
5
1/200 pcs
As required
by project
specs.

NOTE: Arch and elliptical pipe shall be tested as required


by job or local specifications

13.1, 13.3, 13.4


WATER TIGHTNESS PIPE and MANHOLES

What goes in here?


Water tightness tests of Sanitary Pipe(Sanitary Sewer Only)
Proof-of-Design Test Results for:
Off-Center Joint Test (Sanitary Sewer Only)
Differential Joint Shear Test (Sanitary Sewer Only)
Storm Sewer/Culvert Joint Test
Test methods and minimum test frequencies are described in
the QCAST manual and appendix.
Results of in-house testing. It is only necessary to test the lowest
class pipe produced for each size and style.
What do I do with it?
Retain on file to verify design integrity. It is not necessary to run
these tests again unless reinforcing designs or joint
configuration changes.
Demonstrate test procedures during QCAST audit.

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92

ACPA QCAST MANUAL

Appendix A:
Procedures and
Sample forms
Appendix B: Audit
Expectations.

93

94

ACPA Certification
Checklist

ACPA Certification Checklist


ACPA
Certification(On
Checklist
Documentation
going)
ACPA
Certification
Checklist
Testing
and Inspection
ACPA
Certification
Checklists
Misc.
Materials
(On going)
Review monthly / required
OK
to develop in-house
frequently
documentation.

CERTIFICATION CHECK LIST


CALIBRATIONS
Item

Date of Previous
Calibrator
Calibration

Concrete Batching Equip


* Water Meter

Ind.

Ind. / In -house

* Additive Dispensing

____________

_____________

____________

_____________

Ind. / In-house

Concrete Compression Tester


3-Edge Bearing Tester

Date of Current
Year Calibration

Ind.

Ind.

____________

_____________

____________

_____________

____________

_____________

Go, No-Go Gages

Ind. / In-house

____________

_____________

Laboratory Scales

Ind. / In-house

____________

_____________

Micrometer
Vacuum Test Equip
Air Test Equip.
Hydro Test Equip.

Ind. / In-house

Ind. / In-house
Ind. / In-house

____________

____________

Ind./ In-house

* Air Content Test Equip.


* Quarterly for Box

____________

In-house

_____________
_____________
_____________

____________

_____________

____________

_____________

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96

What happens
on Audit Day?

97

Audit Day

DOCUMENTATION
The auditor will check your
documentation files for
completeness and content.

Audit Day:
Production Verification and
Testing (Highlights)
98

REINFORCING
Have detailed reinforcing design in the fabrication
area.
Show how cages are measured.
Measured cages being used must meet specifications.

CONCRETE BATCHING
Batches proportioning must follow mix designs.
Show competence in batching.

FORMS
Inspect condition and cleanliness of forms.

Production Verification and


Testing (Highlights)

99

Plant personnel shall show competency when


performing the following tests:
Compressive strength: cylinder
preparation, handling, curing and
testing.
Slump, Flow, Temp, Air content
testing.
Concrete absorption testing. (If done
in house)
Aggregate gradation testing. (If done
in house)

Production Verification and


Testing (Highlights)

100

Plant personnel shall show competency when


performing the following inspections:
Gasket Testing (If done in house)
Sanitary (if done in-house):
Pallet Inspection
Header Inspection
Truing Ring Inspection

Production Verification and


Testing (Highlights)

101

CURING
Plant personnel shall demonstrate curing
methods and retrieve results.

Finished Product Inspection


Testing (Highlights)

102

Inspection and review of plant


procedures for:
Pipe/MH barrel appearance
Pipe/MH joint appearance
Box appearance
Precast appearance

Inspection & Testing


(Highlights)
The auditor shall witness the following
inspections and tests for procedure,
equipment and results.

Barrel/Box dimensions
Pipe/MH/Box joint inspection
Water tightness tests (sanitary)
Three-edge bearing tests
Off center hydrostatic joint test (sanitary)
Differential joint shear test (sanitary)
Storm sewer and culvert joint test
Compressive strength test

103

Audit Day

104

Finally, the auditor shall verify


plant procedures for:

Product marking
Handling and storage
Repairs
Segregating of reject pieces
Final inspection

105

Manholes
ASTM C478
Pre-pour each piece (wet-cast)
Sanitary manholes

Joint design calcs/drawings


Gasket tests
Joint forming equipment
Dimensional checks of spigots
Water-tightness Vacuum/Hydro
ASTM C1244

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106

Precast
Standard and non-standard
products
ASTM or local specs control
Reinforcing drawings and
tolerances
Pre-pour min. one cage/shift/type
Post-pour critical
dimensions/blockouts
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107

Box Culvert
ASTM C1433/C1577 (C1504 3sided)
Monthly Gradations, air pot
calibrations 1/4ly, & w/c <=0.45
max.
Pre- and Post- product
inspections
Fit test
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109

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SEE!
ITS EASY!

110

1. Break the Program down into smaller


parts.
2. Document well.
3. Ask for help if you need it.
4. Show the auditor what you know.

SET A DATE FOR


CERTIFICATION SOON.
If you dont set a goal - you
will never get there.
Apply today!

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