QCM-001 2023 Comment Period

“Dedicated to expanding the use of quality precast concrete”
NPCA QUALITY CONTROL MANUAL

For Precast Concrete Plants
16th EDITION
2023
Copyright 2023 by
National Precast Concrete Association (NPCA)
16th Edition, 2023
All rights reserved.
No part of this manual may be reproduced

in any form without permission in writing from
the National Precast Concrete Association.
NPCA
1320 City Center Dr
Suite 200
Carmel, Indiana 46032
800-366-7731 (phone)
317-571-0041 (fax)
www.precast.org
T T
TABLE OF CONTENTS – 16th Edition
Page
TABLE OF CONTENTS …………………………………………………………………………………..i
FOREWARD…………..…………………………………………………………………………………...1
CHAPTER 1- GENERAL .............................................................................................................6

1.1 PLANT QUALITY CONTROL PROCEDURES AND MANAGEMENT
POLICIES ........................................................................................................... 6
1.1.1 Plant Management and Personnel............................................................ ..6
1.1.2 Plant-Specific Quality Control Manual ........................................................ 7
1.1.3 QC Personnel Training ............................................................................... 8
1.1.4 Continuous Improvement ..………………………………………………………8
1.1.5 Plant Requirements ………………………………………………………………9
1.2 PLANT SAFETY ................................................................................................ ..10
1.2.1 Safety Program ........................................................................................ 10
1.2.2 Plant Requirements ................................................................................. .10
1.3 DRAWINGS & MOCK-UPS………………………………………………………………..11
1.3.1 Drawings………………………………………………………………………….11
1.3.1.1 Drawings for custom-made precast units…………………………..11
1.3.1.2 Drawings for standard precast units………………………………...11
1.3.2 Mock-ups……………………………………………………………………….....11
CHAPTER 2 – MATERIALS ....................................................................................................................... … .13

2.0 BUY AMERICA…………………………………………………………………….........13
2.1 CONCRETE......................................................................................................... 13
2.1.1 Portland Cement ...................................................................................... 13
2.1.2 Blended Hydraulic and Hydraulic Cements .…………………………………13
2.1.3 Aggregates ............................................................................................... 14
2.1.3.1 Aggregate Gradation .................................................................. 14
2.1.3.2 Deleterious Substances……………….……………………………. 15
2.1.4 Lightweight Aggregate .............................................................................. 17
2.1.5 Mixing Water ............................................................................................ 17
2.1.6 Chemical Admixtures................................................................................ 18
2.1.7 Supplementary Cementitious Materials .................................................... 19
2.1.8 Plant Requirements .................................................................................. 19
2.2 REINFORCEMENT .............................................................................................. 20
2.2.1 Reinforcing Bars ....................................................................................... 20
2.2.2 Reinforcing Wire ....................................................................................... 21
2.2.3 Welded-Wire Reinforcement..................................................................... 21
2.2.4 Zinc or Epoxy-Coated Reinforcement ....................................................... 21
2.3 MISCELLANEOUS MATERIALS ......................................................................... 22
2.3.1 Lifting Inserts and Lifting Hardware .......................................................... 22
2.3.2 Embedded Steel Shapes and Plates ........................................................ 22
2.3.3 Headed Studs and Deformed Anchor Studs ............................................. 23
2.3.4 Manufacturing Accessories....................................................................... 23
2.3.5 Fiber Reinforcement ................................................................................. 23
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CHAPTER 3 - CONCRETE ...................................................................................................... 26
3.1 CONCRETE MIXES ............................................................................................. 26
3.1.1 Mix Proportions ........................................................................................ 26
3.1.1.1 Normal, Heavyweight, and Mass Concrete….………………….....26
3.1.1.2 Self-Consolidating Concrete...………………………………………27
3.1.1.3 Dry-Cast / Zero Slump Concrete……………………………………27
3.1.1.4 Ultra High Performance Concrete (UHPC) ...……………………..27
3.1.1.5 Mix Compatibility When Using Face Mix…………………………..28
3.1.2 Water-Cementitious Materials Ratio ......................................................... 28
3.1.3 Air Content ............................................................................................... 29
3.1.4 Compressive Strength .............................................................................. 29
3.1.5 Admixtures ............................................................................................... 31
3.2 BATCHING AND MIXING .................................................................................... 32
3.2.1 Requirements for Batching and Mixing Plants .......................................... 32
3.2.2 Storage of Cement and Supplementary Cementitious Materials ............... 32
3.2.3 Handling and Storage of Aggregates ........................................................ 33
3.2.4 Batching Equipment ................................................................................. 33
3.2.5 Discharge of Materials into Mixers ............................................................ 34
3.2.6 Mixers ...................................................................................................... 35
3.2.7 Mixing ....................................................................................................... 35
3.2.8 Ready-Mixed Concrete ............................................................................. 35
CHAPTER 4 - PRODUCTION PRACTICES ............................................................................. 37

4.1 GENERAL............................................................................................................ 37
4.1.1 Plant Layout ............................................................................................. 37
4.1.2 Housekeeping .......................................................................................... 37
4.1.3 Forms and Forming Equipment ................................................................ 38
4.1.4 Handling Equipment ................................................................................. 38
4.1.5 Machine-Made and/or Dry-Cast Products ................................................. 39
4.1.6 Architectural Precast Concrete ................................................................. 40
4.1.6.1Surface Finishes………………………………………………………40
4.1.6.1.1 As Cast……………………………………………………..40
4.1.6.1.2 Exposed Aggregate Finish……………………………….41
4.1.6.1.3 Abrasive Blast Finish……………………………………...41
4.1.6.1.4 Acid Etch Finish…………………………………………...41
4.1.6.1.5 Honed or Polished………………………………………...42
4.1.6.1.6 Bush Hammered or tooling……………………………….42
4.1.6.1.7 Unformed Surfaces………………………………………..42
4.1.6.1.8 Special Finishes…………………………………………...42
4.1.6.1.9 Architectural Finishes……………………………………..42
4.1.6.1.10 Embedded Veneer……….………………………………43
4.1.6.1.10.1 Stone Products………………………………..43
4.1.6.1.10.2 Clay Products………………………………….44
4.2 FABRICATION OF REINFORCEMENT AND BLOCKOUTS ................................ 46
4.2.1 Fabrication of Reinforcement.................................................................... 46
4.2.2 Welding of Reinforcing Steel .................................................................... 47
4.2.3 Welding of Steel Assemblies .................................................................... 47
4.2.4 Fabrication and Positioning of Blockouts .................................................. 48

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4.3 PRE-POUR OPERATIONS .................................................................................. 49
4.3.1 Cleaning of Forms .................................................................................... 49
4.3.2 Application of Form Release Agent .......................................................... 49
4.3.3 Positioning of Reinforcement .................................................................... 49
4.3.4 Positioning of Miscellaneous Embedded Items ......................................... 51
4.4 CASTING CONCRETE ........................................................................................ 52
4.4.1 Transporting Concrete .............................................................................. 52
4.4.2 Depositing Concrete into Forms ............................................................... 52
4.4.2.1 Placing Face Mix……………………………………………………..53
4.4.2.2 Placing Back-up Mix………………………………………………....53
4.4.3 Consolidating Concrete ............................................................................ 53
4.4.4 Finishing Unformed Surfaces .................................................................. 54
4.4.5 Secondary Pours ...................................................................................... 55
4.4.6 Hot Weather Precautions ......................................................................... 56
4.4.7 Cold Weather Precautions ........................................................................ 56
4.5 CURING CONCRETE .......................................................................................... 58
4.5.1 General .................................................................................................... 58
4.5.2 Curing by Moisture Retention ................................................................... 61
4.5.3 Curing with Heat and Moisture ................................................................. 62
4.6 STRIPPING PRODUCTS FROM FORMS............................................................ 63
4.6.1 Minimum Strength Requirement ............................................................... 63
4.6.2 Product Damage During Stripping .......................................................... . 63
4.6.3 Formed Surfaces ...................................................................................... 64
4.6.4 Post-Pour Inspection ................................................................................ 64
4.7 REPAIRING CONCRETE .................................................................................... 65
4.7.1 Repairing Minor Defects ........................................................................... 65
4.7.2 Repairing Major Defects ........................................................................... 66
4.7.3 Inspection of Repairs ................................................................................ 66
4.8 MARKING, STORAGE, AND SHIPMENT OF PRODUCTS ................................. 67
4.8.1 Product Marking ....................................................................................... 67
4.8.2 Storage Areas .......................................................................................... 67
4.8.3 Storage of Products .................................................................................. 67
4.8.4 Shipment of Products ............................................................................... 68
4.8.5 Final Inspection ........................................................................................ 68
CHAPTER 5 - QUALITY CONTROL OPERATIONS ................................................................ 70

5.1 SUMMARY OF REQUIRED RECORDS .............................................................. 70
5.1.1 Raw Material Test Records ...................................................................... 70
5.1.1.1 Independent Third Party Testing Laboratory………………………71
5.1.2 Work Orders and Product Drawings ......................................................... 71
5.1.3 Equipment Calibration Records ................................................................ 71
5.1.4 Aggregate and Concrete Test Records..................................................... 72
5.1.5 Concrete Batching Reports....................................................................... 73
5.1.6 General Plant and Product Inspection Records ........................................ 73

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5.2 AGGREGATE TESTING ...................................................................................... 73
5.2.1 Aggregate Gradation ................................................................................ 73
5.2.2 Moisture Content ...................................................................................... 74
5.2.2.1 Conventional and Dry-Cast Concrete ......................................... 74
5.2.2.2 Self Consolidating Concrete ....................................................... 74
5.3 CONCRETE TESTING ........................................................................................ 75
5.3.1 Slump, Slump Flow, and Visual Stability Index ......................................... 75
5.3.1.1 Slump ........................................................................................ 75
5.3.1.2 Slump Flow and Visual Stability Index........................................ 76
5.3.2 Temperature ............................................................................................. 76
5.3.3 Density (Unit Weight)................................................................................ 77
5.3.4 Air Content ............................................................................................... 78
5.3.5 Compressive Strength .............................................................................. 79
5.3.5.1 Wet-Cast .................................................................................... 79
5.3.5.2 Dry-Cast and/or Machine-Cast ................................................... 79
5.3.5.3 SCC ........................................................................................... 80
5.3.5.4 Compressive Strength Specimens ............................................. 80
5.3.5.5 Cores…………………………………………………………………..80
5.3.5.6 Calibrated Impact Rebound Hammer Use .................................. 81
Table 5.3.6.a .………………………………………………………………….83
Table 5.3.6.b .………………………………………………………………….84
Table 5.3.6.c .………………………………………………………………….85
CHAPTER 6 – SPECIAL REQUIREMENTS FOR SPECIFIC PRODUCTS ……………………..86

6.1 PRODUCTS MANUFACTURED ACCORDING TO ASTM INTERNATIONAL
AND OTHER INDUSTRY STANDARDS ........................................................... 86
6.1.1 Product Manufacture ................................................................................ 86
6.1.2 Proof of Conformance .............................................................................. 86
6.2 CONCRETE PIPE REQUIREMENTS .................................................................. 87
6.2.1 Stormwater Concrete Pipe Requirements................................................. 87
6.2.1.1 Reinforcing Steel Inspection…………………………………………87
6.2.1.2 Three-Edge Bearing Testing ...................................................... 87
6.2.1.3 Absorption Testing ..................................................................... 88
6.2.1.4 Dimensional Checks .................................................................. 89
6.2.1.5 Joint Design and Testing............................................................ 89
6.2.1.6 Watertightness Hydrostatic Testing………………………………...89
6.2.1.7 Watertightness Vacuum Testing……………………………………90
6.2.1.8 Gasket Quality Control……………………………………………….90
6.2.1.9 Plant Requirements…………………………………………………..91
6.2.2 Sanitary Concrete Pipe Requirements...................................................... 92
6.2.2.1 Reinforcing Steel Inspection…………………………………………92
6.2.2.2 Three Edge Bearing Testing…………………………………………92
6.2.2.3 Absorption Testing……………………………………………………93
6.2.2.4 Dimensional Checks………………………………………………….93
6.2.2.5 Joint Design and Testing............................................................ 94
6.2.2.6 Watertightness Hydrostatic Testing ....................................................... 94
6.2.2.7 Watertightness Requirements .................................................... 95

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6.2.2.8 Off-Center Joint Proof of Design Testing…………………………..95
6.2.2.9 Joint Shear Proof of Design Testing…………………….…………95
6.2.2.10 Confined Gasket Proof of Design Testing………………………..95
6.2.2.11 Gasket Quality Control ............................................................. 96
6.2.2.12 Plant Requirements ................................................................. 97
6.3 ROUND MANHOLE REQUIREMENTS ................................................................ 97
6.3.1 Reinforcing Steel Inspection ..................................................................... 97
6.3.2 Flat Slab Tops .......................................................................................... 98
6.3.3 Base, Riser and Cone Sections ................................................................ 98
6.3.3.1 Absorption Testing ..................................................................... 98
6.3.3.2 Step Testing............................................................................... 99
6.3.3.3 Dimensional Checks .................................................................. 99
6.3.3.4 Sanitary Manhole Vacuum Testing .......................................... 100
6.3.4 Joint Design ........................................................................................... 100
6.3.5 Gasket Quality Control ........................................................................... 100
6.3.6 Plant Requirements ................................................................................ 101
6.4 BOX CULVERT REQUIREMENTS .................................................................... 102
6.4.1 Absorption Testing ................................................................................. 102
6.4.2 Joint Design ........................................................................................... 102
6.4.3 Pre-Pour Inspections .............................................................................. 103
6.4.4 Dimensional Checks ............................................................................... 103
6.5 SEPTIC TANK REQUIREMENTS ...................................................................... 104
6.5.1 Structural Proof-of-Design ...................................................................... 104
6.5.2 Watertightness Testing ........................................................................... 104
6.6 GREASE INTERCEPTOR REQUIREMENTS .................................................... 106
6.6.1 Structural Proof-of-Design ...................................................................... 106
6.6.2 Watertightness Testing ........................................................................... 106
APPENDIX A – STANDARDS CITED IN THE MANUAL AND REFERENCES ………………..108
APPENDIX B – SAMPLE FORMS…………………………………………………………………...119
NPCA PLANT CERTIFICATION TERMS AND CONDITIONS……………………………………141
NPCA PRECAST PLANT CERTIFICATION PROGRAM GRADING SCHEDULE.….…………168
STANDARDIZED GRADING TABLES……………………………………………………………....177

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FOREWORD
Since its introduction in 1987 the NPCA Quality Control Manual for Precast Concrete Plants
(also known as the NPCA QC Manual) has been a reliable quality management tool for the
precast concrete industry. Its use in day-to-day plant operations enables management and
production personnel to understand the requirements for manufacturing quality precast
concrete. The NPCA QC Manual’s practical information and adherence to accepted
industry standards helps provide consistency to plant operations.
The National Precast Concrete Association and its Board of Directors strives for openness
and impartiality in all aspects of the Plant Certification program. Through our quality
assurance policy for the Plant Certification Program, we make every effort to ensure
confidentiality of plant information and guard against any instances of conflict of interest in
the conduct of the program.
One of the NPCA QC Manual’s purposes is to define the fundamental requirements for a
quality control program for precast concrete plants. The manual furnishes a framework for
management decisions regarding equipment, procedures or personnel, which may be
necessary to create a quality manufacturing environment.
Specifiers and users of precast concrete products are constantly seeking ways to identify
high quality products. The NPCA Plant Certification Program is based on the premium
quality control program outlined in this manual and is intended to assure that precast
concrete plants are capable of manufacturing quality products.
The first edition of the NPCA QC Manual was published in 1987 in consultation with the
members of the National Precast Concrete Association, and has been revised regularly
since then. The Sixteenth edition of the NPCA QC Manual was recommended for approval
by NPCA’s Quality Assurance/Quality Control Committee to the NPCA Board of Directors in
October 2022.
NPCA Quality Assurance/Quality Control Committee Members (2021 - 2022):
• Richard Alvarado, Western Precast Concrete Inc. (Chairman)

• Sam Lines, Concrete Sealants Inc. (Board Liaison)
• Chad Anderson, Pro-Cast Products Inc.
• Taylor Clark, Maine Department of Transportation
• Jason Cross, Norwalk Concrete Industries
• Charles Curry, Forterra Pipe & Precast
• Joe Fisher, Voeller Mixers
• Scott Grumski, Forney LP
• Marvin Hanks, ParkUSA dba Northwest Pipe Company
• Hugh Martin, Oldcastle Infrastructure
• Stephen Matt McSweeney, Pennsylvania Department of Transportation
• Matt McSweeney, Pennsylvania Department of Transportation
• Mitchell Rainero, Permatile Concrete Products Co.
• Tim Sander, Gainey’s Concrete Products Inc.
• Rusty Stever, Jensen Precast
• Jason Tucker, Texas Department of Transportation
• Charles E. Watkins, Advanced Concrete Technologies Inc.
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• Todd Whittington, North Carolina Department of Transportation
• Drew Wieser, Wieser Concrete Products Inc.
INTRODUCTION
This manual outlines the basic requirements of precast concrete Information in the
plants to assure the production of quality precast concrete Commentary should be
products. Because the sizes of precast plants vary widely, hence considered as explanatory.
the quality control facilities will vary as well. For example, a large The purpose of the
plant is more likely to find that a well-equipped quality control Commentary is to provide
laboratory is justified while a small plant is likely to have few additional information and
quality control facilities onsite, and instead will use a commercial comments, not to add
laboratory for testing. Both plants can produce quality products. requirements.
Reference is made to many standards of the American Concrete

Institute (ACI), American Association of State and Highway
Transportation Officials (AASHTO), ASTM International (ASTM),
Canadian Standards Association (CSA), the Precast Prestressed
Concrete Institute (PCI), the Concrete Reinforcing Steel Institute
(CRSI), and the American Welding Society (AWS). References
are made using ASTM, plants that are subject to other standards
referenced above may do so in complete equivalence throughout
this manual. Where titles of standards are cited, the word
“standard” many have been omitted. The most recent edition of
these standards shall be used unless otherwise noted.
Technical terms used in this manual are defined in ACI 116,

“Cement and Concrete Terminology.” The technical terms in this
manual are those generally used in the concrete industry in
North America. There are many terms used only in certain
regions and the authors have tried to avoid such terms. Readers
are encouraged to write to NPCA if they feel that certain terms
used in the manual should be defined.
OBJECTIVES
The main purpose of this manual is to outline the quality The quality guidelines
requirements for precast concrete plants. In cases where the presented in this manual
project or product specifications imposed by an authority having are based on industry
jurisdiction are more stringent then they shall apply. If certain consensus.
requirements are not specified in the design, the requirements
outlined in this manual will apply. In cases where specific
project criteria are defined
This manual defines a minimum satisfactory level of quality that or specified, those
the purchaser of precast concrete products can reasonably expect requirements should
and that the precast concrete products manufacturer should prevail.
provide.
Quality control requires the attention and cooperation of all

management and production personnel. An effective quality
QCM-001 Rev 0 09-12-22 (16.0)

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control program typically requires management to make
necessary changes in equipment, procedures or personnel to
produce quality products.
MAJOR FACTORS IN QUALITY CONTROL
The single most important factor in quality control is

management’s commitment to produce quality products.
Management must implement a quality control program that
monitors quality and reports on conformance with requirements.
Qualified personnel are also required. Qualifications include a

thorough knowledge of precast concrete and successful
completion of NPCA’s Production & Quality School Level I.
Plants should maintain training records of all employees and key
individuals should be qualified and trained.
Items that must be monitored and compared with standards

include:
a. Completeness of work orders and product drawings

b. Quality of raw materials
c. Quality of forms
d. Fabrication and Positioning of Reinforcing Steel
e. Concrete Quality
f. Placement and consolidation of concrete
g. Product dimensions
h. Positioning of embedded items
i. Curing of concrete
j. Handling, storing and transporting products
k. Recordkeeping
Another aspect of a successful QC program is the concept of

continuous improvement. There is substantial benefit derived
from documenting materials, procedures and/or products that do
not conform to the applicable standards and using those
documents to develop corrective action so that the
nonconforming issues are reduced or eliminated in the future.
Quality of products is generally defined to be the consistent

conformance with requirements. Quality control of precast
concrete products requires much more than achieving the
required concrete strength. Procedures for implementing the
monitoring of the quality of products should be established by
management and management should assure that the
procedures are implemented. Qualified Production Quality
School (PQS) courses in concrete technology and precast
concrete production are offered by NPCA both online and in
person.
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PQS courses include:
PQS Level I – Basics –

Fundamentals of manufacturing quality precast concrete
products and for those who are quality control auditors or aspire
to be QC auditors
PQS Level II – Safety

A comprehensive, precast-specific course that will review the
safety issues associated with the precast production process.
PQS Level II – Technical

Technical concepts such as Center of Mass and Structural
Analysis will be presented in layman’s terms so that
reinforcement placement and proper lifting techniques can be
better understood. Additional topics include blueprint reading,
knowledge of specifications and much, much more.
PQS Level II – QA/QC

Covers Introduction – Quality, Water and Cement, Aggregate
Properties, Durability and Transport Mechanisms, Concrete
Testing, Hot and Cold Temperature Concreting, Variability,
Troubleshooting & Root Cause Analysis, Mix Design and
Developing and Maintaining a Quality Assurance Program for
Certified Plants.
PQS Level II - Production

Topics include: concrete consolidation, proper application and
use of release agents, reinforcement cages, curing, finishing,
plant layout efficiency and lean manufacturing.
PQS Level III –Leadership

Topics include recruiting, hiring, training, communicating
effectively, leading by example and celebrating success time
management, goal setting, stress management and multi-cultural
issues.
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DISCLAIMERS
1. This manual does not claim or imply that it addresses all safety-related issues, if any,
associated with its use. Manufacture of concrete products may involve the use of
hazardous materials, operations and equipment. It is the responsibility of the plant
personnel to determine appropriate safety, health and environmental practices and
applicable regulatory requirements associated with the use of this manual and the
manufacture of concrete products.
2. Use of this manual does not guarantee the proper function or performance of any
product manufactured in accordance with the requirements contained in the manual.
Routine conformance to the requirements of this manual should result in products of
an acceptable quality according to current industry standards.
3. This publication is designed to provide accurate and authoritative information in

regard to the subject matter covered; however, The National Precast Concrete
Association acts a mediator without approving, disapproving or guaranteeing the
validity or accuracy of any data, claim or opinion appearing herein. Information is
provided and disseminated with the understanding that the National Precast
Concrete Association is not engaged in rendering engineering, legal or any other
professional services. If engineering, legal or other professional assistance is
required, the services of a competent professional should be obtained. The National
Precast Concrete Association does not assume and hereby disclaims liability to any
person for any loss or damage caused by errors or omissions in the material
contained herein, regardless of whether such errors result from negligence, accident
or any other cause whatsoever.
4. The Building Energy Code and Building Fire Code are not referenced, nor do they
apply to this program.
5. Proprietary products manufactured under Underwriters Laboratories (UL), U.S.

Department of Defense (DoD) requirements are not subject to the requirements of
the NPCA Plant Certification Program unless explicitly noted in contract documents.
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STANDARD COMMENTARY
CHAPTER 1 - GENERAL
1.1 PLANT QUALITY CONTROL PROCEDURES AND

MANAGEMENT POLICIES
1.1.1 Plant Management and Personnel
Plant management and personnel must be committed to the Management must support
production of a consistently high-quality product. and be dedicated to the
Understanding the company policies and a commitment to production of quality
quality is essential. Frequent training reinforces this commitment. products; otherwise, a
Also, personnel must be given the authority to enforce minimum Quality Control Program is
Quality Control (QC) policy over production requirements. The unlikely to be successful.
organizational structure of a precast concrete plant shall include The plant QC Policy
the implementation of a Quality Control Program, which is the Statement should clearly
responsibility of the general manager or chief executive officer. state the management’s
commitment to producing
high-quality products. This
policy should be frequently
discussed with employees
and customers.
A person not directly

involved in production and
who is responsible to the
general manager or chief
executive officer
administers quality control
functions most effectively.
NPCA supports construction sustainability and advocates good The use of fly ash or
stewardship of the environment. Producers are encouraged to granulated blast furnace
use and document the use of reclaimed materials in slag as cementitious
manufactured products. Manufacturers seeking LEED materials in concrete mix
(Leadership in Energy and Environmental Design) status for their designs qualifies for the use
projects must document the use of reclaimed materials. of reclaimed materials.
Reclaimed crushed
concrete as an aggregate or
as a surface finish is
another use of a reclaimed
material.
Note: Use of supplementary

cementitious materials
(SCMs) must comply with
the appropriate ASTM and
ACI test methods and
standards.
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STANDARD COMMENTARY
1.1.2 Plant-Specific Quality Control Manual
The plant shall have a plant-specific QC manual that details the A plant-specific quality
production and QC policies and procedures used by the plant. control procedural manual
The manual shall be compiled in one notebook or binder a should specifically define
format for easy review by plant personnel or by an inspector. At any attributes or practices
a minimum, the manual shall include the requirements of this unique to the plant. The
manual and the following sections: plant specific manual
should be reviewed a
1. Management QC policy statement minimum of every twelve
(12) months and updated
2. Company QC personnel organizational chart as necessary.
3. Description of responsibilities for QC personnel
Standard Operating
4. Description of training requirements for QC personnel, Procedures (SOP) are a
production staff, forklift operators and drivers. good way to define QC
expectations.
5. Housekeeping plan
6. Product pre-pour, casting, post-pour and final inspection
procedures A review process of all QC
records should be
7. Plant curing procedures for all seasons incorporated into the
8. Minimum strength requirements for stripping and shipping plant’s QC operations with
product the intent of continually
improving operations and
9. Product repair policy and procedures quality. This can include a
periodic review of
10. Product and reinforcing steel dimensional tolerances unless documentation indicating
shown on product detail drawings and/or production nonconforming materials,
documentation. production procedures
11. Form tolerances and maintenance policy and/or products and
establishing appropriate
12. Mix design qualification and testing procedures corrective action.
13. Raw material testing policy and procedures
14. Equipment calibration policy and procedures Products manufactured
under the International
15. Product performance test policy and procedures applicable Building Code (IBC) may
to Chapter 6 require the Professional
Engineer to be the
16. Examples of all documentation and forms used by plant to
Professional of Record
record QC and production processes
(POR) for the certification of
17. Documentation of products manufactured under franchise or Special Inspections
licensing agreements, including all design specifications and performed by the QC
drawings. personnel of a producer
seeking Precertified Plant
status. The local building
official can grant
Precertification Status.
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STANDARD COMMENTARY
1.1.3 QC Personnel Training
1. Plant QC Lead and assigned backup inspectors personnel Because of the importance
shall hold current certificates of completion for: of properly trained
personnel, training must
a. NPCA Production and Quality School (PQS) remain current.
Plant QC Lead and assigned backup inspectors personnel
shall re-certify in NPCA PQS every five years by retaking NPCA Courses available
PQS Level I Refresher, PQS Level I, or PQS Level II QA/QC, for retraining every five
PQS Level II Technical, or PQS Level II Production. Plant years in the NPCA
QC Lead and assigned backup inspectors personnel with Production and Quality
expired NPCA PQS must re-take PQS Level I. Plant QC School (PQS) are:
personnel maintaining an active Master Precaster PQS Level I
PQS Level I Refresher
certification are exempt from the five year re-certification of
PQS Level II QA/QC
PQS. PQS Level II Technical
2. Plant QC Lead and assigned backup shall hold current PQS Level II Production
certifications for applicable concrete testing by: Master Precaster
a) the American Concrete Institute (ACI) Concrete Field

Testing Technician – Grade 1
OR
b) an industry recognized ACI equivalent
OR
c) an independent third-party professional. Evidence of
certification will be in the form of a formal certificate or
equivalent document stamped by a professional engineer
noting ASTM or equivalent test methods evaluated.
1.1.4 Continuous Improvement
The plant shall engage in continuous improvement activities By definition, ‘continuous

each and every year and keep on file objective evidence of these improvement’ is an ongoing
activities in the form of documentation, policies and procedures, effort to improve products,
and visual example. services or processes.
Organizations efforts can
Continuous improvement activities shall be demonstrated in one seek incremental
or more of the following areas: improvement over time or
breakthrough improvement
1. Production all at once.
2. Processes
3. Facilities Examples of Continuous
4. Operational Improvement Activities that
qualify include, but are not
limited to:
Production: Documented
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STANDARD COMMENTARY
In order to be considered for continuous improvement points, the rearrangement of the

plant shall first, at a minimum do two of the following: production floor based on
work flow or new product
1. Actively participate in the Producer Portal (see Part 2.5 of introduction. Process: A
the Plant Terms and Conditions); documented 5s or 6s
2. Perform semi-annual self-audits using the self-audit tool activity in the plant.
available in the Producer Portal (see example Self-Audit Process: Batching Kaizen –
report in Appendix B); using quality data (raw
3. Educate plant staff beyond quality personnel (see Part material data, mix data,
2.5 of the Plant Terms and Conditions). plastic testing, compressive
testing) to drive mix
optimization, cost
reductions and process
stability. Operational: A
document control program
for all plant documents.
Facilities: Expansion or
additions to production or
office spaces improving
efficiencies.
As an Education example,
the plant may register for a
free NPCA one-hour
webinar and train the entire
plant over a lunch hour.
Alternatively, the plant may
also register for four free
15-minute Precast Learning
Labs and use them as
plant-wide toolbox talks
while collecting signatures
to prove attendance.
1.1.5 Plant Requirements:
1. Maintain a current copy of this NPCA Manual in ready

access to inspectors and plant personnel.
2. Develop and periodically update a written or digital plant-
specific QC manual.
3. Maintain current copies of applicable ASTM International test
methods and specifications on file.
4. Maintain files of project specifications and requirements.
5. Maintain employee training records in company files.
6. Designate and train a plant QC Inspector Lead for each work
shift, with an assigned individual designated as backup. The
QC Inspector Lead shall report to plant management and not
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STANDARD COMMENTARY
directly to production personnel. In small plants, the

designated QC Inspector Lead can be included in daily
production duties. A designated QC Inspector Lead, or their
backup shall be present any time the plant is in production.
7. Management or a designated representative shall hold QC
meetings with QC and plant personnel a minimum of once
every 6 months. A record of the minutes of these meetings
and a list of attendees shall be kept in the plant files.
a. All NPCA Certified Plants shall discuss and
maintain documentation tracking customer
complaints and subsequent corrective actions
taken by the plant related to product quality
issues. Documentation shall be kept on file for a
period of three years and made available to the
auditor during each plant audit.
1.2 PLANT SAFETY
1.2.1 Safety Program
Each plant shall have an active plant safety program. The

program shall include requirements of local, state, and federal
laws, and in particular the requirements of the Occupational
Safety and Health Administration (OSHA).
1. Maintain a plant safety manual and documented safety

program. A plant-specific safety manual developed in
accordance with the NPCA Guide to Plant Safety, or similar
manual shall be in ready access to inspectors and plant
personnel.
2. Management or designated representative shall hold safety
meetings with plant personnel a minimum of once every
month. A record of the minutes of these meetings and a list
of attendees shall be kept in the plant files.
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STANDARD COMMENTARY
1.3 DRAWINGS & MOCK-UPS

1.3.1. Drawings
Erection drawings shall include at a minimum: elevations,
dimensions, connection details, exposure of each piece.
1.3.1.1. Drawings for custom-made precast units
The drawings for custom-made precast concrete units shall be

shop drawings furnished by the precast concrete producer for
approval by the customer. These drawings shall show complete
design, installation, and construction information in such detail as
to enable the customer to determine the adequacy of the
proposed units for the intended purpose. Details of steel
reinforcement size and placement as well as supporting design
calculations, if appropriate, shall be included. The drawings shall
also include exposure of each piece, include all details for
reveals, finish or finishes, The precast concrete units shall be
produced in accordance with the approved drawings.
1.3.1.2. Drawings for standard precast units
The drawings for standard precast concrete units shall be shop

drawings furnished by the precast concrete producer for approval
by the customer. These drawings shall demonstrate that the
applicable industry design standards have been met. Installation
and construction information shall be included on shop drawings
upon request. Details of steel reinforcement size and placement
as well as supporting design calculations, if appropriate, shall be
included. The precast concrete units shall be produced in
accordance with the approved drawings. Drawings shall indicate
assumptions used in the design of standard units. It is the
responsibility of the project’s engineer-of-record to verify that the
design assumptions are suitable for the proposed application.
1.3.2 Mock-ups
Prior to production of architectural precast units, the plant shall Mock-Ups

provide representative samples for evaluation. At a minimum, a Following approval of a
12 inch x 12 inch sample shall be submitted to show representative sample and if
representation of color and texture of the finished surface. One required by project
sample for each different finish (including if the back side of the specifications, a complete
precast is to be exposed) should be submitted if more than one or a portion of a full scale
finish is being specified. production unit is usually
Any change in materials or mix proportions requires new produced. The mock-up
samples be evaluated prior to change in production. unit (s) will establish the
range of acceptability with
respect to color and texture
variations, uniformity of air
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STANDARD COMMENTARY
void distribution, surface

defects, and overall
appearance.
Mock-up unit (s) or panels

etc should be viewed at a
distance that equals their
distance on the structure;
however this distance is not
less than 20 feet. Mock-ups
are usually approved and
signed off by the architect or
a designated representative
and are stored at the plant
and used as a comparison
to production units. If
requested, a mock-up may
be shipped to the jobsite for
comparison to the units
installed on the project.
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STANDARD COMMENTARY
CHAPTER 2 – MATERIALS
2.0 BUY AMERICA PROVISIONS
Plants shall abide by all Buy America Provisions as specified by

federal, state and/or local requirements. Plants shall obtain and
keep on file certificates of compliance as noted in the applicable
sections of this chapter. Plants shall obtain and keep on file
certificates of origin for all raw materials as defined by the
applicable Buy America Provision (reinforcing steel tie wire and
other raw materials may be exempted only as expressly noted
in the individual project specification, by federal, state or
municipal mandate). Materials not produced domestically shall
be segregated from those materials approved for use in Buy
America products.
2.1 CONCRETE
2.1.1 Portland Cement
Cement shall conform to the requirements of ASTM C150, Six base types of portland
“Standard Specification for Portland Cement.” Evidence of cement are specified in
conformance shall be a certified mill test report for each ASTM C150
shipment or lot of cement.
Type I - This cement is
2.1.2 Blended Hydraulic and Hydraulic Cements most commonly available in
most of North America and
Cement shall conform to the requirements of ASTM C595, is intended for use in
“Standard Specification for Blended Hydraulic Cement” or general concrete
ASTM C1157 “Standard Performance Specification for construction.
Hydraulic Cement”. Evidence of conformance shall be a
certified mill test report for each shipment or lot of cement. Type II - Provides moderate
sulfate resistance and is
used extensively where
soils or groundwater are
moderately high in sulfates.
Type II(MH) – Provides

moderate sulfate resistance
and moderate heat of
hydration and is a newer
cement type that may not
be available in all areas.
Type III - High early

strength cement is used
where rapid strength gain is
needed.
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STANDARD COMMENTARY
Type V – Provides high

sulfate resistance and is
specified where high sulfate
resistance is needed.
The remaining cement type

is not readily available in
most parts of the country.
Type IV, low heat of
hydration cement, is
typically manufactured only
for large dam construction.
When using blended

cements, trial batches
should be tested to ensure
adequate strength is
reached prior to stripping
the product.
In architectural concrete, it is especially important to use cement
of the same type and brand and obtained from the same mill
and the same lot throughout the project to minimize color
variation.
2.1.3 Aggregates
Fine and Coarse aggregates shall conform to the requirements Uniformity of aggregate
of ASTM C33, “Standard Specification for Concrete gradation is needed to
Aggregates.” Evidence of compliance shall be a certification maintain uniformity of
from the supplier that the aggregate meets the ASTM C33 concrete quality. A
standard. In addition, aggregates shall be evaluated per ASTM reduction in the amount of
C1778,”Standard Guide for Reducing Risk of Deleterious Alkali- material passing the No. 30
aggregate reaction on Concrete” and documentation maintained (0.600 mm) and No. 50
on file at the plant for potential deleterious expansion due to (0.300 mm) sieves may
alkali reactivity, unless the aggregates are received from a state tend to cause excessive
department of transportation approved source and are known bleeding so it may be
not to be reactive. advisable to blend in a fine
masonry sand, increase the
sand content in the mix
2.1.3.1 Aggregate Gradation (and reduce the coarse
Fine aggregate shall be tested for gradation for each 1,500 tons aggregate content), or
(1,350 metric tons) of fine aggregate used, or once a month, increase the amount of
whichever occurs first. cement in the mix. It may
be necessary to blend two
Coarse aggregates shall be tested for gradation for each 2,000 coarse aggregate sizes to
tons (1,800 metric tons) of coarse aggregate used, or once a achieve an optimal
month, whichever occurs first. gradation that is satisfactory
for the concrete mix being
produced. An increase in
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STANDARD COMMENTARY
The maximum size of coarse aggregate shall be as large as fines may permit a
practical, but shall not exceed one-fifth of the minimum reduction in the sand
thickness of the precast concrete product, or three-fourths of the content in the mix.
clear cover between reinforcement and the surface of the
product. Larger maximum sizes of aggregate may be used if Aggregate suppliers may
evidence shows that satisfactory concrete products can be offer to perform testing at
produced. no charge. If the aggregate
supplier will not perform the
2.1.3.2 Deleterious Substances required testing, the plant
Fine and coarse aggregate from all suppliers shall be tested for may perform the testing in-
deleterious substances initially, then annually thereafter and house (for gradation and
whenever the aggregate is suspected of contamination. Current organic impurities) or may
test reports shall be dated not more than one year at the end of employ a local testing
the month from the date of the last test or certification. laboratory.
Deleterious substance testing must conform to the requirements
and limits stated in ASTM C33 “Standard Specification for Sands with organic
Concrete Aggregates.” impurities may result in
erratic setting times of the
concrete. In addition, some
organic impurities such as
roots and vegetable or
wood fibers may affect the
appearance and durability
of exposed concrete
products. Sands that fail to
meet the organic impurity
tests should not be used in
precast concrete products.
Most specifications indicate

that sand must be free of
organic impurities. The test is
relatively simple to perform in
the plant. If there are no
organic impurities, the results
are positive and no additional
tests are needed, but if the
results indicate possible
contamination of the
aggregates, strength tests of
mortar cubes made with the
sand in question should be
made and tested in
compression.
Companion cubes made of

sand containing no organic
impurities should be made
and tested in compression
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STANDARD COMMENTARY
at the same age as those

made with the sand in
question. If the strength of
the questionable cubes is at
least 90% of the strength of
the companion cubes, the
sand may be used for
making concrete. It should
be noted that some organic
impurities will affect setting
time of concrete, but the
organic impurities test does
not give an indication of
setting time.
Additional aggregate test

methods not listed in this
manual may be necessary if
contamination is suspected.
If possible, coarse and fine

aggregates should be
obtained from sources
approved for use in highway
pavements by state
departments of
transportation. Otherwise it
will be necessary to obtain
test reports that show that
the aggregates not only
conform to ASTM C33 but
also are non-reactive and
are stable.
Aggregate suppliers may

offer to perform testing at
no charge. If the aggregate
supplier will not perform the
required testing, the plant
may perform the testing in-
house (for gradation) or
may employ a local testing
laboratory.
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STANDARD COMMENTARY
2.1.4 Lightweight Aggregate

To assure a uniform quality
Lightweight aggregates shall conform to the requirements of of lightweight concrete, the
ASTM C330, “Standard Specification for Lightweight gradation and dry-loose unit
Aggregates for Structural Concrete.” Tests for lightweight weight of the lightweight
aggregate gradation and unit weight shall be performed initially aggregates should be
and for each 200 cubic yards (150 cubic meters) of lightweight consistent. Variation in
aggregate supplied, or once a month, whichever occurs first. either the gradation or the
Test records shall be maintained at the plant. density generally requires
adjustments to the mix
proportions in order that
uniform concrete will be
produced. Control of
aggregate moisture can be
even more important with
lightweight aggregates. It is
best practice to store
lightweight aggregate in a
wet, saturated condition and
adjust the mix water for
excess water on the
aggregate.
2.1.5 Mixing Water
Water used in mixing concrete shall conform to the Water from municipal water
requirements of ASTM C1602, “Standard Specification for supply systems or from
Mixing Water used in the Production of Hydraulic Cement other sources approved for
Concrete” and shall be free from deleterious amounts of oils, drinking can be used for
acids, alkalis, salts, organic material or other substances that making concrete.
may adversely affect the properties of fresh or hardened Seawater, brackish water,
concrete. or other water with high
chloride contents should not
Mix water shall not contain iron or iron oxides that may cause be used in reinforced
staining when using white cement. concrete. Impure water can
affect setting time and algae
in water can entrain
additional air.
ASTM C1602 covers the

compositional and
performance requirements
for mixing water used in
hydraulic cement concrete.
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STANDARD COMMENTARY
2.1.6 Chemical Admixtures
Admixtures shall conform to the applicable specification as

follows:
Specification
Admixture Type Specification Title Designation
Air entrainment “Standard Specification ASTM C260 Chemical admixtures may
for Air-Entraining be helpful or may be
Admixtures for Concrete” needed to improve the
properties of fresh or
hardened concrete. Such
admixtures include
Water reducers, “Standard Specification ASTM C494 those used to entrain air,
retarders, for Chemical Admixtures retard or accelerate set,
accelerators, for Concrete” reduce water content,
high-range water reduce permeability, make
reducers, specific “Standard Specification the concrete more
performance for Chemical Admixtures ASTM workable, reduce steel
admixtures for Use in Producing C1017 corrosion or to add color to
(Viscosity / Flowing Concrete”* the concrete.
Rheology
Modifying
Admixtures)
Coloring “Standard Specification ASTM C979

for Pigments for
Integrally Colored
Concrete”
Corrosion “Standard Test Method ASTM G109 Corrosion Inhibitors are

Inhibitors for Determining the evaluated through test
Effects of Chemical method outlined in ASTM
Admixtures on the G109. Calcium chloride or
Corrosion of Embedded admixtures containing high
Steel Reinforcement in chloride concentrations are
Concrete Exposed to not recommended for use
Chloride Environments" in precast concrete
products that contain
reinforcement or other
metals.
Admixtures shall be products from manufacturers from whom test
data are available to establish their effects on concrete and
compatibility with other materials in the mix.
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STANDARD COMMENTARY
2.1.7 Supplementary Cementitious Materials When using SCMs and

depending on the cement
Supplementary cementitious materials (SCMs) shall conform to replacement levels, certain
the applicable specifications shown below. Evidence of SCMs may delay the initial
conformance shall be a certified mill test report for each strength gain of the
shipment or lot of SCMs. concrete. Proper measures
should be taken to ensure
product has achieved
adequate strength prior to
stripping and shipping.
Pozzolans “Standard Specification Standard types fly ash:
for Coal Fly Ash and • Class C fly ash
Metakaolin Raw or Calcinated ASTM C618 • Class F fly ash
Natural Pozzolan for Variations to standard types
Use in Concrete” fly ash commonly used:
• MFA – Modified fly
ash
• UFFA – Ultra-fine fly
ash
GBA – Ground Bottom ash
“Standard Specification
Silica Fume for Silica Fume Used in ASTM C1240
Cementitious Mixtures”
Slag Cement “Standard Specification ASTM C989

for Slag Cement for use
in Concrete and
Mortars”
1. The following documentation shall be maintained current in Unless records of

the plant records: aggregate and concrete
- Cement and supplementary cementitious material tests are identified in such a
certified mill test reports or certificates for each shipment manner that make it
or lot, possible to determine which
- Aggregate supplier and test reports, products were made with
- Mix water potability test reports or other test records the tested materials, they
indicating the acceptability of the mix water. Current test are not very useful. A
reports shall be dated not more than one year at the end simple orderly method of
of the month from the date of the last test or certification. relating such records to
Municipal water supply is acceptable without testing. specific products can make
- Chemical admixture and other additive certified test the test reports valuable.
reports or certifications shall be dated not more than Placing the cast date on the
one year at the end of the month from the date of the product is usually sufficient
last test or certification. to track the product to the
daily quality control records
and raw materials.
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STANDARD COMMENTARY
2. Documentation of conformance to ASTM C33 (excluding

gradation testing) and test reports indicating that the Documentation showing
aggregates are non-reactive and stable shall be maintained that the aggregate source is
for each aggregate source used. Such documentation shall department of
be obtained from the supplier, an appropriate state agency, transportation approved is
or a testing laboratory engaged by the plant, a minimum of an acceptable means of
once per year for each material used. Current test reports documenting aggregates
shall be dated not more than one year at the end of the are non-reactive and stable.
month from the date of the last test or certification. The
maximum aggregate size shall be proper for the products
being cast.
Tests for aggregate gradation and deleterious substances

shall be performed at the minimum frequency. Lightweight
aggregate shall be tested for gradation and unit weight at
the minimum frequency.
3. Records of incoming raw materials and plant materials tests

shall be kept current and on file for a minimum of three
(3) years.
4. The cement type, supplementary cementitious materials,

and chemical admixtures shall be appropriate for the
intended use.
2.2 REINFORCEMENT
2.2.1 Reinforcing Bars
Steel reinforcing bars shall conform to the specification required

in the design:
“Standard Specification for Deformed and Plain Billet – Steel

Bars for Concrete Reinforcement” ......................... ASTM A615 Bars conforming to ASTM
A706 have a low carbon
“Standard Specification for Low-Alloy Steel Deformed and Plain equivalency and can be
Bars for Concrete Reinforcement” ......................... ASTM A706 readily welded. However,
they are not commonly
Other bars may be used for specific purposes if permitted by stocked by suppliers and
the design or project requirements. generally rather sizeable
minimum quantities must be
Reinforcing bar suppliers shall furnish mill certificates for each ordered.
shipment. Records of incoming reinforcing steel mill certificates
shall be kept current and on file for a minimum of three (3)
years.
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STANDARD COMMENTARY
2.2.2 Reinforcing Wire Section 2.2.2 permits the

use of wire other than the
Reinforcing steel wire shall conform to the applicable types listed, but it is
specifications: recommended that other
types of wire not be used
“Standard Specification for Steel Wire, and Welded Wire unless specifically specified.
Reinforcement, Plain and Deformed, for Concrete” ASTM
A1064
Other wire may be used for specific purposes if permitted by the

design or project requirements. Reinforcing wire suppliers shall
furnish mill certificates for each shipment. Records of incoming
reinforcing wire mill certificates shall be kept current and on file
for a minimum of three (3) years.
2.2.3 Welded-Wire Reinforcement
Welded wire reinforcement shall conform to the specification Welded wire reinforcement
required in the design: delivered in rolls should be
used in circular or curved
“Standard Specification for Steel Wire, and Welded Wire products, unless the
Reinforcement, Plain and Deformed, for Concrete” ASTM reinforcement is first
A1064 straightened. Otherwise it
is quite difficult to position
Suppliers of bar mats and welded wire reinforcement shall and support the
furnish mill certificates with each shipment. Records of reinforcement within
incoming reinforcing steel mill certificates shall be kept current straight-walled product.
and on file for a minimum of three (3) years.
2.2.4 Zinc or Epoxy-Coated Reinforcement
Where required by the design, reinforcement shall be Currently there are no

galvanized in accordance with ASTM A767, “Standard ASTM Standards for zinc-
Specification for Zinc-Coated (Galvanized) Steel Bars for coated welded wire
Concrete Reinforcement,” ASTM A641, “Standard Specification reinforcement. However,
for Zinc-Coated (Galvanized) Carbon Steel Wire,” or epoxy the product is available and
coated in accordance with ASTM A775, “Specification for may be used in precast
Epoxy-Coated Reinforcing Steel Bars,” ASTM A884, “Standard concrete products when
Specification for Epoxy-Coated Steel Wire and Welded Wired specified.
Fabric for Reinforcement,” or ASTM A934, “Standard
Specification for Epoxy-Coated Prefabricated Steel Reinforcing
Bars.” Epoxy-coated reinforcing steel shall be supplied by a
CRSI-certified applicator and accompanied by a certification or
certificate of compliance. Epoxy-coated reinforcement shall be
stored and handled in such a manner as to minimize damage to
the epoxy coating.
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STANDARD COMMENTARY
1. Mill certificates and certificates of conformance shall be

maintained current for all reinforcement including reinforcing
bars, reinforcing wire, bar mats, welded wire reinforcement
and coated reinforcing.
2. The plant QC Inspector shall crosscheck that certificates
are on file for all reinforcing heat numbers being used or
stored.
3. Certificates shall be maintained in the plant records for a
minimum of three (3) years.
2.3 MISCELLANEOUS MATERIALS
2.3.1 Lifting Inserts and Lifting Hardware
Lifting inserts used in precast concrete products shall be Other applicable codes and
verified for capacity and shall have an adequate factor of safety standards are ANSI A10.9
for lifting and handling products taking into account the various and ASTM C857, C890 and
forces acting on the device including form release suction, C913.
impact, and various positions of the product during handling.
The capacity of commercial lifting devices shall be marked on
the devices or posted in production areas.
Lifting inserts which are embedded or otherwise attached to

precast concrete members shall be capable of supporting at
least four times the maximum intended load applied or
transmitted to them, as required in OSHA 29 CFR 1926.704 (c).
Lifting hardware such as slings, lift bars, chains, hooks, etc.,

shall be verified for capacity and shall have an adequate factor
of safety for lifting and handling products.
Lifting hardware shall be capable of supporting at least five

times the maximum intended load applied or transmitted to the
lifting hardware, as required in OSHA 29 CFR 1926.704 (d).
2.3.2 Embedded Steel Shapes and Plates If embedded steel shapes

or plates will be exposed to
Steel shapes and plates that are to be embedded in precast moisture or other corrosive
concrete shall conform to the requirements of ASTM A36, environments, they should
“Standard Specification for Carbon Structural Steel.” Other be galvanized, stainless
types of steel shapes and plates may be used if the steel, or coated with
requirements are specified in the design. Applicable mill test suitable rust-inhibiting
reports shall be maintained at the plant for each shipment materials.
received.
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STANDARD COMMENTARY
2.3.3 Headed Studs and Deformed Anchor Studs
Studs to be welded to steel shapes or plates for concrete Proper use of stud welding
anchors shall conform to the requirements of ASTM A108, equipment is necessary to
“Standard Specification for Steel Bars, Carbon, Cold-finished, assure adequately strong
Standard Quality,” unless higher strengths are required by welds. Studs should be
design. able to withstand 30 degree
bend test without failure.
Test bending of studs
should be made on the first
two studs at the start of
each welding production
period. If welds fail the 30
degree bend test,
adjustments should be
made to the settings on the
generator, timer and stud
gun. If adjustments fail to
produce suitable welds, the
equipment should not be
used until acceptable welds
can be produced
consistently.
2.3.4 Manufacturing Accessories
Spacers for reinforcement, inserts, form ties, and similar Corrosion caused by metal
accessories incidental to the manufacture of precast concrete bar chairs is unsightly and
products shall be adequate for their intended purposes and for certain products might
shall result in minimum marring of the concrete surfaces. Use be objectionable. More
of accessories of dissimilar metals shall be avoided, unless serious, however, is
surfaces of the manufacturing accessories are permanently galvanic corrosion caused
protected against corrosion. by dissimilar metals. For
example, aluminum conduit
Coated tie wires shall be used with epoxy-coated reinforcement. embedded in reinforced
concrete is likely to corrode,
particularly if it is in contact
with reinforcing steel or if
there are chlorides in the
concrete.
2.3.5 Fiber Reinforcement
Data shall be provided to show conclusively that the type, Only two types of fibers are
brand, quality and quantity of fibers to be included in the typically used: synthetic and
steel fibers.
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STANDARD COMMENTARY
concrete mix are not detrimental to the concrete or to the

precast concrete product. Synthetic fibers are typically
used in concrete to reduce
Fiber reinforced concrete shall conform to ASTM C1116, plastic shrinkage cracks
“Standard Specification for Fiber-Reinforced Concrete and and / or to improve impact
Shotcrete,” (Type I or Type III). resistance. They can help
to reduce chipping of
products that are stripped.
Synthetic fibers do not
increase the compressive
strength of concrete.
Synthetic fibers are
characterized as micro or
macro fibers. Micro fibers
are typically used to reduce
plastic shrinkage cracks
and improve impact
resistance. Macro fibers can
be used in some situations
as secondary
reinforcement.
Steel and some synthetic

fibers increase the flexural
strength of concrete, but the
concrete mix should be
designed so that the mix is
workable. It is important to
follow manufacturer’s
instructions on introducing
the fibers into the mix and
on safety precautions.

OSHA requirements for
1. Commercial lifting inserts and hardware shall be certified and lifting devices and
posted for maximum capacity. As a minimum, inspect all apparatus are documented
lifting apparatus and maintain inspection records in the plant in “Code of Federal
files. Current inspection reports shall be dated not more Regulations” Title 29 Part
than one year at the end of the month from the date of the 1926.
last test or certification. More frequent inspection
of lifting devices may be
2. Non-commercial lifting inserts and hardware shall be proof-
required to meet local
tested by a certified testing lab for the rated working load limit
safety requirements or for
devices under severe
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STANDARD COMMENTARY
(WLL). A factor of safety in compliance with the requirements working conditions.

of the OSHA regulation 29 CFR 1926.704 (c & d) shall be met. Personnel using lifting
devices and apparatus are
3. Embedded steel shall be protected from corrosion when
expected to visually
necessary and dissimilar metals shall not be in contact.
inspect each device prior
4. Accessories and fiber reinforcement shall be appropriate for to use.
their intended use.
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STANDARD COMMENTARY
CHAPTER 3 - CONCRETE
3.1 CONCRETE MIXES
3.1.1 Mix Proportions
Concrete mixes shall be proportioned in accordance with ACI Concrete should be

211.1, “Practice for Selecting Proportions for Normal, proportioned so that it will
Heavyweight, and Mass Concrete,” ACI 211.2, “Practice for (1) be adequately
Selecting Proportions for Structural Lightweight Concrete,” ACI workable, (2) have the
211.3, “Practice for Selecting Proportions for No-Slump required properties after it
Concrete,” or ACI 237 “Self-Consolidating Concrete.” (SCC) Mix hardens (durability,
proportions shall be determined by a commercial laboratory, strength, impermeability,
project specifications, or by qualified precast plant personnel for acceptable volume change
each combination of aggregates, cement, water, and admixtures. characteristics, etc.), and
Mix proportions shall be appropriately modified for changes in (3) be economical. To
source of materials, gradation of aggregates, moisture content of achieve the required
aggregates, cement content, or admixtures. properties after hardening
requires an adequately low
water-cementitious
materials ratio and proper
air entrainment. Economy
of raw materials is best
achieved by using the
maximum practical size of
coarse aggregate, the
optimum fine-to-coarse
aggregate ratio, and the
stiffest mix that is practical
while maintaining the
correct water-cementitious
material ratio and air
content.
3.1.1.1 Normal, Heavyweight, and Mass Concrete
Plants using normal, heavyweight, and mass concrete shall Slump values for Normal,
include specific quality control procedures in their plant-specific Heavy Weight and Mass
QC manual, as discussed in 1.1.2. At a minimum, detailed Concrete have a range of
written procedures shall address the steps necessary for initial 2 inches to 9 inches.
mix qualification and subsequent daily quality control operations.
Initial mix qualifications shall be documented in the plant files.

Documentation shall include trial batching and in-depth concrete
testing. Mix qualification procedures shall include the
establishment of acceptable tolerance ranges for test results of
daily quality control testing (See example Mix Qualification Form
in appendix B.)
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STANDARD COMMENTARY
Subsequent daily quality control operations must follow the daily

quality control testing acceptance criteria established during the
initial mix qualification (see Section 5.2 and 5.3).
3.1.1.2 Self-Consolidating Concrete
Plants using self-consolidating concrete (SCC) shall include The plant should consult
SCC-specific quality control procedures in their plant-specific QC with their admixture
manual, as discussed in 1.1.2. At a minimum, detailed written supplier in developing
procedures shall address the steps necessary for initial mix appropriate quality control
qualification and subsequent daily quality control operations. operations. The plant may
also consider consulting
Initial mix qualifications shall be documented in the plant files. the “NPCA Guide to
Documentation shall include trial batching and in-depth concrete Implementing SCC”, ASTM
testing. Mix qualification procedures shall include the Standards, ACI and other
establishment of acceptable tolerance ranges for test results of recognized national
daily quality control testing (See example SCC Mix Qualification standards and guides for
Form in appendix B.) the use of Self-
Consolidating Concrete.
Subsequent daily quality control operations must follow the daily Daily quality control testing
quality control testing acceptance criteria established during the does not need to be the
initial mix qualification (see Section 5.2 and 5.3). same as the more involved
initial mix design
qualification process.
Slump Flow values for SCC

have a range of
20 inches to 30 inches.
3.1.1.3 Dry-Cast / Zero Slump Concrete
Plants using dry-cast / zero slump concrete shall include specific

quality control procedures in their plant-specific QC manual, as
discussed in 1.1.2. At a minimum, detailed written procedures
shall address the steps necessary for initial mix qualification and
subsequent daily quality control operations.

Documentation shall, include trial batching and in-depth concrete
daily quality control testing.

initial mix qualification.
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STANDARD COMMENTARY
3.1.1.4 Ultra High Performance Concrete (UHPC)
Plants using ultra high performance concrete shall include

specific quality control procedures in their plant-specific QC
manual, as discussed in 1.1.2. At a minimum, detailed written
procedures shall address the steps necessary for initial mix
qualification and subsequent daily quality control operations.

Documentation shall, include trial batching and in-depth concrete
daily quality control testing.

initial mix qualification.
3.1.1.5 Mix Compatibility When Using Face Mix
When using different mixes for face mix and back-up mix, the
characteristics of each mix shall be considered to ensure there is
minimal difference in shrinkage, thermal coefficient of expansion,
and modulus of elasticity.
3.1.2 Water-Cementitious Materials Ratio
Water-cementitious materials ratio for each mix design shall be Careful control of all water
calculated and documented. Concrete that will be exposed to going into the concrete is
freezing and thawing shall contain entrained air and shall have important to achieving
water-cementitious materials ratio of 0.45 or less. Concrete consistent, high quality
which will not be exposed to freezing, but which is required to be concrete. Reducing the
watertight, shall have a water-cementitious materials ratio of 0.48 water-cementitious
or less if the concrete is exposed to fresh water. For corrosion materials ratio increases
protection, reinforced concrete exposed to deicer salts, brackish concrete strength, reduces
water or seawater shall have a water-cementitious materials ratio concrete permeability, and
of 0.40 or less. results in a more durable
concrete.
The values of water-

ratio cited in section 3.1.2
are needed for adequate
durability.
It is recommended that the

workability be achieved by
using water-reducing
admixtures instead of
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STANDARD COMMENTARY
increasing cement
contents. Without water-
reducing admixtures in the
concrete, it is likely that
600 to 700 pounds (270 kg
to 320 kg) of cement will
be needed per cubic yard
of concrete. Even higher
cement contents may be
needed if aggregate
gradations are poor or if
high slump concrete is
used.
Very wet mixes from which

the water is removed by
pressure or vacuum de-
watering contain little or no
entrained air. However,
such concrete can be
durable if the water-
ratio is low enough.
3.1.3 Air Content (Plastic)
The air content of concrete that will be exposed to freezing and

thawing shall be within the limits given in Table 3.1.3.
TABLE 3.1.3
TOTAL AIR CONTENT FOR FROST - RESISTANT CONCRETE**
Nominal Maximum Aggregate Size
Size (inches) *Air Content, %

Severe Exposure Moderate Exposure
3/8 6.0 to 9.0 4.5 to 7.5
1/2 5.5 to 8.5 4.0 to 7.0
3/4 4.5 - 7.5 3.5 to 6.5
1 4.5 to 7.5 3.0 to 6.0
1 1/2 4.5 to 7.0 3.0 to 6.0
* For specified compressive strengths greater than 5,000 psi (34 MPa), air content may be
reduced 1%.
** Table 3.1.3 is a modified version of Table 4.1, ACI 201.2R
3.1.4 Compressive Strength
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STANDARD COMMENTARY
A compressive strength test is defined as the average of the

strengths of two specimens made from the same concrete batch,
cured in the same manner, and tested at the same age. The
compressive strength of the concrete as determined from test
specimens shall be equal to or greater than that specified by
design. If no strength is specified, the strength shall be sufficient
to minimize damage caused by product handling, and in no case Compressive strength is
shall the concrete strength be less than 2,500 psi (17 MPa) at commonly specified using
the time the product is shipped. cylinders made, cured, and
tested in a standard
manner, usually tested 28
days after the cylinders are
cast. However, some
specifications require
minimum strengths at ages
different than 28 days, and
some require cylinders to
be cured in the same
manner as the concrete
they represent.
If strengths are
consistently low, several
cylinders should be made
from one batch; some
should be cured in a
standard manner
(laboratory conditions
defined in ASTM C31),
while the rest are cured in
the same manner as the
product represented.
If the strengths of those
cured in the standard
manner are lower than
expected, the mix
proportions must be
adjusted to give higher
strengths. If specimens
cured in the standard
manner have satisfactory
strengths, while those
cured with the products are
low, curing must be
improved or the mix
adjusted, or both.
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STANDARD COMMENTARY
Most precast concrete

producers furnish their
products with strengths in
excess of 4,000 psi (28
MPa). Lower strength
concrete is damaged more
readily while it is being
handled. A minimum
strength of 2,500 psi (17
MPa) at the time of
shipment might be too low
to minimize damage for
some types of products, so
higher strengths are
recommended. A
minimum of 80 percent of
the 28-day design strength
is sometimes specified
prior to shipping products.
3.1.5 Admixtures
Admixtures shall be used in accordance with the manufacturers’ Some admixtures

instructions. If more than one admixture is used in a concrete conforming to ASTM C494
mix, data shall be obtained to assure that each admixture are affected by
performs as required without adversely affecting the composition of the cement,
performance of the others. Admixtures shall be introduced into particularly the tricalcium
the concrete mix in a controlled manner to assure uniform aluminate and the sulphur
distribution into the mix. trioxide contents. Thus it is
recommended that the
Admixture supplier shall supply certification of admixture dosing effectiveness of
equipment. Current certifications shall be dated not more than admixtures be evaluated in
one year at the end of the month from the date of the last test or concrete mixes at the plant
certification. so that the reaction
between the cement being
used and the admixture
can be noted. Some
admixtures are not
compatible with other
admixtures, particularly if
they are introduced into
the mix in a sequence
other than that
recommended by the
manufacturer.
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STANDARD COMMENTARY
1. Mix proportions for each mix shall be clearly listed and

maintained in the plant files and at the mixer. The water –
cementitious materials ratio of the mixes shall not exceed the
limits stated in Section 3.1.2 and shall be documented in the
mix proportion. The concrete shall be air-entrained if it will
be exposed to freezing and thawing per Table 3.1.3.
2. Compressive strength (7- or 28-day age) of the concrete
shall be tested a minimum of every 150 cubic yards (115
cubic meters) of concrete of each mix or once per week,
whichever occurs first. Strength data shall be retained in the
files for a minimum of three (3) years. If product is shipped
prior to obtaining strength data, additional compressive
cylinders shall be tested prior to shipping to ensure minimum
strength requirements are met. Rebound hammer tests can
also be used as an indicator for strength if the rebound
hammer has been properly calibrated. Strength data shall be
routinely reviewed and tracked by the quality control
manager.
3.2 BATCHING AND MIXING
3.2.1 Requirements for Batching and Mixing Plants
Plants shall be equipped so that batching and mixing will result in A wide variety of batch
adequately mixed concrete of the correct proportions with the plants from manual to fully-
desired workability of the fresh concrete and required properties automated can provide
of hardened concrete in adequate quantities to maintain the concrete of consistent
casting schedule. Plants for batching and mixing concrete and quality and can conform to
their operations shall conform to ASTM C94, “Standard these requirements.
Specification for Ready-Mixed Concrete.” Alternatively, plants
may conform to the requirements for batching and mixing given
in ASTM C685, “Standard Specification for Concrete Made by
Volumetric Batching and Continuous Mixing.”
3.2.2 Storage of Cement and Supplementary Cementitious

Materials
Separate bins or silos shall be provided for each type of bulk Cement will begin to
cement and supplementary cementitious materials. Bins and hydrate when it comes in
silos shall be watertight to prevent intrusion of moisture. Cement contact with water. Partly
and supplementary cementitious materials in bags shall be hydrated cement forms
stored under cover to prevent contact with moisture. lumps, which are difficult to
pulverize, and thus should
not be used. If lumps of
cement are discharged
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STANDARD COMMENTARY
from the bin, the bin should

be emptied and repaired if
necessary. Bagged
cement, which is lumpy,
should be discarded.
3.2.3 Handling and Storage of Aggregates
Aggregates shall be handled and stored in such a manner that Minimal handling of
segregation of particle sizes is minimized, gradations are kept aggregates is
within specified limits, contamination from underlying soil does recommended to curb
not occur and cross-contamination between adjacent aggregate segregation. Storing
stock does not occur. aggregates in conical piles
should be avoided.
In addition, organic matter (such as leaves and twigs) shall not Preferably aggregates
be allowed to accumulate and plants shall not be allowed to grow should be stored on slabs
in aggregate stockpiles. or on planking in horizontal
layers. Methods for
minimizing segregation of
aggregates are described
in ACI 304, “Guide for
Measuring, Mixing,
Transporting, and Placing
Concrete.”
3.2.4 Batching Equipment
Weigh batching equipment shall be maintained and operated in The tolerances given in
accordance with ASTM C94 or ASTM C685. this section are those
specified in ASTM C94
3.2.4.1 Mass Batching ASTM C94 and ASTM C685. Methods
For plants that utilize mass batching or a combination of mass for calibrating the
and volumetric (for liquid) batching, the equipment must be measuring equipment are
capable of measuring and batching the concrete raw materials outlined in those
within the following tolerances: standards. There are two
reasons for displaying
Cement ±1% calibration records
Cement plus supplementary prominently. Records that
cementitious materials ±1% show deviations should be
(for batches less than used by plant personnel to
1 cubic yard) 0 to +4% obtain correct readings.
Water ±1% Also, inspectors from
Fine Aggregates ±2% outside agencies can be
Coarse Aggregates ±2% assured that the
Cumulative Weigh Batch equipment has been
Aggregate ±1% calibrated recently.
Admixtures ±3% or ± dosage per bag of
cement, whichever is Cumulative Weigh Batching
greater of aggregate applies when
load cell equipment is fixed to
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STANDARD COMMENTARY
Scales shall be calibrated each year or any time there is a the hopper/bucket for weight
reason to question their accuracy. Calibration stickers shall be measurement rather than a
displayed prominently at the batch control location. Current weigh belt.
calibration and stickers shall be dated not more than one year at
the end of the month from the date of the last test or certification. Note that when using self-
Records for calibration of batch plant scales shall be readily consolidating concrete, very
accessible to the equipment operator. small discrepancies in batch
water content can be
Scale calibrations shall include the entire anticipated range of detrimental to the desired
use and the percent error at each test weight shall be properties of the mix.
documented. Scales shall be calibrated to within 0.2% of the
certified test weight at each quarter of the anticipated load range.
Liquid admixtures shall be measured by weight or volume.

Powdered admixtures shall be measured by weight. Calibration
of the admixture dispensers shall be performed each year.
Current calibration reports shall be dated not more than one year
at the end of the month from the date of the last test or
certification.
3.2.4.2 Volumetric Batching ASTM C685

Plants that utilize volumetric or continuous batching shall be
capable of proportioning the component materials in concrete
within the following tolerances:
Cement 0 to + 4% (mass)
Water ±1% (mass or volume)
Fine Aggregates ±2% (mass)
Coarse Aggregates ±2% (mass)
Admixtures ±3% (mass or volume)
3.2.4.3 Dry-Cast Concrete

For plants that utilize mass batching or a combination of mass
and volumetric (for liquid) batching, the equipment must be
capable of measuring and batching concrete raw materials within
the following tolerances:
Cement +/- 1% (mass)

Cement plus supplementary
Cementitious materials +/- 0.5 lb, or =/- 1% whichever
is greater (mass)
Aggregate +/- 2% (mass) individual or
cumulative
Water +/- 3% (mass or volume)
Admixtures (mass or volume) +/- 3% of total amount required
or plus or minus the amount or dosage required for 100 lbs. of
hydraulic cement, whichever is greater.
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STANDARD COMMENTARY
For plants that utilize volumetric batching and continuous mixing

ingredients shall be measured by volume. The equipment must
be capable of measuring and batching concrete raw materials
within the following tolerances:
Cementitious 0 to +4% (mass)
Fine Aggregate +/- 2% (mass)
Coarse Aggregate +/- 2% (mass)
Admixtures +/- 3% (mass or volume)
Water +/- 3% (mass or volume)
3.2.5 Discharge of Materials into Mixers
Mixer drum or blades shall be rotating while materials are Materials should be
discharged into the mixer. Materials shall be discharged into the discharged into the mixer
mixer in a sequence that ensures a homogenous mix. in a sequence that
approaches the ideal
Admixtures shall be fed into the mixer in a sequence that is condition. Each facility
recommended by the admixture supplier and to ensure uniform should develop and
distribution in the mix. The sequence of discharge and mixing document a sequence that
shall be documented and maintained at the concrete batching results in a uniform mix.
station.
For lightweight aggregates,
pre-wetting is
recommended to prevent
mix-water absorption. It is
also advisable to develop a
specific batching sequence
starting with the lightweight
aggregates and part of the
water before adding the
other materials.
3.2.6 Mixers
The batch size shall not exceed the capacity recommended by The condition of the mixer
the manufacturer. Mixers shall be capable of producing concrete should be checked daily
of uniform consistency and uniform coarse aggregate distribution for mortar or concrete
as required by ASTM C94 for batch mixing, ASTM C685 for build-up and worn blades.
continuous mixing, or ASTM C1837 for dry-cast. The manufacturer’s
drawing of the mixer tools
Mixers shall be checked daily for cleanliness, clearances on showing all dimensions
blades and shoes, proper gate seals, lockout controls. should be available so that
the amount of wear can be
determined. Blades and
mixing tools worn more
than 10% should be
adjusted or replaced.
Concrete and mortar build-
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STANDARD COMMENTARY
up should be removed and

discarded.
3.2.7 Mixing
Concrete may be mixed by (a) stationary central mixer, (b) ASTM C94 gives the
mixing screw (volumetric type), or (c) truck mixing and delivery. maximum permissible
differences in results of
For batch mixers, mixing time or number of drum rotations shall tests of samples of
be established by uniformity tests in ASTM C94, either by the concrete taken from two
equipment manufacturer or by qualified plant personnel. locations in a batch. Items
to be tested include unit
Daily reports of actual concrete mix proportions used in each weight, air content, slump,
batch and quantities of produced concrete shall be kept by the coarse aggregate content,
precast plant for at least three (3) years. and compressive strength.
If the differences in values
are within the tolerances
given in ASTM C94, the
mixer should be approved.
However, if the differences
in test results are greater
than the tolerances in
ASTM C94, the mixer
should not be used.
3.2.8 Ready-Mixed Concrete
Concrete supplied by a ready-mixed concrete producer shall The plant should verify that
meet the requirements of ASTM C94 (whether located at the the ready-mixed concrete
same location as the precast plant or off-site) and shall conform supplier is operating in
to the requirements given in Sec. 3.2.1 through 3.2.7. The accordance to ASTM C94.
facilities for batching concrete supplied by a ready-mixed
concrete producer shall conform to the same requirements of It is suggested that plants
batch plant facilities cited above. Certification of the supplier’s consider testing every
facilities by the National Ready Mixed Concrete Association truck load for slump,
(NRMCA) or State DOT shall be evidence of conformance to temperature, air content,
Sec. 3.2.1 through 3.2.7. In addition, the plant shall maintain a and density prior to casting
file of current mixture designs, batch plant printouts, truck products to ensure
delivery receipts, and appropriate raw material certifications and consistency beyond the
gradations. Total quantities of raw materials used by the precast minimum requirements of
plant shall be used to determine the required frequency of raw Section 5.3. Mark any
materials testing. added water on the
delivery batch ticket for
Concrete testing shall be performed per Section 5.3 of this each truck and keep on
manual at the location of final placement. file.
Truck delivery receipts shall be received with each load. Record

all water added at the plant to the ready-mixed concrete
deliveries.
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STANDARD COMMENTARY
“Bring-back” concrete or any other concrete originally intended

for an entity other than the precast concrete manufacturer shall
not be used for production of precast concrete products.
1. Aggregate stockpiles shall be properly configured to

minimize segregation and contamination.
2. Scales shall be calibrated each year and the calibration
sticker displayed prominently at the concrete batch control
station. Current calibration reports and stickers shall be dated
not more than one year at the end of the month from the date
of the last test or certification.
3. Batching tolerances for all concrete components shall
conform to the tolerances listed in Section 3.2.4.
4. Mixers shall be checked daily for cleanliness, clearances on
blades and shoes, proper gate seals, lockout controls, etc.
5. Ready-mixed supplied concrete shall be from a NRMCA or
State DOT certified plant or conform to all above
requirements. Documentation of the ready-mix supplier’s
conformance shall be maintained in the files at the precast
plant. Truck delivery receipts and any water added at the
precast plant shall be documented. Only fresh concrete
intended for the precast concrete manufacturer is permitted
to be used for production of precast concrete products.
6. Daily reports of actual concrete mix proportions used in each
batch and concrete quantities produced shall be kept by the
precast plant for at least three (3) years.
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STANDARD COMMENTARY
CHAPTER 4 – PRODUCTION PRACTICES
4.1 GENERAL
4.1.1 Plant Layout
The physical layout of the plant shall be such that production, Because of the wide range in
handling, storage and shipment of concrete products can be sizes of precast concrete
done in an efficient, safe manner and with minimal product manufacturing plants and in
damage. the diversity of products
manufactured, there can be
The plant layout shall incorporate the following general no standard or ideal
guidelines: organization structure or plant
layout.
1. Minimize transport distances of fresh concrete.
2. Adequate workspace to minimize safety and tripping
hazards.
3. Avoid stripping or lifting products over personnel or
equipment.
4. Prevent marking or splash on other products during casting
operations.
5. Adequate storage space for materials.
6. Adequate space to strip products and perform post-pour
inspections and repairs.
4.1.2 Housekeeping
Each plant shall have an active housekeeping program. The A clean plant provides a
purpose of the program shall be to provide a clean and safe much better environment for
environment so that quality precast concrete products can be producing quality products
manufactured efficiently. than does a cluttered plant. A
clean plant is also good for
The plant QC Inspector shall spot-check housekeeping daily. morale of workers, minimizes
safety hazards, and generally
improves production
efficiency and quality.
Some plants require each

worker or crew to be
responsible for the
cleanliness of a particular
area of the plant. In other
plants a “clean-up” or
housekeeping crew is
responsible for the
cleanliness of the entire plant.
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STANDARD COMMENTARY
In general, management
attitude will dictate the effort
expended in keeping a plant
clean.
4.1.3 Forms and Forming Equipment
Forms and forming equipment for manufacturing precast Forms that are well built and
products shall be of a quality that prevents product damage due properly maintained can be
to forces and vibrations subjected to the forms. used almost daily for 20
years or more. Quality
All forms and forming equipment (including pallets, headers, forms are rugged yet
truing rings) shall be measured prior to initial use and/or after produce surface defect -free
repairs for dimensional conformance with applicable tolerances. products within dimensional
Reports shall be maintained in the plant records for a minimum tolerances. Typically, form
of three (3) years. dimension tolerances should
be about half the product
Forms shall be carefully cleaned of concrete build-up after each tolerances specified.
use. Coatings of form release agents shall not be allowed to Follow your form
build up. manufacturer’s form leveling
and setup
Forms for manufacturing precast concrete products shall be of recommendations.
the type and design consistent with industry standards and It is suggested that plants
practices. They should be capable of consistently providing give each piece of forming
uniform products and dimensions. Forms shall be constructed so equipment a unique
that the forces and vibrations to which the forms will be subjected identification number in
can cause no product damage. order to easily track and
document their
measurements
A routine maintenance
program to repair hinges,
remove bulges, minimize
seam leakage, etc.; can
result in improved quality as
well as reduced production
costs.
4.1.4 Handling Equipment
Equipment such as hoists, overhead cranes, gantries, mobile Routine inspections should
cranes, and fork lift trucks shall be used to lift and handle be made of all handling
products which weigh less than the rated capacity of the equipment to assure that
equipment. safety is not compromised.
Worn cables and other parts
Inspection and maintenance records for all handling equipment should be replaced or
must be maintained in accordance with applicable requirements. repaired. The equipment
operators should make daily
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STANDARD COMMENTARY
inspections of all handling

equipment.
Ensure all crane and lift

operators are properly
trained and meet OSHA
requirements. Forklift
operators should be familiar
with local and OSHA safety
requirements and the NPCA
Guide to Plant Safety.
4.1.5 Machine-Made and/or Dry-Cast Products
Precast concrete products that are manufactured by mechanized Many products such as
equipment and/or dry-cast process shall conform to the patio stones, interlocking
applicable provisions of this manual. pavers, and manhole
sections can be dry-cast or
Verification of the reinforcing steel for conformance with the manufactured with
design shall be performed and documented on a minimum of mechanized equipment. In
one (1) reinforcing steel cages or 3% of each production run such operations, control of
daily, whichever is greater, chosen on a random basis by QC the concrete mixture is
personnel for products produced in the plant with mechanized critical because the
equipment. At least one cage shall be checked when a shift products are stripped
change occurs during the course of a production run and immediately after they are
whenever a setting is changed. These reinforcing steel checks cast, and the concrete
shall be documented and maintained in the plant records for a units must retain their
minimum of three (3) years. shape.
Dimensions of machine-made products shall be within See section 4.2.1 for

acceptable tolerances regardless of any slumping of the inspection requirements for
concrete after stripping. reinforcement that is not
fabricated in the plant
Dimensional checks of machine-made products shall be using mechanized
performed daily for each type of product cast. Dimensional equipment.
checks shall be performed on a minimum of one (1) product or
3% of each production run daily, whichever is greater, chosen on
a random basis by QC personnel. These dimensional checks
shall be documented and maintained in the plant records for a
minimum of three (3) years.
If non-conforming product is discovered, the plant shall take

immediate action to correct all non-conforming issues.
4.1.6 Architectural Precast Concrete
Architectural precast concrete is defined as concrete which will Concrete products can be
be permanently exposed to view and when required by owner or created through
specification requires special care in selection of concrete adjustments to shape,
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STANDARD COMMENTARY
materials, forming, placing and finish to obtain the desired color, finish/texture or
architectural appearance. design to create an
By its inherent nature, the level of quality, in terms of appearance that fits the
appearance, is of the utmost importance. Final product shall needs of the public and/or
match previously approved samples and/or already established project specific design
industry standards stated in individual job specifications. requirements. Color can
Consistent quality shall be maintained through documented be affected by the choice
plant-specific procedures, as required in Section 1.1.2. Strength of cement, coarse and fine
and durability shall not be compromised for architectural aggregates or pigment
appearance, unless a specific application or specification allows used and how they are
deviations. proportioned. Finishes can
be applied in a number of
Natural stone or clay products may be used as a veneer to ways such as
create the desired finish. Procedures to accommodate sandblasting, pressure
differences in thermal and moisture movement between the wash or other mechanical
veneer and the concrete shall be established. means.
4.1.6.1 Surface Finishes Various procedures for an

architectural finish may
All exposed surfaces shall be free of form defects, joint marks vary from plant-to-plant. It
and shall be within the color variation as defined by the approved is the precast concrete
samples and/or mock up. All details such as false joints, producer’s responsibility to
chamfers, etc. shall be as designed on the approved shop establish the proper
drawings. methods to achieve a
Architectural finishes shall be according to the requirements of specific finish.
project documents and performed per industry standards or
supplier specifications. Depending on the type of
Precast concrete producers shall submit finishes for approval product, a wide range of
when required by the project documents. Life size mockups are strength and durability
recommended for the approval of architectural finishes, because requirements may be
color variations and surface imperfections are not always expected (i.e. a birdbath
apparent on small scale samples. The sample finishes shall be and a post-tensioned wall
approved prior to the start of production. panel will not necessarily
be expected to perform
4.1.6.1.1 As Cast equally).
Surfaces shall be cast against approved forms following industry Careful attention shall be
practices in cleaning forms, designing concrete mixes, placing made when using veneers.
and curing concrete. Slight color variations, small surface holes Establishing standards to
(up to ¼ inch diameter) caused by air bubbles will be accepted accommodate material
but no major imperfections, excessive honeycombing, sand incompatibility shall be well
streaks or other major defects shall be permitted. Particular researched.
attention should be paid to selection of raw materials, and control
of water-cementitious materials ratio in order to minimize color
variation.
Proper casting procedures and mix design as per chapter 4 shall
be used to minimize air voids on surfaces.
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STANDARD COMMENTARY
Mockups should be cast for approval for acceptance of color

variation and quantity of voids.
4.1.6.1.2 Exposed Aggregate Finish
By means of chemical surface retarders which shall be removed

by water washing, brushing or abrasive blasting or a combination
as defined in the project specifications. The finish shall be free of
honeycombing or segregation of aggregates.
Surface retarders must be applied evenly and consistently to the

form. Keep concrete drop heights low during placement to
reduce damage to the surface retarder. Also, vertical and curved
sections may have surface retarders scoured during placement.
Place the concrete from the lowest to the highest part of the form.
Once the retarder has been applied to the form, water shall not
come in contact with that retarder. Follow retarder
manufacturer’s recommendations.
4.1.6.1.3 Abrasive Blast Finish
Materials used for blasting shall be free of deleterious

substances. Proper safety gear should be worn to prevent
inhalation of fine particles. Pieces shall be blasted at the same
age to ensure consistency.
Remove the surface of the concrete, to a specified approximate

depth, by means of an abrasive grit which is typically projected at
the surface pneumatically.
4.1.6.1.4 Acid Etch Finish
Acid etching should be performed only after adequate curing and

a minimum compressive strength of 4,000 psi. Prior to applying
acid, paint or seal all exposed metal surfaces and exposed
insulation.
The concrete surface must be thoroughly wetted prior to applying
acid to avoid streaking and overexposure. Pay special attention
to returns, flat areas or locations where acid may puddle or
concentrate, as this may also cause overexposure. The surface
should be flushed with clean water to remove all residue within
15 minutes of the original acid application.
Use only acid-resistant siliceous aggregate in the concrete.

Provisions must be made to protect hardware and insulation if
applicable.
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STANDARD COMMENTARY
4.1.6.1.5 Honed or Polished
Remove the surface of the concrete, to a specified approximate

depth, by means or grinding with water and an abrasive grit. The
compressive strength of the concrete should be a minimum of
5,000 psi, with all repairs and filling of bug holes completed and
cured prior to grinding.
4.1.6.1.6 Bush-hammered or tooling
The use of tooling techniques, hammers or equipment to abrade

the surface of the precast should only be performed by trained
personnel. The protective cover of the reinforcement should be
increased to account for the removed concrete surface.
4.1.6.1.7 Unformed Surfaces
Surfaces shall be finished with a vibrating screed, or by hand with

a float. Normal color variations, minor indentations, minor chips
and spalls will be accepted but no major imperfections, excessive
honeycombing or other major defects shall be permitted. If no
finishing procedure is specified, such surfaces shall be finished
using a strike-off to level the concrete with the top of the form.
4.1.6.1.8 Special Finishes
Trowel, broom or other finishes shall be according to the

requirements of project documents and performed per industry
standards or supplier specifications.
Precast concrete producers shall submit finishes for approval

when required by the project documents. The sample finishes
shall be approved prior to the start of production.
4.1.6.1.9 Architectural Finishes
Architectural finishes shall be according to the requirements of

project documents and performed per industry standards or
supplier specifications.
Precast concrete producers shall submit finishes for approval
when required by the project documents. Life size mockups are
recommended for the approval of architectural finishes, because
color variations and surface imperfections are not always
apparent on small scale samples. The sample finishes shall be
approved prior to the start of production.
With all finishes, aggregate exposure shall be no greater than 1/3
the average diameter of coarse aggregate and not more than ½
the average diameter of smallest size coarse aggregate.
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STANDARD COMMENTARY
A groove or recess shall be incorporated into the surface of a unit

having two or more different mixes or finishes. The different face
mixes shall have relatively similar behavior with respect to
shrinkage, to avoid cracking at the groove or recess.
4.1.6.1.10 Embedded Veneer
When designing with veneer, it is important to take into account

differences in properties between the veneer material and the
concrete backer. These and other factors such as concrete
shrinkage rates, exposure, span lengths, connection design and
thickness of veneer material and precast backer may lead to an
increase in potential bowing (typically outward). The differences
in coefficients of thermal expansion between the veneer material
and the concrete backer should be minimized (see Table 1).
Otherwise, length change may occur at different rates resulting in
differential stresses that may result in outward bowing. To offset
this concern precasters may build an inward bow or camber into
the form when casting the panels, use prestressing or, when
panel thickness allows, use a double reinforcing cage. Additional
tie-back connections have also been known to help restrain
bowing potential.
4.1.6.1.10.1 Stone Products
A bond breaker is typically used to prevent concrete from directly
bonding with the stone. Bond breakers allow for differential
movement between the precast concrete backer and the stone
veneer, helping prevent staining and cracking of the veneer.
Some common materials used to create a bond breaker are:
• 6 to 10 millimeters polyethylene sheet

• Closed cell, 1/8- to 1/4-inch-thick foam pad
• Thin liquid bond breaker (such as polyurethane)
A flexible, mechanical anchor should be used to attach stone to

precast concrete. Anchors should also be corrosion-resistant.
Anchors differ in shape, depending on the type and strength of
the stone. However, most anchors have a recognizable cross
pattern with the veneer-embedded portion arranged at a 30 to 45
degree angle from the back of the stone, penetrating
approximately 3/4-inch or half the thickness of the veneer –
whichever is greater.
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STANDARD COMMENTARY
4.1.6.1.10.2 Clay Products
Clay products are typically cast into or bonded to the concrete,

creating a monolithic unit. Properties of the clay product, such as
coefficients of thermal expansion (see Table 1), absorption,
modulus of elasticity and volume change should be considered in
the design as well as in-service conditions, such as temperature
differentials between the exterior and interior surfaces.
Many clay products are “fired” and expand in the presence of
moisture, including effects from humidity. However, this can be
compensated in the precast concrete panel. For example, grout
or concrete mortar between the clay products shrinks and helps
compensate for expansion. The mortar joints may also
experience elastic deformation under stress, which can
compensate for expansion of the clay brick.
There are specific recommendations when using certain clay
products in precast concrete. First, while there are several types
of bricks available, not all bricks are acceptable for use in
precast. Precast concrete requires tight tolerances in the
individual bricks due to the form tolerances and the alignment of
units. Bricks should meet ASTM C1088, Type TBX. (Note: the
recommended tolerance for bricks used in precast is plus zero or
minus 1/8 inch.) Otherwise, bricks may be moved or tilted by
concrete placement and require repair. As for non-brick clay
products, glazed or unglazed ceramic tile should conform to
ANSI A137.1 and adhere to a tolerance of 1 percent. Terra cotta
is usually a custom product and has a maximum length and width
tolerance of plus or minus 1/16 inch.
The absorption and initial rate of absorption of clay products

directly bonded to precast concrete will have an effect on bond.
Brick absorption should be between 6 percent and 9 percent
when tested in accordance with ASTM C216. Bricks should have
an initial rate of absorption less than 20 grams per minute per 30
square inches, according to ASTM C67. These bricks are not
required to be wetted. Bricks exceeding this value should be
wetted to avoid removing moisture from the concrete and
reducing bond. Terra cotta is typically soaked prior to use to
avoid excessive suction of the moisture from the curing concrete.
Generally, the bond strength between a veneer material and
precast concrete exceeds the bond strengths of conventional
field-laid applications.
Clay products should also have some physical characteristic for
mechanical means of bonding with the concrete such as grooves
or scoring on the back side of the piece.
Almost any pattern, such as running bond or stack patterns for
brick can be used. Custom designs or combinations of materials
may also be incorporated. Units should be designed to minimize
cutting of the smaller veneer products.
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STANDARD COMMENTARY
1. Maintain an active housekeeping plan. Continual efforts

shall be made by all production personnel to maintain a clean
work area. Spot-check by QC Inspector at least once each
work shift.
2. Maintain inspection records of all handling equipment in
accordance with applicable requirements.
3. For reinforcement fabricated with mechanized equipment
and used in machine-cast, or dry-cast products, perform and
document reinforcing checks on a minimum of one (1)
reinforcing cages or 3% of each production run daily,
whichever is greater. At least one cage shall be checked
when a shift change occurs during the course of a production
run and whenever a setting is changed.
4. For machine-cast and/or dry-cast products, dimensional
checks shall be performed and documented on a minimum of
one (1) products or 3% of each production run daily,
whichever is greater.
5. Appearance of architectural precast concrete shall match
approved samples and meet industry standards.
Compatibility of veneers shall be established and
documented. Production and quality control measures shall
be developed and documented in the plant-specific QC
manual.
6. Unless otherwise noted, maintain records for a minimum of
three (3) years.
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STANDARD COMMENTARY
4.2 FABRICATION OF REINFORCEMENT AND

BLOCKOUTS
4.2.1 Fabrication of Reinforcement*
All reinforcing steel shall be fabricated to a detailed reinforcing * Critical Requirement –

steel plan document in conformance with the precast concrete plants participating in the
product tolerances and / or tolerances provided in the project NPCA Plant Certification
specifications or plans. If no dimensional tolerances have been Program must receive a
established, or references given, the plant shall specifically state minimum passing grade, as
on the plan documents or in the plant specific quality control shown on the grading
manual, the dimensional tolerance scheme that will govern for schedule, for section 4.2.1
the product; such as but not limited to the Concrete Reinforcing and others designated as
Steel Institute (CRSI) publication, “Placing Reinforcing Bars” and Critical Requirements, when
/ or the Reinforcing Steel Institute of Canada / Institut D’acier applicable.
D’armature du Canada (RSIC / IAAC) publication, “ Reinforcing
Steel, Manual of Standard Practice” Adequate concrete cover
is required in order to
Reinforcing steel cages shall be inspected for conformance to protect the steel against
approved design requirements and documented with the pre- corrosion and to provide
pour inspection. The inspection requirements are detailed in adequate structural bond
Section 4.3.3 Positioning of Reinforcement. between the steel and
concrete. Cages should
All reinforcing bars shall be bent in accordance with standard be made so that concrete
CRSI and RSIC / IAAC fabrication practices and bend diameters cover requirements are
shall not be less than those established by CRSI and RSIC / maintained.
IAAC.
When inspecting
Cages of reinforcement shall be fabricated either by tying or reinforcing steel cages, the
clipping the bars, wires or welded wire reinforcement into rigid approved design
assemblies, or by welding where permissible in accordance with documentation they are
Section 4.2.2. compared to may consist
of plant shop drawings.
Damage to the coating on epoxy-coated reinforcing steel shall be
repaired with patching material in a manner conforming to the
patching material manufacturer’s recommendations. When
epoxy-coated reinforcing steel is cut or welded, the cut ends and
the weld areas shall be repaired with patching material. Epoxy-
coated reinforcing steel shall not be flame cut.
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STANDARD COMMENTARY
4.2.2 Welding of Reinforcing Steel
Cages of reinforcement may be welded if permitted by the Reference the American

applicable ASTM product standards. Welding of reinforcing steel Concrete Institute’s
may be also permitted in other situations as determined by the Building Code (ACI 318)
manufacturer where the steel is not used for structural purposes. and The American Welding
Society publication (AWS
In all cases care and discretion must be used to assure that the D1.4). Each references
integrity of the precast product is maintained. each other within their
codes. Both contain
Reinforcing steel used for structural purposes may be welded as complete and useful
long as it is accomplished in compliance with standards set forth guidelines for welding of
in the American Concrete Institute’s “Building Code reinforcing steel.
Requirements for Reinforced Concrete” (ACI 318) and The
American Welding Society’s “Structural Welding Code -
Reinforcing Steel” (AWS D1.4).
Welding of ASTM A615 reinforcing steel is not generally an

acceptable practice. According to the American Welding Society
D1.4 Structural Welding Code for Reinforcing Steel, the carbon
equivalent for bars to be welded should be less than
0.45 percent for bars larger than #7 and 0.55 percent for #6 bars
and smaller. If ASTM A615 steel is to be welded, the carbon
equivalent shall be calculated and the bars preheated if
necessary.
Use of ASTM A706 weldable grade rebar for welding

applications is acceptable.
The Carbon Equivalent (CE) for ASTM A615 reinforcing steel is

calculated as follows:
CE = %C + %Mn/6
The Carbon Equivalent (CE) for ASTM A706 reinforcing steel is

calculated as follows:
CE = %C + %Mn/6 + %Cu/40 + %Ni/20 + %Cr/10 -

%Mo/50 - %V/10
4.2.3 Welding of Steel Assemblies
Welding of steel assemblies which are cast into or attached to Most structural steel
precast concrete products shall be performed in accordance with assemblies in precast
American Welding Society D1.1, “Structural Welding Code - concrete consist of ASTM
Structural Steel.” A36 steel, which is readily
weldable with standard
equipment. Welding of
stainless steel and steels
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STANDARD COMMENTARY
other than ASTM A36 steel

should be performed in
accordance with AWS
D1.1.
4.2.4 Fabrication and Positioning of Blockouts
Blockouts may be made of any rigid, non-absorptive material that Expendable blockouts are
will not harm the concrete and that can be held in place during often made of non-
the casting and curing of concrete. Dimensional blockout absorptive expanded
tolerances shall be specified for each product and blockout type. polystyrene. Reusable
blockouts are made of a
Blockouts may be held in place during casting with non-corrosive variety of materials such as
supports or with reinforcing steel, unless prohibited by project wood, steel, sheet metal,
specifications. rubber, neoprene, and a
variety of plastics. Most
blockouts tend to float
during and immediately
after casting concrete so
they must be held rigidly in
place. Blockouts should
be designed to minimize
damage to the concrete
when they are removed.
Coring holes in the
hardened concrete is
sometimes used instead of
installing blockouts.
1. Reinforcement shall be fabricated within applicable

tolerances and supported rigidly.
2. Welding of ASTM A615 reinforcing steel is allowed when

following an approved welding procedure meeting the
requirements of AWS D1.4/D1.4M. Copies of the approved
welding procedure shall be included in the Plant Specific
Quality Control Manual and available for review.
3. Blockouts shall be non-absorptive and held rigidly in

place with non-corrosive supports or with reinforcing
steel, unless prohibited by project specifications.
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STANDARD COMMENTARY
4.3 PRE-POUR OPERATIONS
4.3.1 Cleaning of Forms
Forms shall be cleaned after each use. Concrete, tape, It is generally easiest to
polystyrene, and other materials adhering to the forms shall be clean forms immediately
removed. after products are stripped.
Waiting too long allows the
concrete to bond more
tenaciously to the forms.
4.3.2 Application of Form Release Agent
Form release agent shall be applied after the forms are cleaned Form release agents
and, if necessary, the seams sealed. Reinforcement and other prevent concrete from
items to be embedded in concrete shall be free of form release bonding or adhering to
agent. Care shall be taken to avoid over-application of form forms. Reinforcement,
release agent, which may lead to puddling. If puddling does inserts and other
occur, the puddle shall be removed prior to casting. embedment items on
which form release agents
have been inadvertently
applied may fail to bond to
the concrete and may be
ineffective in performing
their intended functions. It
is recommended that form
release agents be applied
in a thin coat and there
should be no puddles.
4.3.3 Positioning of Reinforcement*
Reinforcing steel shall be positioned as specified by the design * Critical Requirement –

and the concrete cover must conform to product requirements. plants participating in the
Unless otherwise required, the tolerance on concrete cover shall NPCA Plant Certification
be one-third of that specified but not more than ½ inch. Concrete Program must receive a
cover shall not be less than ½ inch, however concrete cover minimum passing grade, as
greater than ½ inch is recommended. Positive means shall be shown on the grading
taken to assure that the reinforcement does not move schedule, for section 4.3.3
significantly during the casting operations. Cages shall be and others designated as
supported away from all form surfaces. Liberal use of chairs, Critical Requirements, when
spacers, and positioning wheels is encouraged especially with applicable.
small diameter bars or wire. Rolled welded-wire reinforcement
shall be mechanically straightened to use in straight-walled
products.
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STANDARD COMMENTARY
Plants shall maintain a documented process of reinforcing steel / For precast products made
cage inspections including information on the required cage in accordance with
design versus the actual cage used; including the following as standards like ASTM (e.g.
applicable to the product produced: manholes, barriers and
• Bar size and/or WWR bar diameter; utility structures) the
• Bar spacing and/or WWR style; reinforcement positions are
• Steel area (As); cited in the standards. For
• The quantity of bars; products not made in
(Inspections may include one or more of the above per accordance with
detailed reinforcing steel plan documents); standards, ACI 318
• The effective depth (d), (the distance from the generally determines
compressive face to the centroid of the tensile reinforcement positioning.
reinforcement member);
• The concrete cover, never less than ½” clear;
• The lap splice length;
• Cage dimensions: length, width, height, and/or diameter,
as applicable;
• Reinforcing steel condition:
o Clean or light red rust, not flaking or pitted;
o Free from oils, dirt, or other contaminants;
o If welded, meets the requirements of section 4.2.2;
o If welded, does not contain any damage, such as
gouges and undercut;
• Reinforcement hooks and bends (90° and 180°). If
design, project specifications, and/or detailed reinforcing
steel plans require a bend in reinforcing steel around a
corner, substitution of straight sections tied together shall
not be acceptable practice.
Verification of the reinforcing steel for conformance with the

design, form dimensions, form tightness, form cleanliness, form
release agent application, embedded items and blockouts shall
be performed and documented on a minimum of
one (1) reinforcing steel cage and form setup or 3%, whichever is
greater, of each production run daily, whichever is greater,
chosen on a random basis by QC personnel for each product
category produced in the plant. At least one cage and form setup
shall be checked when a shift change occurs during the course of
a production run.
These reinforcing steel, form dimensions, form tightness, form
cleanliness, form release agent application, embedded items and
blockouts checks shall be maintained in the
plant records for a minimum of three (3) years.
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STANDARD COMMENTARY
4.3.4 Positioning of Miscellaneous Embedded Items
Embedded items shall be positioned at locations specified in the Some embedded items are
design. Inserts, plates, weldments, lifting devices and other placed in the concrete after
items to be embedded in precast concrete products shall be held concrete has been cast but
rigidly in place during casting operations. before it hardens. If
embedded items such as
lifting inserts are required
to develop significant
stresses, care should be
taken to ensure adequate
consolidation of the
concrete around the item.
1. Pre-pour inspections shall be performed prior to casting each

form. Form dimensions, form tightness, form cleanliness,
form release agent application, positioning and securing of
reinforcing, embedded items and blockouts shall be checked.
2. The plant shall have a procedure to identify when a form has
received a pre-pour inspection and is ready for casting.
3. Documentation of the pre-pour inspections can be on a piece
or production shift basis and must be documented at least
daily.
4. Pre-pour inspections for machine-made products shall be a
minimum of checking the form condition prior to each work
shift and checking and documenting reinforcing cages as
required in Section 4.1.5.
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STANDARD COMMENTARY
4.4 CASTING CONCRETE
4.4.1 Transporting Concrete
Concrete may be transported from the mixer to the casting After concrete is
location by any means that does not contaminate the concrete or discharged from a mixer all
cause excessive segregation. Concrete discharged directly from casting operations tend to
the mixer into the forms is permitted. cause segregation.
Excessive segregation is
undesirable. Thus all
casting operations should
be done in such a way that
segregation is minimized.
An effective method of
minimizing segregation is
to minimize handling of the
concrete. If possible,
concrete should be
delivered directly to the
forms after it is discharged
from the mixer.
4.4.2 Depositing Concrete into Forms
Conventional concrete shall be deposited into forms as near to Generally concrete can be
its final location as practical keeping free fall of concrete to a deposited into forms with
minimum. minimal free fall.
Conventional concrete (not
SCC shall be deposited into forms at a minimum distance to SCC) should first be
avoid segregation and allowed to flow freely in order to deposited in one corner or
completely fill the form. edge of flat forms and
additional concrete should
be deposited into
previously cast concrete
until the form is filled. For
vertical forms such as
walls or pipe sections,
concrete should be cast in
horizontal layers instead of
depositing the concrete to
full height at one point and
allowing the concrete to
flow to other locations.
There are exceptions to
that rule. For example,
when using SCC or when
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STANDARD COMMENTARY
casting a wall section with

a large rectangular
blockout, concrete is
generally cast high on one
side of the blockout and
the concrete is allowed to
flow beneath the blockout
until the level of concrete
on the opposite side is
higher than the bottom of
the blockout.
Similarly, when casting an

open-top, five-sided box,
concrete is allowed to flow
from one vertical side
beneath the top form of the
bottom slab until the
concrete begins to rise on
the opposite side. For
such products, the use of
high-range water reducers
(superplastercizers) and
continuous vibration are
recommended unless a
self-consolidating concrete
mix is used.
4.4.2.1 Placing Face Mix
When placing a face mix, care must be taken to avoid coating

the reinforcing with cement paste that may affect the proper
bonding of the back-up mix.
4.4.2.2 Placing Back-up Mix
When placing back-up mix, care must be taken not to disturb

face mix.
4.4.3 Consolidating Concrete
Concrete shall be consolidated in such a manner that Proper use of vibrators to

segregation of the concrete is minimized. Vibrators used to consolidate concrete
consolidate concrete shall have frequencies and amplitudes requires trained operators.
sufficient to produce well-consolidated concrete. High slump concrete, such
as concrete with slumps
Internal vibrators shall be lowered vertically into the concrete greater than about 5
without being forced downward until the tip of the vibrator inches can easily be over-
reaches the bottom of the form or until it penetrates into a vibrated thus causing
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STANDARD COMMENTARY
previously consolidated lift. Vibrate the concrete until air bubbles excessive segregation.
within the vibrator’s field of action essentially stop coming to the Low slump concrete, (i.e.,
surface. Withdraw the vibrator slightly slower than it was slump less than about 3
lowered. Reinsert the vibrator making sure the fields of action inches) is seldom over-
overlap and repeat the vibration process until all of the concrete vibrated to the point that
in the product has been consolidated. Do not use vibrators to excessive segregation
move concrete laterally. occurs. Excessive
vibration can reduce the
External vibrators (form vibrators) shall be mounted on the form amount of entrained air in
structure in locations that best distribute their impact, but not the concrete and can
directly on the form skins. External vibrators shall operate until adversely affect the
air bubbles essentially stop coming to the surface. durability of concrete
exposed to freezing and
Surface vibrators (vibrating screeds) shall be moved at a rate thawing environments.
such that air bubbles essentially stop coming to the surface. Trained operators follow
the procedures given in
Similarly, vibrating tables shall operate only long enough that air Sec. 4.4.3 and can sense
bubbles essentially stop coming to the surface. the effectiveness of
vibration by watching the
Consolidation of machine-made products shall be considered to surface, and by the sound
be adequate if the products are free of honeycombed areas. of the vibrator when the
concrete is fully
SCC is often referred to as concrete that does not consolidated.
require vibration. For more intricate formwork, or formwork
containing heavy reinforcement or blockouts, the producer may Refer to Section 3.1.1 for
find that light vibration or tapping of the forms will allow for the the use of self-
concrete to be fully compacted. This can eliminate problems of consolidating concrete.
bugholes, honeycombing, voids and incomplete filling of
formwork.
4.4.4 Finishing Unformed Surfaces
Unformed surfaces of wet-cast precast concrete products, such After concrete has been
as step and, platform slabs which will serve as wearing surfaces consolidated and struck
for foot traffic or light vehicular traffic, shall be finished as off, no finishing, except
specified. If no finishing procedure is specified, such surfaces perhaps edging, should be
shall be finished using a strike-off to level the concrete with the done until the concrete is
top of the form. stiff enough to support the
weight of a man without
leaving footprints deeper
than about 1/4 inch
Excess bleed water on the
surface should be removed
using a squeegee or a
rubber hose pulled across
the surface before finishing
the concrete. The surface
should then be floated
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STANDARD COMMENTARY
using a wood or
magnesium float, followed
by troweling, if required.
For hard, dense surfaces,
repeated trowelings may
be needed.
Recommended procedures
for finishing are given in
ACI 302, “Guide for
Concrete Floor and Slab
Construction.”
ACI 350, “Environmental

Engineering Concrete
Structures” cites the
surface finish as a
significant factor for water
tightness.
4.4.5 Secondary Pours
For products that require secondary pours, procedures shall be The surfaces of the
established to assure that concrete cast during the secondary product against which the
pour adequately bonds to the precast concrete product and secondary pour is to be
becomes an integral part of that product. made should be free of
laitance, dirt, dust, grease
or any other material that
will tend to weaken the
bond between the original
and new concretes. If the
surface is very smooth, it
should be roughened to
help promote good bond.
The procedures given in
Sec. 4.7.1 may be useful in
assuring secondary pours
of adequate quality and
bond.
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STANDARD COMMENTARY
4.4.6 Hot Weather Precautions
In hot weather the temperature of concrete at the time of placing There are generally more
shall not exceed 90 degrees F (32 degrees C). problems in placing concrete
in hot weather than there are
If allowed by project specifications or authority having jurisdiction, in cold weather, therefore
the maximum temperature of concrete at the time of placement emphasizing the importance
shall not exceed 95 degrees F (35 degrees C) of quality practices. Refer to
ACI 305R, “Specifcation for
For the purposes of this manual and according to ACI 305R, Hot Weather Concreting.”
“Specification for Hot Weather Concreting,” hot weather is
defined as any combination of the following conditions that tend The following list presents
to impair the quality of freshly-mixed or hardened concrete by some hot weather rules-of-
accelerating the rate of moisture loss and the rate of cement thumb:
hydration:
- High ambient temperature 1. Concrete sets and
- High concrete temperature hardens faster. This
- Low relative humidity means that concrete
- Wind must be deposited,
- Solar radiation consolidated and
finished quickly if the
Special precaution shall be taken in hot weather for concrete that concrete temperature is
is cast out-of-doors in order to prevent plastic shrinkage cracking high.
and low strengths. These precautions may include:
2. On warm windy days,
plastic shrinkage cracks
1. Using cold water or adding ice as part of the mixing water.
are likely to form unless
2. Sprinkling aggregate stockpiles. precautions are taken.
3. Fog spraying forms immediately prior to casting. 3. Unless curing begins
immediately, the surface
4. Placing fog sprays upwind and above the products during
of the concrete is likely
concreting, particularly during finishing of unformed surfaces.
to dry out, resulting in
5. Application of a product that aids in the control of evaporation cracking or weakening of
of water from the concrete surface, such as wet burlap, the concrete surface.
plastic sheeting and / or curing compound as soon as
concreting is completed.
6. Monitor concrete temperatures during curing.
4.4.7 Cold Weather Precautions
In cold weather the temperature of concrete at the time of In cold weather, if concrete
placing shall not be less than 45 degrees F (7 degrees C). does not freeze before its
strength reaches at least
For the purposes of this manual and according to ACI 306R, 500 psi (3.4 MPa), it will
“Cold Weather Concreting,” cold weather is defined as a period eventually be stronger than
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when the ambient air temperature of the casting environment, similar concrete cast in
for more than three (3) consecutive days, the following warm weather. Setting time
conditions exist: is delayed in cold weather
- The average daily air temperature is less than 40 and concrete gains strength
degrees F (5 degrees C), and slowly, but most properties
- The air temperature is not greater than 50 degrees F of concrete are improved.
(10 degrees C) for more than one-half of any 24-hour Because of the slow strength
period. gain, curing with heat is
often used. Refer to ACI
Concrete that freezes before its compressive strength reaches 306R,” Cold Weather
at least 500 psi (3.4 MPa) shall be discarded. Suitable Concreting.”
precautions shall be taken in cold weather to prevent concrete
from freezing. Such precautions may include: The average daily air
temperature is the average
a. Heating the mixing water, but not above 180 degrees F of the lowest and the highest
(82 degrees C). temperatures occurring
b. Avoid using frozen aggregates. during the period from
c. Heat forms prior to and after casting. midnight to midnight. As
d. If concrete does not freeze and no heat is applied, do such, cold weather, as
not strip the product until adequate strength is attained. defined by ACI 306R,
e. Monitor concrete temperatures during curing. generally starts during the
fall and continues until
spring.
1. Plant equipment used to transport concrete shall be

inspected daily by the plant QC Inspector to ensure that
concrete does not segregate or become contaminated. The
QC Inspector shall perform and document a spot-check of
the concrete transport, placement, consolidation, and
finishing of each product line.
2. Workers shall be properly trained in the use of internal and

external vibrators.
3. The plant shall maintain written procedures for concreting

during hot and cold weather conditions, if applicable, as
required in Section 1.1.2.
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4.5 CURING CONCRETE
Internal concrete temperature monitoring criteria is established

to help prevent Delayed Ettringite Formation (DEF). Further
guidance is also given in the commentary by including five
concrete mix design options that will mitigate for both Alkali
Silica Reaction (ASR) and DEF.
4.5.1 General
Effective curing shall begin as soon as possible, prior to the Concrete hardens by the
formation of shrinkage cracks, and no longer than 4 hours after chemical reaction between
casting the precast concrete unit. The concrete shall not cement and water, a process
exceed 150 degrees F (65 degrees C). If approved measures called hydration. Hydration
to prevent delayed ettringite formation (DEF) are employed continues for years provided
concrete temperatures shall not exceed 160 degrees F (71 moisture is present, but if
degrees C). Monitor a minimum of once every 3 months the concrete dries, hydration
maximum concrete temperature in the highest internal concrete stops and concrete stops
temperature location(s). The highest internal concrete gaining strength. Like most
temperature shall be determined by testing. Verification testing chemical reactions,
and monitoring shall consider all product sizes, mix designs, hydration proceeds faster at
and curing conditions when selecting the minimum amount of warm temperatures than at
necessary testing. cooler temperatures. Curing
of concrete means providing
the proper environment for
If concrete is cured with steam or radiant heat, curing hydration to occur. Thus the
procedures must be established and records kept of the necessary factors are
temperature of the concrete and environment during the curing moisture, time and
period (see 4.5.3). temperature. Concrete can
be cured by covering it with
damp burlap, ponding the
surface, steam, or by other
means of preventing
moisture within the concrete
from evaporating. Alternate
wetting and drying during the
first few days after casting is
almost as bad as no curing.
Research has shown that if

concrete temperatures
during curing are kept below
158°F problems from
Delayed Ettringite Formation
(DEF) can be avoided.
When testing for the highest

internal concrete
temperature location(s) the
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STANDARD COMMENTARY
temperature monitoring
device should be located in
the hottest section (usually
largest mass) of the product.
Concrete mix designs that
generate the highest internal
concrete temperatures such
as mixes containing
accelerating admixtures,
corrosion inhibitors, Type III
cement, or heated
aggregates should be
selected. Product close to
any heat source should also
be selected.
Mix designs to prevent DEF

should include the
replacement of cement with
a Supplemental
Cementitious Material
(SCM). The SCM’s most
commonly used for DEF
mitigation include fly ash,
slag cement, silica fume,
and metakaolin. Mix designs
that contain SCM’s in the
proper replacement
percentages inherently have
lower peak concrete
temperatures, and mitigate
DEF, even at concrete
temperatures above 158°F.
DEF and ASR mitigating mix

design options include but
are not limited to:
Option 1. Replace 20% to

45% of the cement with
Class F fly ash.

50% of the cement with slag
cement.

50% of the cement with a
combination of Class F fly
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STANDARD COMMENTARY
ash, slag cement,

metakaolin, or silica fume;
however, no more than 35%
may be fly ash, and no more
than 10% may be silica
fume.
Option 4. Use Type IP,

Type IS, or Type IT cement.
Up to 20% of a Type IP,

Type IS, or Type IT cement
may be replaced with Class
F fly ash, slag cement, or
silica fume. Use no more
than 10% silica fume in the
final cementitious material
mixture if the Type IT
cement contains silica fume,
and silica fume is used to
replace the cement.

50% of the cement with a
combination of Class C fly
ash and at least 6% of silica
fume, or metakaolin.
However, no more than 35%
may be Class C fly ash, and
no more than 10% may be
silica fume.
Mix design options

containing ultra fine fly ash
(UFFA) or modified Class F
fly ash (MFFA) may be
acceptable with proper
testing documentation.
The PCA Manual 16th

Edition ‘Design and
Control of Concrete
Mixtures states:
Ettringite is a normal
reaction product during
the hydration of cement.
When concrete is exposed
to temperatures in excess
of 158°F, substantial
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STANDARD COMMENTARY
amounts of sulphates are

bound in an unusual form
in the cement matrix, and
the normal formation of
ettringite is stopped. At
later ages and in the
presence of moisture, the
bound sulphates desorb
back into solution and
react with calcium
monosulfoaluminates to
form ettringite. This
delayed formation of
ettringite can exert
pressures on the concrete
because it forms in a
limited space and under
supersaturation. Since
concrete is rigid and if
there are insufficient voids
to accommodate the
ettringite volume increase,
expansion and
subsequent cracking can
occur. In addition, some of
the initial ettringite may be
converted back to
monosulfoaluminate at
high temperatures and
upon cooling revert back
to ettringite. Because
ettringite takes up more
space than
monosulfoaluminate from
which it forms, the
transformation is an
expansive reaction.
4.5.2 Curing by Moisture Retention
Preventing moisture from evaporating from the exposed Covering the exposed
surfaces of precast concrete elements shall be considered an surfaces of products while in
effective method of curing, provided the concrete temperature forms immediately after
is above 55 degrees F (13 degrees C). If the concrete casting is often adequate to
temperature is lower than 55 degrees F (13 degrees C) but assure that hydration will
above 35 degrees F (2 degrees C), and moisture evaporation is continue. Covers made of
prevented, the curing period must be extended. Forms shall be polyethylene sheets should
considered effective in preventing evaporation from the contact be at least 6 mils (0.15 mm)
surfaces. The use of a membrane-curing compound applied thick. There should be no
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STANDARD COMMENTARY
thick enough to prevent evaporation of moisture shall also be air circulation beneath the
considered an effective curing method. cover. Curing compounds
should be applied at a rate
Local regions and ambient temperature and humidity not to exceed about 200
conditions will influence the need for curing with heat combined square feet per gallon (5
with moisture. square meters per liter).
Laboratory cured cylinders

may not reflect in-place
strength of concrete unless
a controlled curing
environment is provided for
the precast product.
Concrete Maturity Testing
provides a good indication
of in-place strength.
4.5.3 Curing with Heat and Moisture
Concrete shall not be subjected to steam, hot air, or other This section applies to
means of accelerated curing until after the concrete has curing with heat and
attained its initial set. This does not include chemical moisture for the purposes of
admixtures. Record the initial set of the concrete (ASTM C403) accelerating the strength
a minimum of once quarterly when heat-curing. Steam, if used, gain of the concrete, not the
shall be applied within a suitable enclosure that permits free maintenance of form and/or
circulation of the steam. If hot air is used for curing, ambient temperatures at
precautions shall be taken to prevent moisture loss from the relatively low temperatures.
concrete. These requirements do not apply to products cured Accelerated curing heat
with steam under pressure in an autoclave. should not be applied to
concrete until about 30
The ambient curing temperature (for both wet-cast and dry-cast minutes after initial set of the
products) shall be monitored and documented a minimum of concrete. Initial set can be
once per week, when employing accelerated curing with heat determined in accordance
and moisture. The plant shall then establish an ambient curing with ASTM C403, “Standard
cycle that ensures that the ambient curing temperature does Test Method for Time of
not exceed 150 degrees F (65 degrees C) unless measures to Setting of Concrete Mixtures
prevent delayed ettringite formation (DEF) are employed. In by Penetration Resistance.”
addition, the rise in ambient curing temperature shall be limited If heat is applied too soon,
to a maximum of 40 degrees F (22 degrees C) per hour. concrete can be damaged
permanently. It is important
Gas-fired heaters shall not be used to directly heat exposed that the heat does not dry
concrete surfaces due to the risk of severe carbonation of the out the surface of the
concrete. concrete, otherwise the
concrete near the surface
will be weak and chalky.
Concrete cured with heat will
gain strength rapidly, but
long-term strength gains are
reduced.
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STANDARD COMMENTARY
1. Verify concrete does not exceed maximum

temperature, per Section 4.5.1, for the highest heat
generating mix designs, largest concrete mass, and
hottest curing conditions.
2. If products are cured with heat and moisture in order

to accelerate the strength gain, the ambient curing
temperature shall be monitored during the curing
period at least once per week. Temperature records
shall be maintained in the plant records.
3. If heat curing is used, the necessary initial-set period

shall be determined, per Section 4.5.3.
4. Products cast outdoors or in dry conditions shall be

protected from moisture loss by application of a curing
compound, moist curing or impervious sheeting.
5. The QC Inspector shall inspect curing of products and

exposed surfaces of stripped products for evidence of
plastic cracking. Damage shall be documented.
4.6 STRIPPING PRODUCTS FROM FORMS
4.6.1 Minimum Strength Requirement
Products shall not be removed from the forms until the concrete Some products, such as
reaches the designed compressive stripping strength. If no such those that serve a structural
requirement exists, the plant shall define product-specific function, are required to
minimum stripping strengths that must be obtained prior to have a certain strength level
stripping. These requirements shall be defined in the plant- at the time of stripping to
specific quality control manual discussed in Section 1.1.2. In assure adequate bond
addition, one-day, or stripping compressive strength tests shall between the concrete and
be performed for each mix design at least quarterly in order to reinforcement, and to
confirm that adequate stripping strengths are being attained. minimize stresses in the
These requirements do not apply to dry-cast and/or machine- product.
made products.
4.6.2 Product Damage During Stripping
Products damaged during stripping shall be evaluated by The “qualified plant

qualified plant personnel to determine if repairs are necessary, personnel” should be
and if so, what repair is required before shipping. completely knowledgeable
about the end use of the
product, including its
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STANDARD COMMENTARY
A record of any major damage and the repairs shall be kept on environment, and should
file with the final inspection report, as required in Section 4.8.5. know which types of repairs
are feasible. It is advisable to
See 4.7.2 for definition of “major repairs.” learn the cause of the
damage so that management
can take action to minimize
similar damage in the future.
4.6.3 Formed Surfaces
Formed surfaces shall be considered satisfactory if they are A minor number of voids in
relatively free of air voids and honeycombed areas, unless the the surface are quite normal.
surfaces are required by the design to be finished. Filling of those voids is done
for cosmetic purposes and
usually only when required by
specifications. For special
surface finishes, it is
recommended that a mockup
panel is made and accepted
by the purchaser prior to
production. The mockup
should be kept until the
project is complete.
4.6.4 Post-Pour Inspection
After products are stripped from the forms, they shall be Post-pour inspections are
inspected for conformance with the design. Items to be repaired useful for managing quality.
shall be classified as “major” or “minor” defects, or as Recurring major defects
honeycombed areas. Post-pour inspection records shall be kept require decisive action by
in the files for a minimum of three (3) years. management. Major defects
in small products usually
See 4.7.1 and 4.7.2 for “minor” and “major” repairs. means rejection of the
products, while major defects
of large products are
generally costly and often
disrupt the orderly operation
of the plant. It is generally
easiest to make repairs while
the product is young, but
repairs should not begin until
appropriate techniques are
developed for making the
repair.
Each producer is required to

use a standard post-pour
inspection checklist to record
dimensions, deviations –
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STANDARD COMMENTARY
damage, etc. This checklist

template is to be included in
the plant-specific QC
Manual.
The American Concrete

Institute, Committee 117,
has established industry
standards for dimensional
tolerances. These tolerances
and the tolerances
prescribed in the Appendix B
of this Manual should be
considered as a standard
specification unless
otherwise specified in the
contract documents.
A post-pour inspection shall be made and documented for 1

piece or 3%, whichever is greater, of each precast product
produced. The inspections shall document any damage,
excessive bugholes or honeycombing, poor dimensional
tolerances, or other problems such as exposed reinforcing. A
mark shall be made on the product indicating whether it is
acceptable, requires repair, or it has been rejected. or the plant
shall have a documented process in place indicating products are
acceptable, require repair, or have been rejected.
4.7 REPAIRING CONCRETE
4.7.1 Repairing Minor Defects
Defects not impairing the functional use or expected life of a It is assumed that qualified
precast concrete product shall be considered minor defects. personnel will judge which
Minor defects may be repaired by any method that does not defects are minor and which
impair the product. are major. The person
making the judgment must be
When honeycombed areas are to be repaired, all loose material thoroughly familiar with the
shall be removed and the areas cut back into essentially functional use of the product,
horizontal or vertical planes to a depth at which coarse including the environment in
aggregate particles break under chipping rather than merely which the product will
being dislodged. Proprietary repair materials shall be used in function. Behavior of
accordance with the manufacturer’s instructions. If a proprietary concrete in the product and in
repair material is not used, the area shall be saturated with that environment must be
water and, immediately prior to repair, the area shall be damp, known. Repairs of minor
but there shall be no excess water. A cement-sand grout or an defects are essentially
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STANDARD COMMENTARY
approved bonding agent shall be applied to the chipped cosmetic, (e.g., the product
surfaces, followed immediately by consolidating an appropriate would behave as intended
repair material into the cavity. without the repairs)
4.7.2 Repairing Major Defects
Defects in precast concrete products that impair the functional Repairs should be made as
use or the expected life of products shall be considered major soon as feasible after the
defects. Unless major defects are repaired the product shall be defect is noted so that
rejected. Major defects shall be evaluated by qualified differential shrinkage
personnel to determine if repairs are feasible and if so, to between the original concrete
establish the repair procedure. Proper repairing procedures and and the repair concrete is
curing shall be inspected. minimized. Concrete used in
repairs of major defects
should be essentially the
same as the original concrete
except that the repair
concrete should contain less
water. Also, the maximum
size of aggregate should be
as large as possible but not
greater than one-half the
minimum dimension of the
repair. The procedures
outlined in Sec. 4.7.1 can be
used to repair the product.
The repair concrete should
become an integral part of
the product with no
delaminations or cracks.
4.7.3 Inspection of Repairs

Even minor repairs should be
Products that require repairs of honeycombed areas or inspected to assure that no
major repairs shall be inspected while repairs are made. damage has been done to
A record of any major repairs shall be documented and products being repaired. The
filed with the final inspection report for that product. inspection records for repairs
of major defects should
indicate any deviations from
the established repair
procedure.
1. The plant shall have documented procedures for repair of

damaged products, including procedures for repair of
honeycombing, excessive air voids, and minor and major
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STANDARD COMMENTARY
defects. The procedures shall list acceptable repair products

to be used.
2. After repairs are completed and inspected, a mark shall be

made on the product indicating that it is acceptable, or that it
is rejected.
3. QC Inspector shall perform checks of repairs.
4. Major repairs shall be documented.
4.8 MARKING, STORAGE, AND SHIPMENT OF

PRODUCTS
4.8.1 Product Marking
Products shall be marked as required by project It is extremely helpful to

specifications. Unless otherwise prevented by product include the date of
specifications or aesthetic reasons, products shall be manufacture in the product
prominently marked indicating conformance with this marking in order to facilitate
manual. For plants participating in the NPCA Plant the tracking of product and
Certification Program this mark shall be the “NPCA raw materials.
Certified Plant” symbol.
4.8.2 Storage Areas
Areas used for storage of products shall be firm enough and It is good practice to place in
level enough to avoid causing damage to stored products. storage only products that
are ready for shipment, thus
minimizing product handling.
Also, repairs are generally
controlled better and done
more effectively in a
designated area than in a
storage yard. Thus, storage
areas should be arranged so
that products will not be
damaged and are readily
accessible.
4.8.3 Storage of Products
Products shall be stored in a manner that will minimize damage Products should preferably
caused by uneven bearing, improperly located dunnage blocks, be stored on level surfaces.
stacking products too high or difficulty in handling. Bearing surfaces should be
large enough to prevent
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Reject product that cannot be adequately repaired shall be chipping or fracturing of the
uniquely marked such that plant personnel can easily identify it product.
as reject. Reject product shall be stored separately from normal
stock.
4.8.4 Shipment of Products
Trucks and other conveyances used to transport precast Trucks and other delivery
concrete products from the plant to the location designated by equipment should be
the customer shall be equipped and maintained to deliver those inspected periodically to
products without damaging them to the extent that they must be ensure products will be
repaired or rejected. delivered without damage.
Copies of delivery receipts
Records shall be kept for at least a year of all products and are normally kept for billing
accessories shipped on each load. The record shall indicate and inventory purposes.
which items, if any, were damaged when delivered. They should also be
reviewed by management to
monitor the number of
products damaged and how
they were damaged, so that
appropriate action can be
taken to minimize future
damage.
4.8.5 Final Inspection
Prior to shipment, products shall be inspected to assure design Many precast products
conformance and proper identification. The precast plant shall should be inspected
establish a procedure for sampling and inspecting products that individually, but some
are shipped in bulk. Products that are handled individually products such as modular
during shipment to the project site shall be inspected pavers and transformer
individually. Inspections shall be documented. bases can be inspected in
groups.
Products not conforming to requirements shall be clearly labeled
and the defects noted on the inspection report. Only products Management should review
conforming to the requirements shall be shipped. The purchaser inspection reports prior to
may, at their discretion, waive certain requirements that are shipment in order to
minor in nature. Management shall be notified of defects prior to minimize sub-quality
shipment so that action can be taken. products leaving the yard.
1. Storage areas shall be maintained firm and level such that

products are not damaged during handling and do not sink
into the ground.
2. Products shall be stored to minimize damage.
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STANDARD COMMENTARY
3. The QC Inspector shall inspect the storage area and the

stored product daily.
4. A final inspection of products prior to shipment shall be
made. This inspection shall be documented in the plant
records. The inspection shall include verification that the
product conforms to project specifications, plans and other
contract documents, contains the proper post-pour
inspection markings, and that repairs have been made and
inspected where needed.
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CHAPTER 5 - QUALITY CONTROL OPERATIONS
5.1 SUMMARY OF REQUIRED RECORDS
Unless otherwise specified in this manual, all required It is suggested that all of
documentation and records shall be kept for a minimum of three the required records be
(3) years. Plants initially entering the NPCA Plant Certification maintained in a central
Program shall have a minimum of 30 calendar days of records location at the plant. In
prior to their initial audit. Thereafter, all required documentation addition, it is very helpful if
and records shall be kept on file until the applicable minimum the records are organized
retention time has elapsed. in a similar sequence as
the sections of this manual.
5.1.1 Raw Material & Test Records
Records of incoming raw materials and certifications, credentials of Test records are useful in
third party personnel and calibration records for third party and/or verifying that materials
plant owned test equipment shall be kept by the precast plant for a used in manufacturing
minimum of three (3) years. These records shall at a minimum precast concrete products
include the following: conformed to the product
specifications. They are
a. Cement mill test reports and certificates useful in isolating problems
b. Aggregate certifications and reports that occur either soon after
c. Mix water potability or suitability tests a product is cast or long
d. Chemical admixture and supplementary cementitious material after a product has been in
test reports and certifications service. Accessories are
e. Reinforcement mill certifications design items included in the
f. Fiber-Reinforcement certification products but do not include
g. Joint sealant, gasket and connector supplier certifications and the wire, chairs, clips.
test reports
h. Accessories supplier certifications and reports
i. Batching records or ready-mixed concrete delivery tickets
j. Buy America Provisions as required by specific project
k. Certificate of compliance for all lifting inserts
l. Laboratory Accreditation or ACI certificates and test equipment
calibration records of any third-party firm or testing agency.
Records that require annual certifications and/or test Example: Aggregates were
reports shall be dated not more than one year at certified by the quarry to
the end of the month from the date of the last test or meet ASTM C33 on March
certification. 15 of the current year.
Aggregates would need to
be recertified by the quarry
no later than March 31 of
the following year.
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STANDARD COMMENTARY
5.1.1.1 Independent Third Party Testing Laboratory
Third party laboratories may be accredited to ISO/IEC

17025, or the applicable AASHTO laboratory
accreditation.
Plants that employ a third-party laboratory for testing

and/or calibration services shall, at a minimum, obtain the
credentials of personnel performing the testing and the
calibration records for the equipment used.
Technicians from a third-party laboratory performing

plastic concrete testing at the precast facility shall provide
a current ACI Field Technician Level I certification.
Technicians from a third-party laboratory performing
compressive strength testing and/or aggregate testing
shall provide an appropriate and current ACI certification
for the testing being performed along with a current
equipment calibration certificate.
Plants subject to owner specific certification and testing

requirements shall have appropriate documentation on
file for auditor review.
5.1.2 Work Orders and Product Drawings
Work orders for each project shall be kept by the precast plant Most work orders are
until the project is completed. Product drawings shall be kept by internal documents and as
the precast plant for at least three (3) years. such need not be kept for
quality control purposes.
However, product drawings
are important documents
that may be useful in
product evaluation years
after the product has been
in service. Precast plants
that make custom products
should have a procedure
for keeping drawings,
electronic scans, microfilms
of the drawings, or other
methods of retaining
product drawings.
5.1.3 Equipment Calibration Records
Records for calibration of equipment shall be maintained so that

the equipment operator has ready access to the records.
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Current calibration stickers shall be attached to and prominently

displayed on all equipment requiring calibration. All of the
following equipment shall be calibrated a minimum of once per
year. Current calibration reports shall be dated not more than
one year at the end of the month from the date of the last
calibration or certification.
- Concrete batching scales

- Water meters
- Admixture batching equipment
- Concrete compression test machines
- Portable scales
- Slump Cone
- Air meter – intervals not to exceed three months, per ASTM C
231
- Density (Unit weight) bucket
- Rebound hammer (if used)
- Thermometers, temperature recorders and clocks
- Three-edge bearing test machines
- Pipe and manhole measuring devices (i.e., go-no-go gages)
- Vacuum and hydrostatic testing equipment
Calibration of batching scales, compression testing machines

and three-edge bearing testing machines shall be performed by
an independent, third-party calibration company. Unless
otherwise specified, all other calibrations shall be performed in-
house, by the supplier, or by an independent, third-party
calibration company.
5.1.4 Aggregate and Concrete Test Records
Records of tests for aggregate gradation, organic impurities in Unless records of

aggregates, and aggregate moisture content shall be kept for a aggregate and concrete
minimum of three (3) years. Records of tests of concrete tests are identified in such
temperature, slump, air content, density (unit weight), and a manner that make it
compressive strength shall be kept by the precast plant for a possible to determine which
minimum of three (3) years. products were made with
the materials tested, they
are not very useful. A
simple orderly method of
relating such records to
specific products can make
the test reports valuable.
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STANDARD COMMENTARY
5.1.5 Concrete Batching Reports
Daily reports of actual concrete mix proportions for each mix A method of identifying
used and quantities of produced concrete shall be documented which products are made
and maintained on file by the precast plant for a minimum of from each batch should be
three (3) years. used in order to make the
records useful. Plants
should backup electronic
batching files a minimum of
weekly.
5.1.6 General Plant and Product Inspection Records
QC Inspector inspection reports and product inspections records Records of final inspections
shall be maintained on file by the precast plant for a minimum of of products are only useful
three (3) years. from the standpoint that
they show the products
were judged to be of
adequate quality when they
left the plant. Thus, they
are most useful as a plant
management tool.
Maintain the required records in an easily accessible and well-

organized file. Documentation shall be easily retrievable and
indexed to specific products by date or piece number. Records
shall be maintained for the minimum duration.
5.2 AGGREGATE TESTING
5.2.1 Aggregate Gradation
Gradation tests shall be made for each 1,500 tons (1,350 metric Gradation tests are used to
tons) of fine aggregate and each 2,000 tons (1,800 metric tons) of determine if aggregates
coarse aggregate by either the aggregate supplier or by the conform to applicable
precast plant. Gradation tests shall be performed in accordance specifications. Concrete
with ASTM C136, “Standard Test Method of Sieve Analysis of mixes are generally
Fine and Coarse Aggregates.” designed based on
aggregates having specific
gradations (particle size
distributions). One of the
reasons for performing
aggregate gradation tests is
to note changes in
gradation so that concrete
mixes can be adjusted, or
perhaps they should be
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STANDARD COMMENTARY
redesigned. A rule of
thumb is that a change in
the fineness modulus of the
fine aggregate of 0.20 or
more indicates that an
adjustment or redesign
should be made. Large
variations in coarse
aggregate gradations may
warrant adjustments to the
concrete mix. Changes in
the amount of material
passing the No. 50 (0.300
mm) sieve often indicate
changes in workability and
in the bleeding
characteristics of the
concrete.
5.2.2 Moisture Content
5.2.2.1 Conventional and/or Dry-Cast Concrete
For conventional and/or dry-cast processes, made without It is very important to know
moisture probes or meters and automatic mixing water the moisture content of the
adjustment systems, aggregate surface moisture content (i.e., aggregate in order to
water in excess of that absorbed by the aggregates) shall be determine the water
determined at least once per day in accordance with ASTM C70, content in the concrete
“Standard Test Method for Surface Moisture in Fine Aggregate,” batch. This information is
by alternate methods such as moisture meters or probes, or by useful for determining and
ASTM C566, “Standard Test Method for Total Evaporable making adjustments to mix
Moisture Content of Aggregate by Drying.” Drying aggregate designs as well.
using a microwave or hot plate shall be permitted in addition to
using an oven.
For conventional and/or dry-cast processes when aggregate bins

fitted with moisture probes or meters, aggregate surface moisture
content shall be determined a minimum of once per week in order
to validate moisture probe accuracy and performance.
For SCC processes when aggregate bins are fitted with moisture Since SCC concrete is very
probes or meters used with automatic mixing water adjustment moisture sensitive, precise
systems, the aggregate surface moisture content shall be control of the water content
determined a minimum of once per week in order to validate is essential. Verifying
moisture probe or meter calibration. Moisture tests shall be aggregate surface moisture
performed in accordance with ASTM C70, “Standard Test will allow for necessary
Method for Surface Moisture in Fine Aggregate,” or by ASTM adjustments in mix water as
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STANDARD COMMENTARY
C566, “Standard Test Method for Total Evaporable Moisture the moisture content of the
Content of Aggregate by Drying.” Drying aggregate using a aggregates changes
microwave or hot plate shall be permitted in addition to using an throughout the day. Slump
oven. Samples for moisture tests shall be taken as close as Flow and VSI testing will
possible to the area where the probe is located. only confirm whether a
SCC mixture is within spec
For SCC processes made without moisture probes or meters and and become necessary for
automatic mixing water adjustment systems, the aggregate this confirmation if moisture
surface moisture content shall be determined at least once a day tests are not performed on
prior to making the first SCC batch and then once every four a regular basis (every 3
hours of elapsed time after the first test, while SCC is being batches).
produced. Moisture tests shall be performed in accordance with
ASTM C70, “Standard Test Method for Surface Moisture in Fine In situations where the
Aggregate,” or by ASTM C566, “Standard Test Method for Total plant is producing SCC, the
Evaporable Moisture Content of Aggregate by Drying.” Drying plant should consider
aggregate using a microwave or hot plate shall be permitted in performing unit weight of
addition to using an oven. the mix in addition to slump
flow and VSI as another
verification of proper mix
proportioning.
Records of aggregate gradations, deleterious substance and

aggregate moisture tests shall be maintained in the plant
records.
5.3 CONCRETE TESTING *
For all concrete testing, plant personnel shall take * Critical Requirement –
corrective action whenever the test result does not fall plants participating in the
within the established acceptable tolerance range from the NPCA Plant Certification
documented initial mix qualification. Program must receive a
minimum passing grade, as
shown on the grading
schedule, for this entire
section and others
designated as Critical
5.3.1 Slump, Slump Flow, and Visual Stability Index Requirements, when
applicable.
5.3.1.1 Slump
A slump test of fresh concrete of each mix design shall be Slump values for Normal,
performed for each 150 cubic yard (115 cubic meters) of Heavy Weight and Mass
concrete, or once a day, whichever comes first. Slump tests Concrete have a range of
shall be performed in accordance with ASTM C143, “Standard 2 inches to 9 inches.
Test Method for Slump of Hydraulic-Cement Concrete.” SCC,
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STANDARD COMMENTARY
no-slump, or dry-cast concrete does not need to be tested for

slump.
5.3.1.2 Slump Flow and Visual Stability Index
For SCC mixtures, slump flow and Visual Stability Index (VSI) Producers using SCC shall
tests of fresh concrete of each mix design shall be performed follow applicable ASTM test
each day by testing one of the first two batches of SCC as methods for air content,
defined by the initial mix qualification process. Reject the unit weight, and casting
concrete if the upper specification limit is exceeded. If the slump compressive strength
flow test result is less than the lower production range limit reject cylinders. Filling in lifts and
the concrete unless the mixture has been approved for vibration rodding are not required
and is subsequently vibrated. Thereafter, slump flow and VSI when using SCC.
testing shall be performed as follows: The slump test is used to
determine the consistency
of fresh concrete and the
- When changing mix designs uniformity of concrete from
- When changing raw materials, batch-to-batch. If the batch
- and weights of cement, water,
- As required in Section 5.2.2.2 and aggregates are
reasonably correct,
changes in slump are
probably due to changes in
Slump flow and VSI tests shall be performed in accordance aggregate moisture or in
with ASTM C1611 “Standard Test Method for Slump Flow dispensing of admixtures.
of Self-Consolidating Concrete” However, slump variations
can also occur because of
changes in aggregate
gradations, temperature
and air content.
The air content of an SCC

mix can affect the desired
properties of the mixture
and it is recommended that
the air content be tested
regularly with the Slump
Flow and VSI.
Slump Flow values for

SCC have a range of
20 inches to 30 inches.
5.3.2 Temperature
The temperature of fresh concrete of each mix design shall be Temperature of fresh
measured when slump or air content tests are made and when concrete affects a number
compressive test specimens are made. The measured concrete of properties of concrete.
temperature shall be recorded together with other fresh concrete Warm concrete sets faster
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STANDARD COMMENTARY
test data. Concrete temperature testing shall be performed in than cool concrete. Warm
accordance with ASTM C1064, “Standard Test Method for concrete gains strength
Temperature of Freshly Mixed Portland Cement Concrete.” faster than cool concrete,
but the strength at later
ages will be lower than that
of cool concrete.
Knowledge of the
temperature of fresh
concrete permits the batch
plant operator to adjust
mixes and allows the
concrete foreman to better
allocate workmen. Also,
warm concrete tends to dry
faster so curing of warm
concrete is even more
important than curing of
cool concrete.
5.3.3 Density (Unit Weight)
Tests for density (unit weight) of fresh concrete of each mix The density (unit weight) of
design shall be performed a minimum of once per week or every concrete is often specified
150 cubic yards, whichever occurs first, to verify the yield of batch for products made of
mixes. Density tests shall be performed for each 100 cubic yards lightweight concrete. If the
(75 cubic meters) of lightweight concrete or once per month, density is higher or lower
whichever occurs first. Tests shall be performed in accordance than the specified limits,
with ASTM C138, “Standard Test Method for Density (Unit adjustments should be
Weight), Yield, and Air Content (Gravimetric) of Concrete.” Unless made to the mix to increase
otherwise specified density (unit weight) does not need to be or decrease the density.
tested for dry-cast concrete. After adjustments are
made, the density should
again be measured. The
best method for checking
the yield of concrete (the
actual volume of concrete
produced from quantities of
materials, which
theoretically are needed for
one cubic yard or one cubic
meter of concrete) is by
dividing the total weight for
a cubic yard or a cubic
meter (theoretical) by the
density of the concrete.
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STANDARD COMMENTARY
5.3.4 Air Content
For all wet-cast concrete of fresh concrete of each mix design Concrete is air-entrained
containing air-entrainment, tests for air content shall be made for not only for its improved
each 150 cubic yards (115 cubic meters) of concrete, but not less resistance to freezing and
often than once each day. For all wet cast concrete of fresh thawing but also because
concrete of each mix design made without air-entrainment, tests air-entrainment reduces
for air content shall be made whenever compressive strength bleeding and segregation.
specimens are cast, but not less often than once per week. Air For frost resistance, air
content shall be determined by either the pressure method, ASTM contents given in Table
C231, “Standard Test Method for Air Content of Freshly Mixed 3.1.3 should be used. Air
Concrete by the Pressure Method,” or the volumetric method, contents higher than the
ASTM C173, “Standard Test Method for Air Content of Freshly values given in that table
Mixed Concrete by the Volumetric Method.” A density (unit will reduce concrete
weight) test, performed in accordance with ASTM C138, may be strength dramatically. Air
substituted for ASTM C231 or ASTM C173 after a correlation contents lower than the
between air content and density (unit weight) has been tabulated values will not
established. Air content does not need to be tested for dry-cast provide adequate frost
concrete. resistance. However, if the
air contents are slightly
lower than the tabulated
values, the concrete will
benefit from reduced
segregation and bleeding
as compared to a non air-
entrained concrete.
For normal-weight
concrete, either the
pressure method or the
volumetric method can be
used, but the pressure
method is generally
preferred because the test
can be done more quickly
and more easily. For
lightweight concrete, the
volumetric method is
generally required and
much more accurate than
the pressure method.
An air indicator is a small

hand-held device, which
utilizes a thimbleful of
material passing a No. 10
(2.0 mm) sieve. It can be
done very quickly and gives
a reasonable indication of
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STANDARD COMMENTARY
air content, provided it has

been calibrated by
comparing a number of air
indicator measurements
with results of air- meter
tests for each concrete
mixture.
5.3.5.1 Wet Cast
Compressive strength cylinders shall be made in accordance with The main reason for
ASTM C31, “Standard Practice for Making and Curing Concrete making and testing
Test Specimens in the Field.” Specimens shall be cured in a compressive strength
manner similar to the curing of the concrete products represented specimens is to determine
by the specimens, unless otherwise required by the project. if the concrete strength
conforms to the
requirements. Strength
tests are also useful at
early ages to evaluate
curing methods and to
determine uniformity of
concrete. Making and
testing 4 x 8-inch cylinders
is easier and costs less
than using 6 x 12-inch
specimens so the use of 4
x 8-inch cylinders is
encouraged unless
specifications prohibit their
use. Use of 4 x 8-inch
cylinders has advantages
that specimens are smaller,
are easier to make, use
less concrete, are easier to
handle and require less
storage space.
5.3.5.2 Machine-Cast or Dry-Cast
For machine-cast and/or dry-cast concrete products, test Often times, dry-cast
cylinders can be vibrated or cores cut from the product. Test equipment is equipped with
cylinders shall be vibrated in the same method as the product test cylinder holding
they represent or fabricated according to the applicable section of devices that enable
ASTM C497. specimens to be vibrated
the same as the product.
Sometimes cores or cubes
cut from products after the
concrete has hardened are
required as test specimens.
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STANDARD COMMENTARY
For small products, the

entire product might be
used as a specimen and
tested in compression.
Whatever the specimen, a
“standard” test procedure
should be established so
that results of tests
conducted at different times
can be correlated.
5.3.5.3 SCC
Compressive strength cylinders shall be made in accordance with

ASTM C1758, “Standard Practice for Fabricating Test Specimens
with Self-Consolidating Concrete.” Specimens shall be cured in a
manner similar to the curing of the concrete products represented
by the specimens, unless otherwise required by the project.
5.3.5.4 Compressive Strength Specimens
At least four compressive strength specimens shall be made for

each 150 cubic yards (115 cubic meters) of concrete of each mix
or once per week, whichever occurs first. Two specimens shall
be tested at or before 7 days and, if the specified design strength
has not been met at that time, the other two shall be tested at or
before 28 days, or at the age specified by design. Specimens
made in cylinder molds shall be tested in accordance with ASTM
C39, “Standard Test Method for Compressive Strength of
Cylindrical Concrete Specimens.” Cubes or cores cut from
products shall be tested in accordance with ASTM C42,
“Standard Test Method for Obtaining and Testing Drilled Cores
and Sawed Beams of Concrete.”
5.3.5.5 Cores
If cylinder tests fall below the specified value, three cores may be Depending upon the level
used from the same date of production and mix design to of consolidation, core
determine concrete strength. Cores shall be obtained and tested samples from the bottom of
in accordance with ASTM C42. sections may result in
higher than average
strength levels. Care
should be taken to avoid
cutting reinforcing bars
where cores are obtained.
Reinforcement in cores can
affect the strength,
depending on the quality
and orientation of the
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STANDARD COMMENTARY
reinforcement. The
average value for cores of
85% of the specified
strength is realistic since
cores will generally yield
lower strength results than
test cylinders because of
differences in size of
specimens, conditions for
obtaining samples and
curing.
5.3.5.6 Calibrated Impact Hammer
If the concrete strength is lower than specified and the Impact rebound hammers
compressive strength test specimens have been depleted, a are useful devices but they
calibrated impact rebound hammer may be used to indicate should be calibrated
strength of the concrete after additional curing of the concrete. periodically. One way of
The rebound hammer should not be used for acceptance or to calibrating the hammer is to
determine structural adequacy but to compare concrete strength compare the rebound
at different locations or for quality control purposes. Impact number on products with
rebound hammer shall be used in accordance with ASTM C805, the compressive strengths
“Standard Test Method for Rebound Number of Hardened of specimens representing
Concrete.” the concrete in the
products. Rebound
numbers on products
should be obtained at the
same age as the age at
which the compressive
strength specimens are
tested.
1. Persons conducting QC tests shall be properly trained to See table 5.3.6 a, b, and c
perform the tests (see Section 1.1.3). for required minimum
2. Proper ACI Field Technician Grade 1 test techniques and frequency of Quality
procedures shall be demonstrated for slump, temperature, Control operations.
density (unit weight), air content, and fabrication of
compressive strength cylinders during the NCPA audit.
3. Track the number of tests on each neoprene compression test
pad, if used.
4. If concrete testing is performed by an outside testing agency,
the testing shall be conducted at the point of placement and
the plant shall obtain the ACI certificate of the tester along
with calibration records of equipment used. Obtaining this
documentation from the supplier insures that the personnel
performing the tests have been properly trained and
equipment used has current calibration.
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STANDARD COMMENTARY
5. Testing of concrete compressive strength cylinders by third

parties is not required to be performed on the plant
premises. Plants using third party suppliers for compressive
strength testing shall obtain copies of the testers ACI
certificate and current equipment calibration certificate.
strength testing shall obtain copies of the testers ACI
certificate and current equipment calibration certificate.
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Table 5.3.6 a
Frequency of Quality Control Operations
Materials Certifications and Equipment Calibrations
Section in Each Each

Each Each 200 Each 150 Each 100
NPCA QC Item 1,500 2,000 Each Pour Daily Weekly Monthly Annually Remarks
manual Shipment CY (d) CY (e) CY (f)
Tons (b) Tons (c)
2.1.1 Cement mill test report X(a)
Reinforcing bars mill

2.2.1 X(a)
certificates
Reinforcing wire mill

2.2.2 X(a)
certificates
Bar mats and welded

2.2.3 wire reinforcement mill X(a)
certificates
Admixture dosing
3.1.4 X(a)
equipment certification
Weigh batch scales

3.2.4 X
calibration
Certificate of
5.1.1.j Compliance for all lifting X
inserts
Current copy of ACI

Certificate of Third Party
5.1.1.k X
Tester and Equipment
Calibrations
Notes:
(a) Items may be furnished by the raw material supplier
(b) 1,350 cubic meters
(c) 1,800 cubic meters
(d) 150 cubic meters
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T able 5.3.6 b
Frequency of Quality Control Operations
Production Practices
Section in Each Each

Each Each 200 Each Each 150 Each 100
NPCA QC Item 1,500 2,000 Daily Weekly Monthly Annually
manual Shipment CY Pour CY CY
Tons Tons
4.1.2 Housekeeping X
Forms cleaned of build-

4.1.3 X
up
Dimensional checks of
4.1.5 machine-made X
products
4.3.5 Pre-pour inspection X
4.6.4 Post-pour inspection X
4.8.3 Final inspection X
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Table 5.3.6 c
Frequency of Quality Control Operations Aggregates and Concrete
Each Each
Each 1,500 2,000 Each 200 Each Each 150 Each 100
Section Item Shipment Tons ( a ) Tons ( b ) CY ( c ) Pour CY ( d ) CY ( e ) Daily Weekly Monthly Annually Remarks
Fine aggregate
2.1.2 gradation and X X whichever occurs first
deleterious substances
Coarse aggregate
Lightweight aggregate
Organic Impurities in fine
5.2.2 X when aggregate is suspect
aggregate
Slump, Slump Flow & whichever occurs first, for
5.3.1 X X
VSI each mix design
when air content or
5.3.2 Termperature of X X slump is tested, for each
Concrete mix design
Except for ligthweight
5.3.3 Density (unit weight) of X X concrete, for each mix
concrete design
Density (unit weight) of
5.3.3 X X for each mix design
lightweight concrete
Air Content of air whichever occurs first, for
5.3.4 X X
entrained concrete each mix design
Compressive strength of whichever occurs first, for
5.3.5.3 X X
wet cast concrete each mix design
Compressive strength of whichever occurs first, for
5.3.5.3 dry cast concrete X X
each mix design
Notes:
(a) 1,350 metric tons
(b) 1,800 metric tons
(c) 150 cubic meters
(d) 115 cubic meters
(e) 75 cubic meters
Rev. 0
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STANDARD COMMENTARY
CHAPTER 6 - SPECIAL REQUIREMENTS FOR

SPECIFIC PRODUCTS
6.1 PRODUCTS MANUFACTURED ACCORDING TO ASTM

INTERNATIONAL AND OTHER INDUSTRY STANDARDS
The requirements in this chapter are in addition and complementary to the The requirements in
requirements in chapters 1 through 5. sections 6.1 through 6.5
are intended for the
producer to demonstrate
that the final product is
capable of performing in a
manner consistent with
ASTM International
specifications and other
industry standards that are
used to verify acceptable
product manufacture and
performance.
6.1.1 Product Manufacture
Precast concrete products, which are covered by ASTM International or If the plant claims to
other industry standards, exclusive of those covered in Sections 6.2 manufacture certain
through 6.5 of this manual, shall be manufactured in accordance with products that meet ASTM
those standards, unless otherwise dictated by project specifications. In specifications, then the
case of conflict between ASTM or other industry standards and product plant should be able to
specifications, the product specifications, drawings, and other contract prove such claims.
document requirements will govern. Additional product-specific
requirements are outlined in Sections 6.2 through 6.5.
Whenever ASTM International or other industry standards are referenced Each individual ASTM
in this manual, the latest edition of the standard shall apply, unless the International standard
specifier specifically requires conformance with an earlier edition. specifically states the
necessary documentation
Applicable precast concrete product-specific ASTM or other industry and proof of conformance
standards include are listed in Appendix A. required.
6.1.2 Proof of Conformance
Proof of conformance to specific ASTM International or other industry Proof of conformance with
standards shall be maintained on file at the plant. Proof of conformance ASTM standards should be
shall consist of one or more of the following: design calculations and a normal part of the quality
drawings, documentation of performance testing, documentation of the control operations, unless
design conditions and specific requirements stated in individual ASTM other more stringent
International or industry standards. design requirements are
specified for projects.
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STANDARD COMMENTARY
Proof of conformance to applicable ASTM International or other industry

standards shall be documented and maintained on file at the plant for all
products being produced according to ASTM International or other industry
standards. Annual test data (or other test data) shall be maintained at the
plant for a minimum of three years.
6.2 CONCRETE PIPE REQUIREMENTS
Plants producing concrete pipe shall specifically conform to the NOTE: Section 6.2 is
requirements in section 6.2 of this manual. intended for pipe that will
be used for sanitary and
stormwater drainage
systems.
Additional testing may be

required for pipe intended
to be used for sanitary
wastewater drainage
systems.
6.2.1 STORMWATER CONCRETE PIPE REQUIREMENTS
6.2.1.1 Reinforcing Steel Inspection *
As required in Section 4.1.5 and 4.2.1, maintain documentation of * Critical Requirement –

reinforcing cage inspections with information on the required cage design plants participating in the
versus the actual cage used, including WWR style, steel area, wire NPCA Plant Certification
diameter, cage diameter, cage length, and welded/tied wire laps. Program must receive a
Concrete pipe reinforcing steel checks shall be performed on a minimum shown on the grading
of one (1) reinforcing steel cages or 3% of each fabrication run daily, schedule, for section 6.2.1.1
whichever is greater, chosen on a random basis by QC personnel, and others designated as
regardless of fabrication method. These checks shall be documented and Critical Requirements, when
maintained in the plant records for a minimum of three (3) years. applicable.
6.2.1.2 Three-Edge Bearing Testing (TEB)*
For reinforced concrete pipe, verification of conformance to applicable * Critical Requirement –

standards (ASTM C76 and C655) shall be documented by performance of plants participating in the
three-edge bearing testing in accordance with ASTM C497. The plant NPCA Plant Certification
shall load the pipe up to the specified design strength D-load to produce a Program must receive a
0.01-inch crack. Test frequency shall be a minimum of one test per year minimum passing grade, as
for each size (and class) of pipe, or as described below, whichever is shown on the grading
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STANDARD COMMENTARY
greater. TEB tests are not required for sizes that have less than 100 schedule, for section 6.2.1.2
pieces manufactured during the current program year if the plant has and others designated as
compressive and proof of design test data on file. Current test reports shall Critical Requirements, when
be dated not more than one year at the end of the month from the date of applicable.
the last test or certification.
Three-edge bearing testing
is critical since it is an
Pipe Size Class Test Frequency* industry-accepted method
12” – 15” Class V and below 1 / 1000 pieces of verifying the strength
18” – 36” Class IV and below 1 / 800 pieces and design of the pipe.
18” – 36” Class V 1 / 400 pieces
42” – 60” Class III and below 1 / 400 pieces
42” – 60” Class IV and V 1 / 200 pieces
66” and larger All Classes As require by project
specifications
For unreinforced concrete pipe, verification of conformance to applicable

standards (ASTM C14 and C985) shall be demonstrated by performance
of three-edge bearing testing in accordance with ASTM C497. The plant
shall test up to the specified design strength ultimate load at the frequency
required by the project specifications.
For pipe designed by direct methods with standard installations, three-

edge bearing shall not be required.
If allowed by project specifications or authority having jurisdiction,

compressive strength cylinder testing and companion rational design
calculations may replace TEB testing.
Unless otherwise required by project specifications, three-edge bearing

testing of elliptical and arch pipe shall not be required.
6.2.1.3 Absorption Testing *
Verification of conformance to the concrete absorption requirements of * Critical Requirement –

applicable standards shall be documented by performance of absorption plants participating in the
testing in accordance with ASTM C497 (Test Method A or B). Absorption NPCA Plant Certification
testing can be performed by ASTM C642 using cores only and the Program must receive a
absorption limits of ASTM C76 shall apply. Testing shall be performed a minimum passing grade, as
minimum of once per year, on the mix design (both wet-cast and dry-cast) shown on the grading
with the lowest amount of cementitious material used at each operation or schedule, for section 6.2.1.3
manufacturing station. Both in-plant and laboratory testing shall be and others designated as
permitted. Current test reports shall be dated not more than one year at Critical Requirements, when
the end of the month from the date of the last test or certification. applicable.
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STANDARD COMMENTARY
6.2.1.4 Dimensional Checks
Verification of conformance to applicable dimensional requirements shall Procedures for checking

be performed and documented on a minimum of three concrete pipes or pipe dimensions and the
3% of each day’s production, whichever is greater, chosen randomly by associated acceptable
plant quality control personnel. tolerances should be
Normal Post-pour inspection requirements apply to both wet-cast and dry- documented in the plant-
cast / machine-cast pipe, as required in Sections 4.6.4 and 4.6.5. specific QC manual, as
outlined in Section 1.1.2 of
At a minimum, dimensional checks shall include internal diameter, wall this manual.
thickness, and length of two opposite sides (measured directly across from
each other). Joints must be checked for dimensional conformance with
either manufacturer’s specifications, applicable standards and/or
specifying authorities. If project specifications or the authority having
jurisdiction requirements are more stringent then they shall apply.
6.2.1.5 Joint Design and Testing
Joints shall be designed according to the applicable requirements in ASTM Proper joint designs are
C443, ASTM C990, or as required by project specifications. Critical crucial to the performance
dimensions and allowable tolerances shall be clearly indicated on the of installed pipe when
resulting joint design drawings. Joint designs drawings must be kept on infiltration or exfiltration are
file and readily available for routine and audit inspection personnel. a factor in the project.
Joint proof-of-design
testing is required only in
The plant shall perform and document joint proof-of-design leakage testing cases where the plant
on each size of gasketed pipe produced at the plant. Testing shall be uses gasketed joints.
repeated whenever joint or gasket designs are modified. Joint proof-of-
design testing, unless otherwise required by the authority or authorities
having jurisdiction, shall consist of either vacuum or hydrostatic testing
conducted in two configurations:
1) Assembled in-line (rectilinearly) and

2) Assembled with one side of the joint open 1/2-in.
more than the opposite side.
6.2.1.6 Watertightness Hydrostatic Testing
Testing shall be performed according to the hydrostatic test method set Pipe temperature should
forth in ASTM C497. Any water leaking from the joint being tested must be be as close to ambient as
collected for measurement at the end of the test. Pipe shall be tested up possible at the time of
to 3.0 psi for 10 minutes and the leakage shall not exceed: testing in order to ensure
0.041 oz / (inch internal pipe dia.)(ft. of pipe length) accuracy and consistency
of test results.
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Pipe that does not pass this test may be repaired and retested.
This test shall be performed initially or whenever equipment or processes

change.
6.2.1.7 Watertightness Vacuum Testing
Testing shall be performed with a negative test pressure (vacuum)

equivalent to 7 inches of mercury. The pipe being tested shall maintain a
minimum of 6.9 inches of mercury throughout the test time period (Ttest),
which is calculated as follows:
Ttest (seconds) = 1.5 x internal diam. of the pipe (inches)
If the pipe being tested does not hold the required vacuum, it may be
repaired and retested.
This test shall be performed initially or whenever equipment or processes

change.
6.2.1.8 Gasket Quality Control
The plant shall ensure that the rubber joint gaskets supplied with precast Gasket quality control
and pipe products are suitable for the application. This suitability shall be documentation is required
determined through the following: only in cases where the
plant actually uses
1. Annual certification of physical properties of the rubber gasketed joints.
compound as required by the specification under which the gaskets
are supplied; and These requirements do not
2. Measurement or certification of critical gaskets physical apply to joint sealants or
characteristics including (at a minimum): pipe-to-structure
- Cross-section height and width (profile and prelubricated gaskets connectors, which are
only) covered in section 2.3.6.
- Volume (ASTM C497) and diameter (o-ring gaskets only)
- Durometer (ASTM D2240) Certificates of
- Cut length (ASTM C497) Conformance should
- Splice strength clearly state that the
gaskets meet the
Measurement or certification shall be accomplished by any of the following applicable ASTM
methods: specification. Concrete
pipe joint gaskets typically
a. The gasket supplier shall furnish documentation of the required must conform to ASTM
characteristics by sampling at least 1 gasket each quarter of each C443.
size and type supplied and provide the aforementioned
measurements for those gaskets; or For height, width and
diameter measurements,
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b. The gasket supplier shall furnish evidence of several measurements

current registration of its quality system to a should be made along the
recognized third-party audited standard (e.g. – ISO 9001-2000) length of the gasket, away
and certify that the aforementioned measurements are recorded from the splice, and the
and maintained within this system once per year; or average value should be
c. Using specifications and tolerances as supplied by the gasket recorded.
manufacturer and the precast manufacturer, the precast
manufacturer or a competent third party technical service shall For splice strength testing,
perform the aforementioned measurements above by sampling at the gasket should be
least 1 of each 300 gaskets of each size and type received and stretched approximately
maintain records of the measurements made. (If project 100% and the splice visually
specifications or the authority having jurisdiction require a inspected for defects and/or
frequency of testing greater than 1/300 then they shall apply.) separation.
If any of the measurements required above indicate that the gasket is not
within acceptable tolerances, additional testing shall be performed to
determine if the remainder of the lot should be used. Gaskets which are
not within acceptable tolerances shall be segregated from usable stock
and clearly marked so as to preclude their use or transfer.
Current certification reports shall be dated not more than one year at the
end of the month from the date of the last test or certification.
6.2.1.9 Plant Requirements:
1. As required in Section 4.1.5, 4.2.1 and 6.2.1, maintain documentation

of reinforcing cage inspections with information on the required cage
design versus the actual cage used.
2. Three-edge bearing testing techniques of concrete pipe, per ASTM

C497 when required by the applicable ASTM standard, shall be
witnessed by the agency inspector during an NPCA Plant Certification
inspection. The plant inspector shall witness all three-edge bearing
tests.
3. Test records and dimensional check documentation shall be

maintained at the plant for a minimum of three (3) years.
4. Detailed reinforcing cage design drawings shall be readily available in

the steel fabrication/production area.
5. Gasket certification records and/or quality control records shall be

6. Joint design and proof-of-design testing documentation shall be

maintained on file at the plant indefinitely.
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7. As required in Section 4.1.3, maintain documentation of pallet, header

and truing rings as long as each respective piece of forming equipment
is in use at the plant.
6.2.2 SANITARY CONCRETE PIPE REQUIREMENTS
6.2.2.1 Reinforcing Steel Inspection *

Concrete pipe reinforcing steel checks shall be performed on a minimum shown on the grading
of one (1) reinforcing steel cages or 3% of each fabrication run daily, schedule, for section 6.2.2.1
whichever is greater, chosen on a random basis by QC personnel, and others designated as
regardless of fabrication method. These checks shall be documented and Critical Requirements, when
maintained in the plant records for a minimum of three (3) years. applicable.
6.2.2.2 Three-Edge Bearing Testing (TEB) *
For reinforced concrete pipe, verification of conformance to applicable * Critical Requirement –

standards (ASTM C76 and C655) shall be documented by performance of plants participating in the
three-edge bearing testing in accordance with ASTM C497. The plant NPCA Plant Certification
shall load the pipe up to the specified design strength D-load to produce a Program must receive a
0.01-inch crack. Test frequency shall be a minimum of one test per year minimum passing grade, as
for each size (and class) of pipe, or as described below, whichever is shown on the grading
greater. TEB tests are not required for sizes that have less than 100 schedule, for section 6.2.2.2
pieces manufactured during the current program year if the plant has and others designated as
compressive and proof of design test data on file. Current test reports shall Critical Requirements, when
be dated not more than one year at the end of the month from the date of applicable.
the last test or certification.
Three-edge bearing testing
is critical since it is an
industry-accepted method
Pipe Size Class Test Frequency* of verifying the strength
12” – 15” Class V and below 1 / 1000 pieces and design of the pipe.
18” – 36” Class IV and below 1 / 800 pieces
18” – 36” Class V 1 / 400 pieces
42” – 60” Class III and below 1 / 400 pieces
42” – 60” Class IV and V 1 / 200 pieces
66” and larger All Classes As require by project
specifications
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For unreinforced concrete pipe, verification of conformance to applicable

standards (ASTM C14 and C985) shall be demonstrated by performance
of three-edge bearing testing in accordance with ASTM C497. The plant
shall test up to the specified design strength ultimate load at the frequency
required by the project specifications.
For pipe designed by direct methods with standard installations, three-

edge bearing shall not be required.
If allowed by project specifications or authority having jurisdiction,

compressive strength cylinder testing and companion rational design
calculations may replace TEB testing.
Unless otherwise required by project specifications, three-edge bearing

testing of elliptical and arch pipe shall not be required.

applicable standards shall be documented by performance of absorption plants participating in the
testing in accordance with ASTM C497 (Test Method A or B). Absorption NPCA Plant Certification
testing can be performed by ASTM C642 using cores only and the Program must receive a
absorption limits of ASTM C76 shall apply. Testing shall be performed a minimum passing grade,
minimum of once per year, on the mix design (both wet-cast and dry-cast) as shown on the grading
with the lowest amount of cementitious material used at each operation or schedule, for section
manufacturing station. Both in-plant and laboratory testing shall be 6.2.2.3 and others
permitted. Current test reports shall be dated not more than one year at designated as Critical
the end of the month from the date of the last test or certification. Requirements, when
applicable.
Verification of conformance to applicable dimensional requirements shall Procedures for checking

be performed and documented on a minimum of three concrete pipes or pipe dimensions and the
3% of each day’s production, whichever is greater, chosen randomly by associated acceptable
plant quality control personnel. tolerances should be
Normal Post-pour inspection requirements apply to both wet-cast and dry- documented in the plant-
cast / machine-cast pipe, as required in Sections 4.6.4 and 4.6.5. specific QC manual, as
outlined in Section 1.1.2 of
At a minimum, dimensional checks shall include internal diameter, wall this manual.
thickness, and length of two opposite sides (measured directly across from
each other). Joints must be checked for dimensional conformance with
either manufacturer’s specifications, applicable standards and/or
specifying authorities. If project specifications or the authority having
jurisdiction requirements are more stringent then they shall apply.
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Joints shall be designed according to the applicable requirements in ASTM

C361, C1628, or as required by the project specifications. Critical
dimensions and allowable tolerances shall be clearly indicated on the
resulting joint design drawings. Joint designs drawings must be kept on
file and readily available for routine and audit inspection personnel.
If required by the project specifications or authority having jurisdiction, joint

design and testing shall be performed in accordance with ASTM C361.
If required by the project specifications or authority having jurisdiction, joint

design and testing shall be performed in accordance with ASTM C 1628.
The plant shall perform and document joint proof-of-design leakage testing
on each size of gasketed pipe produced at the plant. Testing shall be
repeated whenever joint or gasket designs are modified. Joint proof-of-
design testing, unless otherwise required by the authority or authorities
having jurisdiction, shall consist of either vacuum or hydrostatic testing
conducted in two configurations:
1) Assembled in-line (rectilinearly) and

2) Assembled with one side of the joint open 1/2-in.
more than the opposite side.
If required by the project specifications or authority having jurisdiction,

testing shall be performed according to the hydrostatic test method set
forth in ASTM C361. Pipe shall be tested up to 13.0 psi for 2 – ½ minutes
with no leakage.
If required by the project specifications or authority having jurisdiction,

testing shall be performed according to the hydrostatic test method set
forth in forth in ASTM C1628. Pipe shall be tested up to 13.0 psi for 2 – ½
minutes with no leakage.
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6.2.2.7 Watertighness Requirements
If required by project specifications or the authority having jurisdiction,

plants shall perform watertightness testing per the following:
Size Frequency Method Test Criteria

12-36" 100% Vacuum ASTM C1618
12-36" 100% Hydrostatic ASTM C497
42" > 1 per 100 Vacuum ASTM C1618
42" > 1 per 100 Hydrostatic ASTM C497
6.2.2.8 Off-Center Joint Proof of Design Testing

plants shall perform and maintain records of Off-Center Joint Proof of
Design testing per ASTM C497 on each applicable size of gasketed pipe.
Testing shall be repeated whenever joint or gasket designs are modified.
6.2.2.9 Joint Shear Proof of Design Testing

plants shall perform and maintain records of Joint Shear Proof of Design
testing per ASTM C497 on each applicable pipe size of gasketed pipe.
Testing shall be repeated whenever joint or gasket designs are modified.
6.2.2.10 Confined Gasket Proof of Design Testing

plants shall perform and maintain records of Confined Gasket Proof of
Design Testing per ASTM C361. Testing shall be repeated whenever joint
or gasket designs are modified.

plants shall perform and maintain records of Confined Gasket Proof of
Design Testing per ASTM C1628. Testing shall be repeated whenever
joint or gasket designs are modified.
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STANDARD COMMENTARY
plant actually uses
gaskets meet the
methods: specification. Concrete
pipe joint gaskets typically
a. The gasket supplier shall furnish documentation of the required must conform to ASTM
characteristics by sampling at least 1 gasket each quarter of each C443.
size and type supplied and provide the aforementioned
measurements for those gaskets; or For height, width and
b. The gasket supplier shall furnish evidence of diameter measurements,
current registration of its quality system to a several measurements
recognized third-party audited standard (e.g. – ISO 9001-2000) should be made along the
and certify that the aforementioned measurements are recorded length of the gasket, away
and maintained within this system once per year; or from the splice, and the
c. Using specifications and tolerances as supplied by the gasket average value should be
manufacturer and the precast manufacturer, the precast recorded.
manufacturer or a competent third party technical service shall
perform the aforementioned measurements above by sampling at For splice strength testing,
least 1 of each 300 gaskets of each size and type received and the gasket should be
maintain records of the measurements made. (If project stretched approximately
specifications or the authority having jurisdiction require a 100% and the splice
frequency of testing greater than 1/300 then they shall apply.) visually inspected for
defects and/or separation.
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STANDARD COMMENTARY
6.2.2.12 Plant Requirements:

design versus the actual cage used.
2. Three-edge bearing testing techniques of concrete pipe, per ASTM

C497 when required by the applicable ASTM standard, shall be
witnessed by the agency inspector during an NPCA Plant Certification
inspection. The plant inspector shall witness all three-edge bearing
tests.
3. Test records and dimensional check documentation shall be



6. Joint design and proof-of-design testing documentation shall be

maintained on file at the plant indefinitely.

6.3 ROUND MANHOLE REQUIREMENTS
Plants producing round manholes and associated components according Section 6.3 pertains to
to ASTM C478 “Standard Specification for Precast Reinforced Concrete manhole structures that
Manhole Sections” shall specifically conform to the requirements in section are intended for utility,
6.3 of this manual. storm water drainage or
sanitary wastewater
drainage structures.
6.3.1 Reinforcing Steel Inspection *

schedule, for section 6.3.1
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STANDARD COMMENTARY
Reinforcing steel inspection is not required if reinforcing steel is not used in and others designated as
certain manhole products or when fiber reinforcement is used in lieu of Critical Requirements, when
conventional reinforcing steel. applicable.
Manhole reinforcing steel checks shall be performed on a minimum of one

(1) reinforcing steel cage or 3% of each fabrication run daily, whichever is
greater, chosen on a random basis by QC personnel, regardless of
fabrication method. These checks shall be documented and maintained in
the plant records for a minimum of three (3) years.
6.3.2 Flat Slab Tops
Verify the design for each size flat slab top produced or stocked by the Note: The minimum
plant, either by maintaining rational design calculations or by proof testing, reinforcing steel
as outlined in the applicable section(s) of ASTM C497. The design shall requirements for flat slab
meet the minimum requirements of ASTM C478. tops outlined in ASTM
C478 represent the
Design calculations shall be performed and stamped by a qualified, absolute minimum steel
licensed engineer. Proof testing (when performed) shall also be reviewed that should be used in flat
and signed-off by a qualified, licensed engineer. tops. Additional
reinforcement and/or slab
thickness may be required
to adequately support the
design loads.
6.3.3 Base, Riser and Cone Sections

ASTM C478 shall be documented by performance of absorption testing in plants participating in the
accordance with ASTM C497 (Test Method A or B). Absorption testing can NPCA Plant Certification
be performed by ASTM C642 using cores only and the absorption limits of Program must receive a
ASTM C478 shall apply. Testing shall be performed a minimum of once minimum passing grade, as
per year, on the mix design (both wet-cast and dry-cast) with the lowest shown on the grading
amount of cementitious material used at each operation or manufacturing schedule, for section 6.3.3.1
station. Both in-plant and laboratory testing shall be permitted. Current and others designated as
test reports shall be dated not more than one year at the end of the month Critical Requirements, when
from the date of the last test or certification. applicable.
In order to obtain a true

representative test for dry-
cast products, it is
suggested that a test from
each manufacturing
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STANDARD COMMENTARY
operation or station be
conducted.
6.3.3.2 Step Testing
Step vertical and horizontal load testing must be performed according to Spot checks of proper
the applicable section(s) of ASTM C497 once per year, per step design installation of steps should
used and whenever a new step supplier is used. The step testing must be be included in post-pour
performed in the precast plant in the product for its intended use. The inspections.
testing must be performed or witnessed and results documented by a
member of the precasters Quality Control Department. The loads achieved
must meet the requirements of ASTM C478. Current test reports shall be
dated not more than one year at the end of the month from the date of the
last test or certification.
Verification of conformance to ASTM C478 dimensional requirements shall Procedures for checking
be performed and documented (regardless of production method) on a manhole dimensions and
minimum of three manhole sections or 3% of each day’s production, the associated acceptable
whichever is greater, chosen randomly by plant quality control personnel. tolerances should be
documented in the plant-
Normal post-pour inspection requirements apply to both wet-cast and dry- specific QC manual, as
cast / machine-cast manholes, as required in Sections 4.6.4 and 4.6.5. outlined in section 1.1.2 of
this manual.
At a minimum, dimensional checks shall include: manhole internal
diameter; wall thickness; height of two opposite sides; verification of hole
locations and size (when applicable); and verification of the invert
dimensions and elevations (when applicable).
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6.3.3.4 Sanitary Manhole Vacuum Testing
If in-plant vacuum testing of sanitary manhole sections is required by the Vacuum testing after
authority having jurisdiction, the plant shall maintain documentation of installation and prior to
such testing on file at the plant for a minimum of three (3) years. backfilling operations is the
preferred method of
watertightness testing of
sanitary manholes. Testing
should be performed
according to ASTM C1244.
6.3.4 Joint Design
Joints shall be designed to perform as required in ASTM C443, ASTM Proper joint designs are
C990, or as required by project requirements. Critical dimensions and crucial to the performance
allowable tolerances shall be clearly indicated on the joint design of installed manhole
drawings. structures when infiltration
or exfiltration are a factor in
the project.
6.3.5 Gasket Quality Control
plant actually uses
gaskets meet the
methods: specification. Manhole
joint gaskets typically must
a. The gasket supplier shall furnish documentation of the required conform to ASTM C443.
characteristics by sampling at least 1 gasket each quarter of each
size and type supplied and provide the aforementioned For height, width and
measurements for those gaskets; or diameter measurements,
b. The gasket supplier shall furnish evidence of several measurements
current registration of its quality system to a should be made along the
recognized third-party audited standard (e.g. – ISO 9001-2000) length of the gasket, away
from the splice, and the
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and certify that the aforementioned measurements are recorded average value should be
and maintained within this system once per year; or recorded.
c. Using specifications and tolerances as supplied by the gasket
manufacturer and the precast manufacturer, the precast For splice strength testing,
manufacturer or a competent third party technical service shall the gasket should be
perform the aforementioned measurements by sampling at least 1 stretched approximately
of each 300 gaskets of each size and type received and maintain 100% and the splice
records of the measurements made. visually inspected for
defects and/or separation.

design versus the actual cage used. Reinforcing steel inspection
documentation shall be maintained on file at the plant for a minimum of
three (3) years.
2. Documentation of rational design calculations and/or proof-of-design

testing of flat slab tops shall be maintained at the plant indefinitely.
3. Documentation of riser and cone section dimensional checks and/or

performance testing shall be maintained at the plant for a minimum of
three (3) years.
4. Joint design documentation shall be maintained at the plant indefinitely.

maintained at the plat for a minimum of three (3) years.


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6.4 BOX CULVERT REQUIREMENTS
Plants producing box culverts shall document proof of conformance with

ASTM C1433 ‘Specification for Precast Reinforced Concrete Monolithic
Box Sections for Culverts, Storm Drains, and Sewers’, ASTM C1577
‘Specification for Precast Reinforced Concrete Monolithic Box Sections for
Culverts, Storm Drains, and Sewers Designed According to AASHTO
LRFD’, or ASTM C1786 ‘Specification for Segmental Precast Reinforced
Concrete Box Sections for Culverts, Storm Drains, and Sewers Designed
According to AASHTO LRFD’ and / or other manufacturing requirements
mandated by the authority having jurisdiction. Plants producing box
culverts shall specifically conform to the requirements of Section 6.4 of this
manual.
6.4.1 Absorption Testing
Absorption testing shall be performed and documented in accordance with

ASTM C497 (Test Method A or B). Absorption testing can be performed by
ASTM C642 using cores only and the absorption limits of ASTM C76 or
C478 shall apply. Testing shall be performed a minimum of once per year,
on the mix design with the lowest amount of cementitious material at each
operation or manufacturing station. Both in-plant and laboratory testing
shall be permitted. Current test reports shall be dated not more than one
year at the end of the month from the date of the last test or certification.
6.4.2 Joint Design
Joints design drawings shall be maintained on file at the plant for each joint Proper joint designs are
design used. Critical dimensions and allowable tolerances shall be clearly crucial to the performance
indicated on the joint design drawings. As a proof of design, the plant shall of installed box culvert
maintain documentation on file indefinitely showing that when assembled; structures when infiltration
the joint gap between any two box culvert sections is not greater than 3/4 or exfiltration are a factor in
inch (19 mm) in any one location. the project. In addition, the
joint must be capable of
transferring loads across
the joint from one section
to another.
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6.4.3 Pre-Pour Inspections *
In addition to standard pre-pour inspections required in Section 4.3 of this * Critical Requirement –
manual, the plant shall also specifically check critical form dimensions plants participating in the
including top, bottom and wall thicknesses. The plant shall verify and NPCA Plant Certification
document compliance with the design drawings by performing a detailed Program must receive a
reinforcement check. As required in Section 4.1.5 and 4.2.1, maintain minimum passing grade, as
documentation of reinforcing cage inspections for each box culvert shown on the grading
reinforcing steel cage with information on the required cage design versus schedule, for section 6.4.3
the actual cage used, steel areas, WWR style, cage length, and and others designated as
welded/tied wire laps. Critical Requirements, when
applicable.
A sample box culvert

inspection form can be
found in Appendix B of this
manual.
6.4.4 Dimensional Checks *
In addition to standard post-pour inspections required in Section 4.6.4 of * Critical Requirement –

this manual, the plant shall also specifically check critical product plants participating in the
dimensions including top slab, bottom slab and wall thicknesses, and NPCA Plant Certification
inside length, width and height. These dimensional checks shall be Program must receive a
performed on at least one box culvert produced in each form per day. minimum passing grade, as
schedule, for section 6.4.4
and others designated as
Critical Requirements, when
applicable.
Procedures for checking

box culvert dimensions
and the associated
acceptable tolerances
should be documented in
the plant-specific QC
manual, as outlined in
section 1.1.2 of this
manual.
1. Pre-pour inspection and dimensional check documentation shall be

maintained at the plant for a minimum of three years.
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2. Joint design documentation shall be maintained on file at the plant

indefinitely. During an NPCA Plant Certification inspection, the
inspector may require the plant to demonstrate that when assembled,
the joint gap between any two box culvert sections is not greater than
3/4 inch (19 mm) in any one location. The inspector may choose box
culverts sections at his/her discretion from reasonably-sized stock in
the plant.

6.5 SEPTIC TANK REQUIREMENTS
Plants producing septic tanks shall document proof of conformance with It is suggested that plants
ASTM C1227 “Standard Specification for Precast Concrete Septic Tanks”, producing septic tanks
IAPMO/ANSI Z1000 ‘Prefabricated Septic Tanks’ or other manufacturing follow the practices
requirements mandated by the authority having jurisdiction. The plant outlined in the “NPCA
shall specifically conform to the requirements in section 6.5 of this manual. Precast Concrete On-site
Wastewater Tanks Best
Practices Manual.”
6.5.1 Structural Proof-of-Design
Structural proof-of-design shall be demonstrated either by calculation or by Proof-of-design should be

proof testing. demonstrated for the
maximum design burial
Design calculations shall be performed and stamped by a qualified, depth, accounting for the
licensed engineer. Proof testing in lieu of design calculations shall be local surface, soil and
reviewed and signed-off by a qualified, licensed engineer. hydrostatic loading
conditions.
6.5.2 Watertightness Testing *
Tank watertightness shall be demonstrated according to the applicable * Critical Requirement –

section(s) of ASTM C1227, ASTM C1719, IAPMO/ANSI Z1000, or the plants participating in the
requirements set forth by the authority having jurisdiction, whichever is NPCA Plant Certification
more stringent. A minimum of one test per year on a septic tank produced Program must receive a
in each septic tank form used at the plant shall be performed and minimum passing grade, as
documented. If the authority having jurisdiction require a greater shown on the grading
frequency of testing, the plant shall maintain records of all additional tests schedule, for section 6.5.2
at the plant. and others designated as
Watertightness testing may be performed and documented at the plant applicable.
and shall be witnessed and signed off by the plant QC Manager.
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Watertightness testing may be conducted in the field prior to backfill and Watertightness testing of a
shall be witnessed and signed off by the authority having jurisdiction. tank produced in each
form is necessary to
In cases when multiple tank sizes are manufactured using the same form, ensure that all forming
watertightness testing shall be performed on the largest (tallest) structure, equipment remains within
as long as the same concrete mix design is used. appropriate tolerances.
Forms, whose castings

have been tested and
meet the requirements,
may be used to produce
septic tanks or grease
interceptors without
additional testing.
For individual tanks models manufactured using panel type forms, a single
tank of each model shall be tested per year. As an example: plants
manufacturing 1,000,
1,500, and 2,000 gallon
tank models with panel
forms, only a single tank
model per year would
require watertightness
testing.
In cases where tanks are physically too large to assemble, water test and
disassemble at the plant without damage, or in areas where the Authority
Having Jurisdiction has no requirements for watertightness testing;
watertightness testing requirement is waived.
Current test reports shall be dated not more than one year at the end of
the month from the date of the last test or certification.
1. Documentation of rational design calculations and/or proof-of-design It is suggested that plants

testing of septic tanks shall be maintained at the plant indefinitely. producing septic tanks
follow the practices
2. Watertightness test records shall be maintained on file at the plant for a outlined in the “NPCA
minimum of three years. Precast Concrete On-site
Wastewater Tanks Best
3. For plants participating in the NPCA Product Listing Program, a Practices Manual.”
watertightness test shall be witnessed by the agency inspector
during an NPCA Plant Certification inspection. The tank to be
tested shall be chosen at random from plant inventory by the
agency inspector.
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6.6 GREASE INTERCEPTOR REQUIREMENTS
Plants producing grease interceptor tanks shall document proof of Proof-of-design should be
conformance with ASTM C1613 “Standard Specification for Precast demonstrated for the
Concrete Grease Interceptor Tanks”, IAPMO/ANSI Z1001 ‘Prefabricated maximum design burial
Gravity Grease Interceptors’, or other manufacturing requirements depth, accounting for the
mandated by the authority having jurisdiction. The plant shall specifically local surface, soil and
conform to the requirements in section 6.6 of this manual. hydrostatic loading
conditions.
Structural proof-of-design shall be demonstrated either by calculation or by

proof testing.
Design calculations shall be performed and stamped by a qualified,

licensed engineer. Proof testing in lieu of design calculations shall be
reviewed and signed-off by a qualified, licensed engineer.
6.6.2 Watertightness Testing *
Tank watertightness shall be demonstrated according to the applicable * Critical Requirement –

section(s) of ASTM C1613, ASTM C1719, IAPMO/ANSI Z1001 or the plants participating in the
requirements set forth by the authority having jurisdiction, whichever is NPCA Plant Certification
more stringent. A minimum of one test per year on a grease interceptor Program must receive a
tank produced in each grease interceptor tank form used at the plant shall minimum passing grade, as
be performed and documented. If the authority having jurisdiction require shown on the grading
a greater frequency of testing, the plant shall maintain records of all schedule, for section 6.6.2
additional tests at the plant. and others designated as
Watertightness testing may be performed and documented at the plant applicable.
and shall be witnessed and signed off by the plant QC Manager.
Watertightness testing of
Watertightness testing may be conducted in the field prior to backfill and any tank produced in each
shall be witnessed and signed off by the authority having jurisdiction. form is necessary to
ensure that all forming
equipment remains within
appropriate tolerances.
In cases when multiple tank sizes are manufactured using the same form, Forms, whose castings
watertightness testing shall be performed on the largest (tallest) structure, have been tested and
as long as the same concrete mix design is used. Otherwise, testing shall meet the requirements,
be performed on each individual tank design. may be used to produce
grease interceptors or
QCM-001, Chapter 6 Rev. 0 09-12-22 (16.0)

106
STANDARD COMMENTARY
septic tanks without

For individual tanks models manufactured using panel type forms, a single additional testing.
tank of each model shall be tested per year. As an example: plants
manufacturing 1,000,
1,500, and 2,000 gallon
tank models with panel
forms, only a single tank
model per year would
require watertightness
testing.
In cases where tanks are physically too large to assemble, water test and
disassemble at the plant without damage, or in areas where the Authority
Having Jurisdiction has no requirements for watertightness testing;
watertightness testing requirement is waived.
Current test reports shall be dated not more than one year at the end of
the month from the date of the last test or certification.
1. Documentation of rational design calculations and/or proof-of-design

testing of septic tanks shall be maintained at the plant indefinitely.
2. Watertightness test records shall be maintained on file at the plant for

a minimum of three years.
3. For plants participating in the NPCA Product Listing Program, a

watertightness test shall be witnessed by the agency inspector
during an NPCA Plant Certification inspection. The tank to be
tested shall be chosen at random from plant inventory by the
agency inspector.
QCM-001, Chapter 6 Rev. 0 09-12-22 (16.0)

107
APPENDIX A
STANDARDS CITED IN THE MANUAL

AND REFERENCES
AASHTO STANDARDS
American Association of State Highway and Transportation Officials can be

obtained from:
American Association of State

Highway and Transportation Officials
444 North Capitol Street, NW
Suite 249
Washington, DC 20001
Web: www.transportation.org
Plants required by federal, state and/or local requirements may substitute the most
recent version of the equivalent AASHTO standard to replace ASTM requirements
in this manual.
ACI STANDARDS
American Concrete Institute standards and other publications can be obtained

from:
American Concrete Institute

PO Box 9094
Farmington Hills MI 48333-9094
Phone: 248-848-3700
Web: www.concrete.org
ACI Standards cited in this manual:
ACI 211.1 “Practice for Selecting Proportions for Normal, Heavyweight, and Mass
Concrete”
ACI 211.2 “Practice for Selecting Proportions for Structural Lightweight Concrete”
ACI 211.3 “Practice for Selecting Proportions for No-Slump Concrete”
ACI 237 “Self-Consolidating Concrete”
ACI 302 “Guide for Concrete Floor and Slab Construction”
ACI 304 “Guide for Measuring, Mixing, Transporting, and Placing Concrete”
ACI 305R “Hot Weather Concreting”
ACI 306R “Cold Weather Concreting”
QCM-001, Appendix A Rev. 0 09-12-22 (16.0)

108
ACI 318 “Building Code Requirements for Structural Concrete”
ACI 350 “Code Requirements for Environmental Engineering Concrete

Structures”
ASTM INTERNATIONAL STANDARDS
ASTM International standards and other publications can be obtained from:
ASTM International
100 Barr Harbor Drive
West Conshohocken PA 19428-2959
Phone: 610-832-9500
Web: www.astm.org
ASTM Standards cited in this manual (SI equivalents may also be applicable):
ASTM A36 “Standard Specification for Carbon Structural Steel”
ASTM A108 “Standard Specification for Steel Bars, Carbon, Cold-Finished,

Standard Quality”
ASTM A184 “Standard Specification for Welded Deformed Steel Bar Mats for
Concrete Reinforcement”
ASTM A615 “Standard Specification for Deformed and Plain Billet-Steel Bars for
Concrete Reinforcement”
ASTM A706 “Standard Specification for Low-Alloy Steel Deformed and Plain
Bars for Concrete Reinforcement”
ASTM A767 “Standard Specification for Zinc-Coated (Galvanized) Steel Bars

for Concrete Reinforcement”
ASTM A775 “Standard Specification for Epoxy-Coated Steel Reinforcing Bars”
ASTM A820 “Standard Specification for Steel Fibers for Fiber-Reinforced

Concrete”
ASTM A884 “Standard Specification for Epoxy-Coated Steel Wire and Welded
Wire Fabric for Reinforcement”
ASTM A934 “Standard Specification for Epoxy-Coated Prefabricated Steel

Reinforcing Bars”
ASTM A1064 “Standard Specification for Steel Wire and Welded Wire
Reinforcement, Plain and Deformed for Concrete”

109
ASTM C14 “Standard Specification for Nonreinforced Concrete Sewer, Storm
Drain, and Culvert Pipe”
ASTM C31 “Standard Practice for Making and Curing Concrete Test
Specimens in the Field”
ASTM C33 “Standard Specification for Concrete Aggregates”
ASTM C39 “Standard Test Method for Compressive Strength of Cylindrical

Concrete Specimens”
ASTM C40 “Standard Test Method for Organic Impurities in Fine Aggregates
for Concrete”
ASTM C42 “Standard Test Method for Obtaining and Testing Drilled Cores and
Sawed Beams of Concrete”
ASTM C70 “Standard Test Method for Surface Moisture in Fine Aggregate”
ASTM C76 “Standard Specification for Reinforced Concrete Culvert, Storm

Drain, and Sewer Pipe”
ASTM C94 “Standard Specification for Ready-Mixed Concrete”
ASTM C136 “Standard Test Method for Sieve Analysis of Fine and Coarse
Aggregates”
ASTM C138 “Standard Test Method for Density (Unit Weight), Yield, and Air
Content (Gravimetric) of Concrete”
ASTM C143 “Standard Test Method for Slump of Hydraulic Cement Concrete”
ASTM C150 “Standard Specification for Portland Cement”
ASTM C173 “Standard Test Method for Air Content of Freshly Mixed Concrete
by the Volumetric Method”
ASTM C216 “Standard Specification for Facing Brick (Solid Masonry Units
Made of Clay or Shale”
ASTM C231 “Standard Test Method for Air Content of Freshly Mixed Concrete
by the Pressure Method”
ASTM C260 “Standard Specification for Air-Entraining Admixtures for Concrete”
ASTM C330 “Standard Specification for Lightweight Aggregates for Structural

Concrete”
ASTM C403 “Standard Test Method for Time of Setting of Concrete Mixtures by
Penetration Resistance”

110
ASTM C443 “Standard Specification for Joints for Concrete Pipe and Manholes,
Using Rubber Gaskets”
ASTM C478 “Standard Specification for Precast Reinforced Concrete Manhole

Sections”
ASTM C494 “Standard Specification for Chemical Admixtures for Concrete”
ASTM C497 “Standard Test Methods for Concrete Pipe, Manhole Sections, or
Tile”
ASTM C566 “Standard Test Method for Total Evaporable Moisture Content of
Aggregate by Drying”
ASTM C595 “Standard Specification for Blended Hydraulic Cement”
ASTM C618 “Standard Specification for Fly Ash and Raw or Calcined Natural
Pozzolan for Use in Concrete”
ASTM C642 “Standard Test Method for Density, Absorption, and Voids in
Hardened Concrete”
ASTM C655 “Standard Specification for Reinforced Concrete D-Load Culvert,

Storm Drain, and Sewer Pipe”
ASTM C685 “Standard Specification for Concrete Made by Volumetric Batching

and Continuous Mixing”
ASTM C805 “Standard Test Method for Rebound Number of Hardened

Concrete”
ASTM C890 “Standard Practice for Minimum Structural Design Loading for
Monolithic or Sectional Precast Concrete Water and Wastewater
Structures”
ASTM C913 “Standard Specification for Precast Concrete Water and

Wastewater Structures”
ASTM C923 “Specification for Resilient Connectors Between Reinforced

Concrete Manhole Structures, Pipes, and Laterals”
ASTM C979 “Standard Specification for Pigments for Integrally Colored

Concrete”
ASTM C985 “Standard Specification for Nonreinforced Concrete Specified

Strength Culvert, Storm Drain, and Sewer Pipe”
ASTM C989 “Standard Specification for Ground Granulated Blast-Furnace Slag

for Use in Concrete and Mortars”

111
ASTM C990 “Standard Specification for Joints for Concrete Pipe, Manholes,
and Precast Box Sections Using Preformed Flexible Joint
Sealants”
ASTM C1017 “Standard Specification for Chemical Admixtures for Use in

Producing Flowing Concrete”
ASTM C1064 “Standard Test Method for Temperature of Freshly Mixed Portland
Cement Concrete”
ASTM C1088 “Standard Specification for Thin Veneer Brick Units Mad From Clay
or Shale”
ASTM C1116 “Standard Specification for Fiber-Reinforced Concrete and

Shotcrete”
ASTM C1157 “Standard Performance Specification for Hydraulic Cement”
ASTM C1202 “Standard Test Method for Electrical Indication of Concrete’s

Ability to Resist Chloride Ion Penetration”
ASTM C1214 “Standard Test Method for Concrete Pipe Sewerlines by Negative
Air Pressure (Vacuum) Test Method”
ASTM C1227 “Standard Specification for Precast Concrete Septic Tanks”
ASTM C1240 “Standard Specification for Silica Fume Used in Cementitious

Mixtures”
ASTM C1244 “Test Method for Concrete Sewer Manholes by the Negative Air
Pressure (Vacuum) Test Prior to Backfill”
ASTM C1433 “Specification for Precast Reinforced Concrete Monolithic Box
Sections for Culverts, Storm Drains, and Sewers”
ASTM C1478 ”Standard Specification for Storm Drain Resilient Connectors

Between Reinforced Concrete Storm Sewer Structures, Pipes and
Laterals”
ASTM C1577 “Specification for Precast Reinforced Concrete Monolithic Box

Sections for Culverts, Storm Drains, and Sewers Design According
to AASHTO LRFD”
ASTM C1602 “Standard Specification for Mixing Water Used in the Production of
Hydraulic Cement Concrete”
ASTM C1610 “Standard Test Method for Static Segregation of Self-Consolidating

Concrete Using Column Technique”
ASTM C1611 “Standard Test Method for Slump Flow of Self-Consolidating

Concrete”
ASTM C1613 “Standard Specification for Precast Concrete Grease Interceptor

Tanks”

112
ASTM C1618 “Standard Test Method for Concrete Sanitary Sewer Pipe by
Negative (Vacuum) or Positive Air Pressure”
ASTM C1621 “Standard Test Method for Passing Ability of Self-Consolidating

Concrete by J-Ring”
ASTM C1628 “Standard Specification for Joints for Concrete Gravity Flow Sewer
Pipe, Using Rubber Gaskets”
ASTM C1712 “Standard Test Method of Static Segregation Resistance of Self-

Consolidating Concrete Using Penetration Test”
ASTM C1719 “Standard Test Method for Installed Precast Concrete Tanks and
Accessories by the Negative Air Pressure (Vacuum) Test Prior to
Backfill”
ASTM C1758 “Standard Test Method for Fabricating Test Specimens with Self-
Consolidating Concrete”
ASTM C1778 “Standard Guide for Reducing Risk of Deleterious Alkali-aggregate

reaction on Concrete”
ASTM C1786 “Specification for Segmental Precast Reinforced Concrete Box

Sections for Culverts, Storm Drains, and Sewers Designed
According to AASHTO LRFD”
ASTM D2240 “Standard Test Method for Rubber Property—Durometer

Hardness”
ASTM E4 “Standard Practice for Force Verification of Testing Machines”
ASTM G109 “Standard Test Method for Determining the Effects of Chemical
Admixtures on the Corrosion of Embedded Steel Reinforcement in
Concrete Exposed to Chloride Environments”
Additional Relevant Precast Concrete Product-Specific ASTM International

standards (SI equivalents may also be applicable):
ASTM C118 “Standard Specification for Concrete Pipe for Irrigation or

Drainage”
ASTM C172 “Standard Practice for Sampling Fresh Mixed Concrete”
ASTM C192 “Standard Practice for Making and Curing Concrete Test
Specimens in the Laboratory”
ASTM C361 “Standard Specification for Reinforced Concrete Low-Head

Pressure Pipe”
ASTM C506 “Standard Specification for Reinforced Concrete Arch Culvert,


113
ASTM C507 “Standard Specification for Reinforced Concrete Elliptical Culvert,
ASTM C822 “Standard Terminology Relating to Concrete Pipe and Related

Products”
ASTM C825 “Standard Specification for Precast Concrete Barriers”
ASTM C857 “Standard Practice for Minimum Structural Design Loading for
Underground Precast Concrete Utility Structures”
ASTM C858 “Standard Specification for Underground Precast Concrete Utility

Structures”
ASTM C877 “Standard Specification for External Sealing Bands for Concrete
Pipe, Manholes, and Precast Box Sections”
ASTM C915 “Standard Specification for Precast Reinforced Concrete Crib Wall
Members”
ASTM C923 “Standard Specification for Resilient Connectors Between

Reinforced Concrete Manhole Structures, Pipes and Laterals”
ASTM C1417 “Standard Specification for Manufacture of Reinforced Concrete

Sewer, Storm Drain, and Culvert Pipe for Direct Design”
ASTM C1479 “Standard Practice for Installation of Precast Concrete Sewer,

Storm Drain, and Culvert Pipe Using Standard Installations”
ASTM C1504 “Standard Specification for Manufacture of Precast Reinforced

Concrete Three-Sided Structures for Culverts, and Storm Drains”
ASTM C1603 “Standard Test Method for Measurement of Solids in Water”
ASTM C1776 “Standard Specification for Wet-Cast Precast Modular Retaining

Wall Units”
ASTM C1818 “Standard Specification for Rigid Synthetic Fiber Reinforced

Concrete Culvert, Storm Drain, and Sewer Pipe”
ASTM C1837 “Standard Specification for Production of Dry Cast Concrete Used
for Manufacturing Pipe, Box, and Precast Structures”
ANSI STANDARDS
American National Standards Institute standards and other publications can be

obtained from:
American National Standards Institute

1819 L Street, NW
6th floor

114
Phone: .202-293-8020
Web: www.ansi.org
ANSI Standards cited in this manual:
ANSI A10.9 “Concrete and Masonry Work Safety Requirements”
ANSI A137.1 “American National Standards Specifications for Ceramic Tile”
AWS STANDARDS
American Welding Society standards and other publications can be obtained from:
American Welding Society

550 NW LeJeune Rd
Miami FL 33126
Phone: 800-443-9353
Web: www.aws.org
AWS Standards cited in this manual:
AWS D1.1 “Structural Welding Code -- Structural Steel”
AWS D1.4 “Structural Welding Code -- Reinforcing Steel”
AWS D1.5 “Bridge Welding Code”
CSA STANDARDS
CSA Group Head Office

178 Rexdale Blvd.
Toronto, Ontario
Canada M9W 1R3
Tel: 416-747-4000
Toll-Free: (800) 463-6727
www.csa-international.org
Plants required by provincial and/or local requirements may substitute the most
recent version of the equivalent CSA standard to replace ASTM requirements in
this manual.
CFR STANDARDS
Copies of the Code of Federal Regulations can be obtained from:
U.S. Government
Printing Office
732 North Capitol St. NW
Phone: 202-512-0000
Web: www.gpo.org

115
CFR Standards cited in this manual:
CFR Title 29 Part 1926 “Safety and Health Regulations for Construction”
(www.gpoaccess.gov/cfr/index.html)
CRSI STANDARDS
Concrete Reinforcing Steel Institute standards and other publications can be

obtained from:
Concrete Reinforcing Steel Institute

933 N. Plum Grove Road
Schaumburg, IL 60173
Phone: 847-517-1200
Web: www.crsi.org
CRSI Standard cited in this manual:

“Placing Reinforcing Bars”
RSIC / IAAC STANDARDS
Reinforcing Steel Institute of Canada / Institut D’acier D’armature du Canada

standards and other publications can be obtained from:
Reinforcing Steel Institute of Canada / Institut D’acier D’armature

du Canada
P O Box 40620
RPO Six Points Plaza
Toronto, Ontario M9B 6K8
(416) 239-RSIO (7746)
RSIC / IAAC Standard cited in this manual:

“REINFORCING STEEL – Manual of Standard Practice”
REFERENCES
National Precast Concrete Association
“Techfiles: A Collection of NPCA Technotes and Techbriefs”
“NPCA Guide to Implementing SCC”
National Precast Concrete Association

10333 North Meridian Street, Suite 272
Indianapolis, IN 46290
Phone: 800-366-7731
Web: www.precast.org

116
ACI 116 “Cement and Concrete Terminology”
ACI 212.2 “Guide for the Use of Admixtures in Concrete”
ACI 301 “Specifications for Structural Concrete for Buildings”
ACI 308 “Practice for Curing Concrete”
ACI 309 “Guide for Consolidation of Concreting”
ACI 311.1 “ACI Manual of Concrete Inspection”
NPCA “NPCA Guide to Implementing SCC”
AMERICAN CONCRETE PIPE ASSOCIATION
ACPA
8445 Freeport Parkway
Suite 350
Irving, TX 75063-2595
Phone: 972-506-7216
Web: www.concrete-pipe.org
QCast Plant Certification Manual
PORTLAND CEMENT ASSOCIATION
Portland Cement Association

5420 Old Orchard Road
Skokie IL 60077
Phone: 847-966-6200
Web: www.cement.org
PCA EB001.16 “Design and Control of Concrete Mixtures”
PCA PA 015 “Tips on Control Tests for Quality Concrete”
“Quality is Free -- The Art of Making Quality Certain” by Phillip B. Crosby

Mentor Book, New American Library
PO Box 999
Bergenfield, NJ 07621
“Concrete Manual” Part 2, 9th ed

NTIS (National Technical Information Services)
US Dept Commerce
Springfield VA 22161
800-553-6847

117
PCI
Prestressed Concrete Institute

175 W. Jackson Blvd.
Chicago, IL 60604
Phone: 312-786-0300
Web: www.pci.org
PCI MNL-116 “Manual for Quality Control for Plants and Production of Structural
Precast Concrete Products”
PCI MNL-117 “Manual for Quality Control for Architectural Precast Concrete”

118
APPENDIX B
SAMPLE FORMS
Standardized forms are useful for recording and keeping information. Industry-wide
forms are too often cumbersome for most plants, so it is recommended that each plant
develop forms applicable to its operations and products. The basic principle in
developing forms is to make each form complete but as simple as possible. The forms
included in this appendix are examples of those being used in the precast concrete
products industry.
QCM-001, Appendix B Forms Rev. 0 09-12-22 (16.0)

119
QMF-002, Rev.0, 10-29-18 (14.0)
RAW MATERIAL REPORT

QUALITY CONTROL DEPARTMENT
Job No Job Name
FINE AGGREGATE
Sieve ASTM C 33 %
Weight Retained % Retained % Passing
Size Passing
3/8" 100
No. 4 95-100
No. 8 80-100
No. 16 50-85
No. 30 25-60
No. 50 5-30
No. 100 0-10
Pan 0-3
Fineness
Modulus
COARSE AGGREGATE
ASTM C ASTM
Sieve
Weight Retained % Retained % Passing 33 size 67 C33 size
Size
% Pass 8 % Pass
1" 100 0
3/4" 90-100 0
1/2" 0 100
3/8" 20-55 85-100
No. 4 0-10 10-30
No. 8 0-5 0-10
No. 16 0 0-5
Date
Technician
Inspector
Rev. 0
QMF-002, Appendix B Forms 120 1-20-19 (15.0)
QMF-003, Rev.0, 10-29-18 (14.0)
PRE-POUR INSPECTION REPORT

PRODUCT: Job #
Casting Date
Casting Number
Form Number
Form Condition
Form Cleanliness
Form Joints
Release Agent/Retarder
Design Length (ft/in)
Set-Up Length (ft/in)
Design Width (ft/in)
Set-Up Width (ft/in)
Design Depth (ft/in)
Set-Up Depth (ft/in)
Blockouts
Squareness
End and Edge Details

Reinforcing Steel -Design v Actual
Size of Reinforcing Design v Actual
Spacing of ReinforcingDesign v Actual
Corrosion
Reinf. Cleanliness
Plates and Inserts

Location of Lifting Devices
Top Finish (wet)
* All applicable boxes shall have actual measurements or actual condition noted, otherwise shall be marked n/a
REMARKS:
QC Supervisor Date Inspector
Rev. 0
QMF-004, Rev. 0, 10-29-18 (14.0)
CONCRETE TESTING REPORT

JOB NUMBER JOB NAME
PRODUCT: DATE:
Slump or Slump Flow & VSI
Air %
Ambient Temperature
Concrete Temperature
Mix Design No.
Cylinder No.
Strength Test Date
Time Made
Time of Strength Test
Curing Age
Load (lbs)
Strength (psi)
Required Strength (psi)
REMARKS:
Report
Inspector Date QC Supervisor
Signature Signature
Rev. 0
QMF-005, Rev. 0, 10-29-18 (14.0)
POST-POUR INSPECTION REPORT

PRODUCT: Job #:
Casting Date
Casting Number
Inspection Date
Mark Number
Stripping Strength
Top Finish
Bottom Finish
Surface Texture
As Cast Length (ft/in)
As Cast Width (ft/in)
As Cast Depth (ft/in)
Cracks
Spalls
Squareness
Chamfers
Honeycomb / Grout Leak
Bowing
Exposed Reinforcement
Exposed Chairs
Plates and Inserts
Radius Quality
Openings / Blockouts
Lifting Devices
Form Condition
* All applicable boxes shall have actual measurements or actual condition noted, otherwise shall be marked n/a.
REMARKS:
Inspector Date QC Supervisor
Rev. 0
QMF-007, Rev. 0,10-29-18 (14.0)
Batch Report Form Batch Report Form

Mix Designation: Date: Mix Designation: Date:
Quantity: Time: Quantity: Time:
Batch Operator: Batch Operator:
Project/Job: Project/Job:
Material Quantity Material Quantity
Cement: lbs. Type: Cement: lbs. Type:
SCM lbs. SCM lbs.
Water: gal./lbs. Water: gal./lbs.
Fine Aggregate: lbs. Type: Fine Aggregate: lbs. Type:
Coarse Aggregate: lbs. Type: Coarse Aggregate: lbs. Type:
Air Entrainment: ozs. Type: Air Entrainment: ozs. Type:
Water Reducer: ozs. Type: Water Reducer: ozs. Type:
Other: Type: Other: Type:
Fine Agg. Moisture: Free or Total % Fine Agg. Moisture: Free or Total %
Coarse Agg.Moisture: Free or Total % Coarse Agg.Moisture: Free or Total %
w/cm Ratio: w/cm Ratio:
Optional QC Information Optional QC Information
Slump: in. Temp. Slump: in. Temp.
Slump Flow: in. Slump Flow: in.
VSI VSI
Air Content: % Air Content: %
Comp. Strength: psi Comp. Strength: psi

3
Density (Unit Weight) lb/ft Density (Unit Weight) lb/ft 3
Rev. 0
QMF-008, Rev. 0, 10-29-18 (14.0)
GASKET QUALITY CONTROL REPORT
Test Number ________________
Product Gaskets will be used on ________________________________
Vendor _________________________ Qty. Ordered ____________
Vendor Order # __________________ Plant P.O.# ____________
Date Received __________
Critical Gasket Dimension Table

Gasket # Durometer Length Dia./Width Height Volume Splice Strength
Measured
1
2
3
4
5
6
7
8
9
10
Required
Printed Marking on Gasket ____________________________________________
Gasket Compliance Status Meets Spec. Does not meet Spec.
Signed _________________________________
Date _________________________________
Remarks: __________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
Rev. 0
QMF-009, Rev. 0, 10-29-18 (14.0)
CONCRETE PIPE DIMENSIONAL INSPECTION FORM

Date ___________________________
Pipe Size ________________________________ Job # __________________________
Pipe Class ________________________________ Lot # __________________________
Pipe Wall ________________________________ Pipe # __________________________
Mfg. Process ________________________________ # Produced ______________________
Position Spigot End Bell End Required
Internal Diameter 0º _______________ _______________ _______________
180º _______________ _______________ _______________
Position Spigot End Bell End Required
0º ______________ ______________ ______________
90º ______________ ______________ ______________

Wall Thickness
180º ______________ ______________ ______________
270º ______________ ______________ ______________
Length Measurements
Position Length Measurement Measurements Required
0º ______________ Maximum Length ______________ ______________
90º ______________ Minimum Length ______________ ______________
180º ______________ Range ______________ ______________
270º ______________
Signed ________________________________
Date ________________________________
Rev. 0
QMF-010, Rev.0, 10-29-18 (14.0)
REINFORCED CONCRETE PIPE THREE-EDGE-BEARING TEST REPORT (ASTM C497)
Test # ______________________ x
PRODUCT INFORMATION Test Date ______________________
Type Size Class Wall Joint Manufacture Date ______________________
Product Age (days) ______________________
Manufacturing Process ______________________
Length Wall Thickness Inside Diameter

Measured Allowable Measured Allowable Measured Allowable
Min. Min. Min.
Max. Max. N/A Max.
REINFORCING INFORMATION
Cage Description Area of Steel Required Area of Steel
Inside:
Outside:
Elliptical:
Comments: ________________________________________________________________________________________________
________________________________________________________________________________________________________
THREE-EDGE-BEARING TEST RESULTS
Actual Load Required Load Actual D-Load Required D-Load
1st Crack
.01" Crack
Ultimate
If Product was not tested to Ultimate Load:

I herby certify that the pipe was tested in accordance
Load when test was stopped:________________lbs. with ASTM C497.
D-Load when test was stopped:______________lbs/ft

Signature: _________________________________
Pipe condition when test was stopped:
________________________________________
________________________________________ Date: _____________________________________
________________________________________
________________________________________
Rev.0
QMF-011, Rev. 0, 10-29-18 (14.0)
SINGLE CELL BOX CULVERT REINFORCEMENT INSPECTION
Date: _____________________
Identification
Inspector: _____________________ Fabrication Date
Span
Comments: _____________________ Rise
Design Table #
_________________________________ Earth Cover, Min.
Earth Cover, Max.
_________________________________
Top Slab
As6 As7
As2
As5
As4 Side Wall
Span
L
As1
Rise
As3
As8
Bottom Slab
Typical Reinforcement Layout
Area of Steel Area of Steel

Used Required Mesh Type Length M
As 1
As 2
As 3
As 4
As 5
As 6
As 7
As 8
Inserts
Spacers
*Lap
Rev.0
QMF-012, Rev.0, 10-29-18 (14.0)
DOUBLE CELL BOX CULVERT REINFORCEMENT INSPECTION

Date: _____________________
Identification
Inspector: _____________________ Fabrication Date
Span
Comments: _____________________ Rise
Design Table #
_________________________________ Earth Cover, Min.
Earth Cover, Max.
_________________________________
M
As6
As6
As9
As2 As7
As1
As5 As5
Span
As10 As4
As4
Rise
As3 As1
As8
As9
Typical Reinforcement Layout
Area of Steel Area of Steel

Used Required Mesh Type Length M
As1
As2
As3
As4
As5
As6
As7
As8
As9
As10
Inserts
Spacers
*Lap
Rev.0
QMF - 031 Grade Ring Rev 3 10-29-18 (14.0)
131
30" <h MH GRADE RING

JOB#: ___ STACK 6 PER SKID
JOB: ______________ SMOOTH BAR
'' HOOP STEEL
GRADE SIZE: _6.;;;.__ _ SIZE 0 QTY
DRAWN BY: ___ #2 3'-2" 1
1 ,, CHAIRS
¢46"
¢30"
w
z
+
0
I-
Cf)
(2) 1 / 4" LIFTING

CABLES
u
u
Cf)
QC REBAR CHECKLIST
SIZE:
LENGTH: ___ DIMENSIONAL TOLERANCES
TYPE: ____ WEIGHT: 31 4# LENGTH, WIDTH, HEIGHT, WALL THICKNESS:_±1/2"
REBAR SPACING: ±1"
COVER: ___ ._______....., CONCRETE COVER OVER REINFORCING:-0",+1/2"
RED HAT FINISH HOLE LOCATION: ±1"
CHECKED: & LIFTERS: HOLE SIZE: ±1/2"
MOLD DIMS &

SET BY: __ PRE POUR: POST POUR: __ POUR DATE: ___
2
·
QMF - 033 Vault Top Rev. 3 10-29-18 (14.0)
133
6' x 8' VAULT TOP

JOB: ______________ FINISH: -'--'"N ,-.;. /A....;.._____ JOB#: ___
PIECE NUMBER: _________ LIFTING DEVICE: ( 4) 6/6 U.L.
72"x96x78" D
VAULT SIZE: STEEL: SEE ATIACHE
WALL THICKNESS: -----'-6_" ______ CHAIR SIZE: __________
MOLD DIMS & RED HAT FINISH
POST POUR: __ POUR DATE: ___
PRE POUR: ___ & LIFTERS: ____
DRAWN BY: ___
CH'D BY:
37"1 GROOVED OPENING
a·
_.A__ I
QC REBAR CHECKLIST I I
1________________1
SIZE: ___
LENGTH: __
lYPE: ___ DIMENSIONAL TOLERANCES
COVER: ___ LENGTH, WIDTH, HEIGHT, WALL THICKNESS:_±1/2"
CHECKED: __ REBAR SPACING:_________±1"
CONCRETE COVER OVER REINFORCING:__ -0", +1/2"
OFFICE CHECK: ____ WEIGHT: 13,620 # HOLE SIZE:___________± . 1/2"
QMF - 034 Vault Top Rebar Rev. 3 10-29-18 (14.0)
134
6'x 8' VAULT TOP REBAR

/
JOB: FINISH: N A JOB#:
PIECE NUMBER: LIFTING DEVICE: (4) 6/6 U.L.
VAULT SIZE: 72"x96x78" STEEL: SEE ATIACHED
WALL THICKNESS: -----'-6_" ______ CHAIR SIZE: __________
POST POUR: __ POUR DATE: ___
PRE POUR: ___ & LIFTERS: ____
-· -10s·--·
'
DRAWN BY: ___
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12 #5 BAR 6'-8'
4 #5 BAR 2'-2'
4 #5 BAR 1'-10'
4 #5 BAR 1'-8'
8 #4 BAR 8'-8'
4 #4 BAR 3'-2'
4 #4 BAR 2'-10'
4 #4 BAR 2'-8'
DIAG
#4 BAR 4'-3'
#4 BAR 10'-2' BENT

#4 BAR 8'-8'
#4 BAR 5'-2' BENT
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SIZE: ___
LENGTH: __ 4 BAR @ 10"
112 • TYP. COVER O.C.E.W.
lYPE: --- *METHOD(S) OF RIGID REINFORCEMENT
COVER:___ SUPPORT/CONNECTION:._______. DIMENSIONAL TOLERANCES
LENGTH, WIDTH, HEIGHT, WALL THICKNESS:_±1/2"
CHECKED: __ REBAR SPACING:________.±1"
CONCRETE COVER OVER REINFORCING:.__-0", +1/2"
OFFICE CHECK: _____ WEIGHT: 13,620 # HOLE SIZE:_________�±1/2"
10" MIN. EDGE
434"
7,645#
SLAB MIN. 612"
SLAB MIN. 612"
434"
7,645#
10" MIN. EDGE
5
SLAB MIN. 612"
434"
7,645#
10" MIN. EDGE
SLAB MIN. 612"

434"
7,645#
10" MIN. EDGE

QMF - 036 Vault Base Rebar Rev. 3 10-29-18 (14.0)
136
6'x 8' VAULT BASE REBAR

JOB: FINISH: N/A JOB#:
PIECE NUMBER: LIFTING DEVICE: (6) 8T S.L./(4) 6/6 U.L.
VAULT SIZE: 72"x96x78" STEEL: SEE ATIACHED
WALL THICKNESS: 6" CHAIR SIZE: 1 1 /2"
POST POUR: POUR DATE:
PRE POUR: & LIFTERS:
DRAWN BY: 108"
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CH'D BY: 96"
1
21"
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7 #4 BAR 8'-8'
14 #4 BAR 6'-8'
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12 #4 BAR 10'-2' (BENT>
12 #4 BAR 8'-8'
48 #4 BAR 5'-2' (BENT>
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lYPE: *METHOD(S) OF RIGID REINFORCEMENT
SUPPORT/CONNECTION: DIMENSIONAL TOLERANCES
LENGTH, WIDTH, HEIGHT, WALL THICKNESS:_±1/2"
COVER:
CHECKED: __ REBAR SPACING: ±1"
CONCRETE COVER OVER REINFORCING: -0", +1/2"
OFFICE CHECK: WEIGHT: 13,620 # HOLE SIZE: ±1/2"
MIX QUALIFICATION FORM
Formula Number: ______________ Plant: ____________________________________
Formula Name: ____________________________________________________________
Design Compressive Strength: _________________ PSI @ 28 days
Water-to-Cementitious Ratio: __________ Design Air Content: __________ %
Design Unit Weight, Batched: ___________ PCF Coarse Aggregate Ratio: __________
Cement (type ___ ): ________________ LBS. Supplier:________________________________
Fly Ash: ___________ LBS. (Fly Ash % = ____) Supplier: _____________________________
Water: ____________ LBS. ______ GAL.
Coarse Aggregate: _____________ LBS. (SSD) (Type: ______________________________ )
Sand: _______________ LBS. (SSD) (Type: _____________________________________ )
Air Entrainment Admixture: ___________ OZ. (Name: _______________________________ )
Water Reducing Admixture: __________ OZ (Name: ________________________________ )
Set Accelerating Admixture: __________ OZ (Name: ________________________________ )
**Attach the sieve analysis and mill reports for the raw materials used.
Plastic Test Documentation:

Time: ___________ Ambient / Air Temperature: _____°F Dew Point: _____°F
Slump: _______ inches
Unit Weight: _______ PCF Air Content: ______% Concrete Temperature: ______°F
Compressive Test Documentation:
@ 1 Days: Cylinder 1: _________ PSI Cylinder 2: _________ PSI Average: _________ PSI
@28 Days: Cylinder 1: _________ PSI Cylinder 2: _________ PSI Average: _________ PSI
Acceptance Criteria:
Slump: Minimum: _______ inches – Maximum: _______ inches
Unit Weight: ______±2 pounds per cubic foot
Air Content: ______±1.5%
Minimum Stripping Strength: ___________ PSI
Minimum Shipping Strength: ___________ PSI
Minimum 28 Day Required Strength: ____________________ ƒ΄cr
Mix Design Approval:

_____________________________________________________________________________
Engineering Date
_____________________________________________________________________________
Production Date
_____________________________________________________________________________
Quality Date
QMF-028 Rev. 0 10-29-18 (15.0)
137
SCC MIX QUALIFICATION FORM
Formula Number: ______________ Plant: ____________________________________
Formula Name: ____________________________________________________________
Design Compressive Strength: _________________ PSI @ 28 days
Water-to-Cementitious Ratio: __________ Design Air Content: __________ %
Design Unit Weight, Batched: ___________ PCF Coarse Aggregate Ratio: __________
Cement (type ___ ): ________________ LBS. Supplier:________________________________
Fly Ash: ___________ LBS. (Fly Ash % = ____) Supplier: _____________________________
Water: ____________ LBS. ______ GAL.
Coarse Aggregate: _____________ LBS. (SSD) (Type: ______________________________ )
Sand: _______________ LBS. (SSD) (Type: _____________________________________ )
Air Entrainment Admixture: ___________ OZ. (Name: _______________________________ )
Water Reducing Admixture: __________ OZ (Name: ________________________________ )
Set Accelerating Admixture: __________ OZ (Name: ________________________________ )
**Attach the sieve analysis and mill reports for the raw materials used.
Plastic Test Documentation:

Time: ___________ Ambient / Air Temperature: _____°F Dew Point: _____°F
Slump Flow: _______ inches T50: ____ seconds Visual Stability Index (VSI): _____
Unit Weight: _______ PCF Air Content: ______% Concrete Temperature: ______°F
Compressive Test Documentation:
@28 Days: Cylinder 1: _________ PSI Cylinder 2: _________ PSI Average: _________ PSI
Acceptance Criteria:
Slump Flow: Minimum: _______ inches – Maximum: _______ inches
Visual Stability Index (VSI): ≤1
Unit Weight: ______±2 pounds per cubic foot
Air Content: ______±1.5%
Minimum Stripping Strength: ___________ PSI
Minimum Shipping Strength: ___________ PSI
Minimum 28 Day Required Strength: ____________________ ƒ΄cr
Mix Design Approval:

_____________________________________________________________________________
Engineering Date
_____________________________________________________________________________
Production Date
_____________________________________________________________________________
Quality Date
QMF-030 Rev. 0 10-29-18 (15.0)
138
Manufacturers Name & Logo
Date of Document: _________
CERTIFICATE of COMPLIANCE
Product Name or Description: ________________________________
This is to certify that the above lifting and handling product has been
manufactured and tested in accordance with the quality control plan
established by _______________________ and meets or exceeds
OSHA 29 CFR 1926.704 when compared to the listed catalog rating for
the lifting device.
This document certifies each manufactured product can be related to

a quality control plan. The manufacturing quality control tests can be
made available upon written request and when appropriate.
The rated capacities are for mechanical capacity of the listed anchor
or insert only. Placement, edge distances, embedment depth,
concrete strength, attachment device, sling angles, and rigging
consideration are not part of this certificate of compliance.
___________________________Title: _______________Date:______
Name, Signature, Title and Date of Company Authorized Agent
QMF-029 Rev. 0 10-29-18 (15.0)

Lifting Insert Certificate of Compliance 139
Tank Watertighness Testing Data Sheet
Date Tested: _________________________________
Location of Test: ___________________________________________________________________
Type of Product Tested: ______________________________________________________________
Test Specifications: ___________________________________________________________________
Septic Tank ASTM C1227

Vacuum Testing per Subsection 9.2.1
Start Reading: ________ End Reading: ________ Hold Time: _________
Pass: _____________ Fail: ____________
Water Pressure Testing per Subsection 9.2.2
Start Time: __________ End Time: __________ Refill: Yes / No Hold Time: _______
Pass: _____________ Fail: ____________
Grease Interceptor ASTM C1613

Vacuum Testing per Subsection 9.1.1
Start Reading: ________ End Reading: ________ Hold Time: _________
Pass: _____________ Fail: ____________
Hydrostatic Testing per Subsection 9.2.2
Start Time: __________ End Time: __________ Refill: Yes / No Hold Time: _______
Pass: _____________ Fail: ____________
Comments: __________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
Test Performed by: __________________________________________________________________
Test Witnessed by: ___________________________________________________________________
QMF-037 Rev. 1 10-24-18(15.0)

140
PLANT TERMS AND CONDITIONS
NPCA PLANT CERTIFICATION and OPTIONAL PRODUCT LISTING FOR WATER and
WASTEWATER TANKS
PART 1
PURPOSE, SCOPE, SUBMITTALS AND AUDITS

1.1 Purpose
1.1.1 To assure a uniformly high degree of excellence in plant facilities,
production, procedures, and quality control operations.
1.1.2 To assist management in achieving excellence in plants and operations.
1.1.3 To provide recognition for plants which achieve a high degree of

excellence.
1.1.4 To assist users and specifiers of precast identify and select high quality
precast concrete manufacturers.
1.2 Scope
1.2.1 The Plant Certification Programs outlined herein are directed at certifying
that plant processes are in place to produce precast concrete products
with a high degree of excellence.
1.2.2 The NPCA Certification programs certify the precast plants processes.
1.2.3 The NPCA Product Listing program certifies that water and wastewater
tanks meet the requirements of applicable industry standards.
1.2.4 Plants making application for product listing must be an NPCA plant is
good standing and hold a current NPCA Plant Certification.
1.3 Submittal
1.3.1 The submittal consists of a complete document package that includes

detailed and stamped structural engineering design calculations for the
precast concrete water or wastewater tank and a complete set of details
illustrating compliance with all sections of the applicable industry standard
(ASTM C913, IAPMO/ANSI Z1002, or ASTM C1227, IAPMO/ANSI Z1000
or ASTM C1613, IAPMO/ANSI Z1001).
1.4 Plant Inspections
1.4.1 A plant qualifies as an NPCA Certified Plant if it meets or exceeds the required
level of excellence during the initial announced inspection and
subsequent annual unannounced inspections. Plants shall remain
certified if all necessary fees are paid and the plant attains the minimum
score on each annual audit.
QMF-019, Plant Terms & Conditions Rev. 9 09-12-22 (16.0)

141
PART 2
ADMINISTRATION OF NPCA PLANT CERTIFICATION and OPTIONAL PRODUCT

LISTING FOR WATER and WASTEWATER TANKS
2.1 Administrators
The administrators of the programs will be members of the NPCA staff. The duties
of the administrators include but are not limited to:
2.1.1 Members of the NPCA Technical Staff, Certification & Technical Services
Administrator, Technical Services Engineer, Director of Quality Assurance
Programs are responsible for implement the policies and directives issued
by the NPCA Quality Assurance Committee, which oversees the NPCA
Plant Certification.
2.1.2 Members of the NPCA Technical Staff, Technical Services Engineers &
Director of Quality Assurance Programs are responsible for the review and
approval of plant submittal packages to the program.
2.1.3 Maintain the files generated by the programs.
2.1.4 Maintain and distribute current lists of NPCA Certified Plants
2.1.5 Coordinate scheduling of audits with plants and audit agency.
2.1.6 Serve as treasurer for the programs by initiating invoices to plants,

approving bills for expenses attributable to the programs, maintaining a
system for collection of receivables, and reporting periodically on the
financial status of the programs to the NPCA Quality Assurance
Committee.
2.1.7 Issue certificates or plaques to each plant that qualifies as an NPCA

Certified Plant.
2.1.8 Issue certificates to each plant for products (s) that meet the requirements
of the NPCA Product Listing.
2.2 NPCA Quality Assurance Committee
Duties of NPCA Quality Assurance Committee include but are not limited to:
2.2.1 Establish policies relating to the requirements of the programs.
2.2.2 Give direction to the administrators of the programs.
2.2.3 Give direction in the selection of plant inspection agency or agencies.

142
2.2.4 Oversee the programs content, including direction on plant inspections and
administration of the programs.
2.2.5 Promote the programs to the NPCA members.
2.2.6 Publicize the programs to buyers of precast concrete products.
2.2.7 Oversee revisions of the NPCA Quality Control Manual for Precast
Concrete Plants and other related publications.
2.2.8 Oversee revisions of the programs, including the grading schedule.
2.2.9 Serve as an Appeals Board (see Part 6).
2.3 Inspection Agency
The NPCA Quality Assurance Committee will select an inspection agency or

agencies that have personnel who are trained, qualified and knowledgeable about
the operations of precast concrete manufacturing plants and production of quality
precast concrete products. They also must have experience in quality control
operations and be able to audit plants with minimal advance notice.
Auditors shall have an engineering degree (preferably civil or structural

engineering), unless otherwise approved by NPCA, and shall have attended NPCA
auditor training and shall have been appropriately trained by NPCA and the agency
and shall have gained experience necessary through shadowing other auditors in
field activities to critically assess the manufacturing process and production of
precast concrete. The auditor shall display knowledge, experience, integrity, ability
and good professional judgment. The auditor shall be thoroughly familiar with the
NPCA QC Manual and all other pertinent technical publications of NPCA, ACI,
ASTM International, and other industry standards. The auditor shall have sufficient
skill in dealing with other persons to earn their respect, and to deal with them
courteously while maintaining the requisite professional distance. The third party
agency shall promptly accede to any request by NPCA that an auditor be replaced
in view of a lack of any of these qualities. All audits shall be performed under the
supervision and reviewed by a Professional Engineer. NPCA Auditors will provide
their official credentials upon meeting with the plant liaison on the day of the plant
audit. All third party agency auditors shall abide by the NPCA confidentiality and
conflict of interest agreement and shall conduct themselves in a professional and
impartial manner.
Before performing any NPCA plant audits, the agency and its personnel must
become familiar with both the NPCA Quality Control Manual for Precast Concrete
Plants and the programs. The agency must also develop a quality assurance

143
program, which will ensure that all audits are made in a uniform manner and that a
uniform grading system is used.
The agency will perform the audits as detailed in the applicable agency specific
contract documents and Part 3 and Part 7.
The NPCA Quality Assurance Committee may select more than one audit agency,
in which case all of the above items are applicable to each agency, including
uniformity of inspections and grading, confidentiality, conflict of interest and
impartiality.
Third party agency auditors shall not be eligible to perform plant audits during the
program year without attending NPCA auditor training and / or as authorized by
NPCA.
Third party agencies shall hold a current accreditation to ISO/IEC 17020.
2.4 Recording Keeping
The Administrators will maintain all pertinent records of the programs. These
records include but are not limited to:
2.4.1 Pertinent correspondence
2.4.2 Meeting minutes of the NPCA Quality Assurance Committee
2.4.3 Program Contracts
2.4.4 Plant certificates
2.4.5 Completed audit reports, and grading schedules, and plant corrective
action responses.
2.4.6 Standardized grading schedules
2.4.7 Correspondence dealing with appeals
2.4.8 Current list of certified plants and products.

144
2.5 Continuous Improvement
Satisfaction of continuous improvement requirements will be based solely on the plant

providing objective evidence to the auditor that activities are in place and/or have taken
place at the plant. A total of eight additional points are available for the plants successful
continuous improvement efforts. These eight possible points will be added to the plant
final score. NPCA plant auditors will be required to visit the NPCA Producer Portal and
view plant documentation online prior to their inspection of the plant. This initial
evaluation of plant records shall include those activities pointed at continuous
improvement activities engaged by the plant.
In order for plants to be considered for continuous improvement points they must
participate in two of the following each program year. The plant will earn up to a total of
two points maximum for successful participation to be added to the plant final score.
(1) The plant shall upload documents to the Certified Producer Portal and earn 1%
to be added to the plant final score for completing the following items;
a. The plant shall update their plant profile sheet annually;
b. The plant shall download their renewal certificate annually;
c. The plant shall download their final inspection report and certificate
annually (hard copies can be made available upon request);
d. At a minimum, the plant shall upload annual certification records for raw
materials, annual calibration of equipment, current ACI certifications and
current PQS certifications for quality personnel;
e. Plants producing stormwater and/or sanitary concrete pipe shall upload
current annual absorption test data;
f. Plants producing round manhole products shall upload current annual
absorption test data;
g. Plants producing septic tanks shall upload current annual watertightness
test data for all models produced;
h. Plants producing grease interceptors shall upload current annual
watertightness test data for all models produced.
(2) The plant shall perform and generate final reports for semi-annual self-audits
using the Self-Audit tool within the Producer Portal. The plant shall earn 1% to be
added to the plant final score for completion of semi-annual self-audits;
(3) The plant shall complete education requirements and uploads equivalent to 1
hour of education for each plant employee annually. The plant shall earn 1% to
be added to the plant final score for completion of the following;
a. Plant Quality Personnel – certificate upload for NPCA PQS training
beyond current minimum specified in section 1.1.3 of the NPCA QC
Manual, PQS Level II QA/QC-Technical, PQS Level II-Production
(including a current Master Precaster certification in year one followed by
4 hours of continuing industry-related education in year two). Industry
related education uploaded information shall include learning objectives,
course description and certificate of completion.
b. Non-Quality Plant Personnel – Any NPCA course offering applies.

Industry-related education uploaded information shall include learning
objectives, course description and certificate of completion.

145
The plant is eligible to earn up to an additional 6 points to be added to the plant final score for
continuous improvement efforts in the four categories of Section 1.1.4 of this manual.
Satisfactory activity in these four categories shall be evaluated by active participation and
objective evidence provided by the plant to the designated third-party auditor during the plants
annual unannounced plant inspection. Participation in all areas is not mandatory and plants are
allowed to have multiple continuous improvement efforts in each category. Plants cannot use
continuous improvement efforts more than a single time, new items must be defined each
program year.
Plants earning probationary status or failing its annual inspection are not eligible for
continuous improvement added values.

146
PART 3
Plant Audits
3.1 Scheduling
The Administrators will help coordinate initial audit between the plant and the
agency, so that the audit is made at a mutually convenient time. Subsequent
unannounced audits shall be released by NPCA to the agency each year and
scheduled by the agency and be performed at least once per calendar year, or as
directed by NPCA. Annual program fees shall be due on or before January 1st of
each calendar year.
3.1.1 Plants must receive their annual audit within 16 calendar months of their
previous audit or may be subject to decertification.
3.2 Plant Liaison Representative
Plant management will assign one person to serve as a liaison representative during
the audit. The plant liaison representative will be available to assist in the audit by
making quality control records, calibration records, drawings, etc., available for
review by the auditor. The Plant Liaison will also be available to accompany the
auditor throughout most of the operations in order to utilize the auditor’s time most
efficiently.
3.3 Duties of the Auditor and Agency Personnel
3.3.1 The auditor will arrive at the plant prepared to begin the inspection.
3.3.2 The auditor will not depend upon the plant for transportation to or from the
plant nor for meals or lodging during the audit.
3.3.3 The auditor will abide by all safety regulations of the plant.
3.3.4 The auditor will neither impede nor delay any of the plant’s operations.
3.3.5 The auditor may videotape parts of the audit or take photographs, but only
if permitted to do so by plant management.
3.3.6 The auditor will observe and grade those items for which points are
assigned on the grading schedule. Using the plants internet connection or
a connection in the vicinity of the facility, the auditor will generate a
preliminary report using the NPCAAuditor proprietary software program.
Items that are not applicable will be so marked.
3.3.7 The auditor shall conduct a close-out interview. Plants shall receive a copy
of their preliminary report and grading schedule and all observed
deficiencies during the close-out interview. See section 7.2.7 for
responsibilities of the plant.

147
3.3.8 At the conclusion of the close-out interview, the auditor and a plant
representative present will sign and date the close-out interview
documents, such as, but not limited to, the preliminary report and grading
schedule and / or the close-out interview form provided by the auditor and
these documents will become part of the permanent record of the
inspection.
3.3.9 If for some reason the plant does not agree with the audit scoring or there
are specific circumstances that cannot be agreed upon at the conclusion
of the close-out interview; the plant representative should not sign the
close-out form. This action will start the appeals process (see Section 6).
3.4.0 Auditors shall maintain the highest level of integrity and professionalism.
Inspection agency employees and inspection personnel shall abide by
the NPCA confidentiality and conflict of interest policies currently in force.
Agency personnel shall exhibit impartiality during inspections
proceedings and when representing the NPCA Plant Certification
programs. Activities of inspection shall not be marketed in such a manner
as to compromise the impartiality of the NPCA certification program.

148
PART 4
GRADING SCHEDULES
4.1 The grading schedules are shown in the section titled “Grading Schedule” in the
NPCA Quality Control Manual for Precast Concrete Plants. It can be seen that the
items listed specifically refer to sections of the NPCA Quality Control Manual for
Precast Concrete Plants.
4.2 Sections to be graded have been assigned “points” (A) shown in the first column on
the right. The auditor grades each section based on the percentage of compliance
with the Quality Control Manual shown in the second column (B). Certain items may
not be applicable (NA) to all plants during an inspection. Those items are not
graded. For each graded item the number of points (A) is multiplied by the grade
percentage (B). The sum of those values is obtained for each chapter. Because
some items are not applicable, an adjustment is made.
4.3 The grade adjustment consists of multiplying the sum of A x (B/100) for each chapter
by 100 and dividing by the total possible points that are applicable and/or
observable. The final plant score represents the percentage of total points earned
by the plant versus the total applicable and/or observable points.
4.4 Completed grade sheets schedules are made available to plant representatives via
the Producer Portal under myNPCA sent to the plant representative, and a copy is
kept on file by the Administrator. No other copies are distributed unless the
applicable plant provides consent or instruction to do so in writing to the program
Administrators.
4.5 Critical sections of the manual are graded with the actual scoring percentage earned
by the plant for each specific element and totaled. Plants scoring less than 75% in
any critical section will be awarded zero ‘0’ points for that element. New plants
scoring less than 75% in any critical section during their initial announced plant
inspection will not be considered for certification. Existing plants scoring less than
75% in any critical section or an overall plant score of less than 80% but greater than
or equal to 75% during their annual unannounced plant inspection will be subject to
probationary status (See part 5.2.1 Probationary Status).

149
PART 5
GRADING, CERTIFICATION STATUS, and CORRECTIVE ACTIONS
5.1 Certified Status
5.1.1 A plant qualifies as a certified plant if it achieves a plant score of 75% or

greater in each applicable Critical Requirement section of the pertinent
grading schedule and achieves an overall score of 80% or greater.
5.1.2 A plant fails its audit if it achieves an overall score less than 75%.
5.1.3 A new plant that fails its audit and wishes to be considered for Certified
Status, must reapply to the program.
5.1.4 A certified plant that fails its audit and does not appeal its audit and wishes
to be considered for Certified Status, must reapply to the program.
5.1.5 A certified plant that fails its audit and wishes to appeal its audit, see
section 5.3 below.
5.1.6 A plant qualifies for NPCA product listing if it provides a complete and
NPCA approved document submittal and passes it’s initial or annual
unannounced audit.
5.1.7 A plant is not eligible for product listing if it earns probationary status or fails
its annual unannounced audit.
5.1.8 Plants with a product listing earning probationary status or failing its annual
unannounced audit will loose listing status and must reapply to the product
listing program.
5.2 Probationary Certification Status
5.2.1 A plant that does not comply with the conditions set forth in section 5.4.1;
Corrective Action response, achieves a score of less than 75% for any
critical requirement or achieves an overall plant score greater than or equal
to 75% and less than 80% is eligible to will receive probationary
certification status.
5.2.2 Probationary Certification status shall remain in effect until such time when
the plant pays applicable fees, responds in writing to all deficiencies with
corrective action, and passes its unannounced re-audit within a period not
to exceed 90 calendar days from the previous audit and the conditions
calling for probationary status no longer exist, as determined by the audit
agency and/or NPCA or its agent. Plants failing to pay applicable fees
within 30 days of the invoice date and receive an unannounced re-audit of

150
the plant within 90 days from the previous audit will not be considered for
certification.
5.2.3 In no way will the plant listing on the NPCA Web site or anywhere else
indicate that a plant has received probationary certification status.
5.2.4 The plant must pass their unannounced re-audit and receive an overall
score of 80% or greater and must score at least 75% on all Critical
Requirements in order to be removed from probationary status.
5.2.5 Plants that fail to pass their unannounced re-audit will be required to
reapply to the program.
5.3 Provisional Certification Status
5.3.1 Provisional Certification Status is effective when a plant that is currently

certified in the program, fails an its annual unannounced audit, and files an
appeals. This period is intended to allow sufficient time to process the
appeal, while maintaining Provisional Certification Status.
5.3.1.1 A certified plant that fails its annual unannounced audit and files a
complete appeal of the results of their audit has 10 days from the
date of the plant audit to file the formal appeal documentation with
NPCA.
5.3.1.2 A complete appeal shall be received by NPCA, from the plant, in

writing and in the form of a letter or an email along with all
supporting documentation sent to the program Administrator.
Supporting documentation shall include items such as, but not
limited to, a copy of the preliminary and/or final report grading
schedule, photographs, completed inspection form, test results,
and copies of material to illustrate compliance to requirements
along with corrective action responses to all deficiencies noted in
the inspection report. The plant representative shall also supply
reasons they believe a scoring appeal is warranted.
5.3.1.3 A plant issuing incomplete appeal documentation will not be

considered for Provisional Certification Status and will need to
reapply to the Certification Program.
5.3.1.4 Hearings for appeals will usually be scheduled to coincide with the
regularly scheduled monthly meetings of the NPCA Quality
Assurance Review Subcommittee, but hearings may be held at
other times which are mutually convenient for the Review
Subcommittee, management of the plant which filed the appeal,
and the inspection agency and may consist of a conference call.

151
5.3.1.5 Hearings for appeals will/shall be closed meetings with only the
Quality Assurance Review Subcommittee, the Administrators,
management of the appealing plant, and if required the agency
representative. The management of the plant which filed the
appeal will/shall first present its case orally and the committee may
ask questions of the speaker. The agency representative will then
orally present its case followed by answering questions raised by
the committee. Management of the appealing plant then will/shall
make its closing statement and that will/shall be followed by the
closing statement of the agency representative. Representatives
of the appealing plant and the agency will/shall then be excused so
that the Subcommittee can deliberate in executive session.
5.3.1.6 If a member of the Quality Assurance Review Subcommittee is a

representative of the appealing plant, or it is determined that they
have a conflict of interest, that Subcommittee member shall excuse
themselves from the deliberations in executive session.
5.3.1.7 Decisions of the Quality Assurance Review Subcommittee

will/shall be sent to both the plant management and the agency
within ten calendar days of the hearing. The Quality Assurance
Review Subcommittee’s decision(s) will/shall be final, and no
further appeals will/shall be considered.
5.3.1.8 A plant that appeals the results of the audit and the appeal is
approved, the Provisional Certification period ends on the date of
the approved appeal. Thereafter, the plant resumes normal
certification status.
5.3.1.9 For plants that appeal the results of their audit, and the appeal is
denied, the Provisional Certification period ends on the date of the
denied appeal and the plant is no longer certified. To re-enter the
certification program, the plant must reapply, pay applicable fees,
and successfully pass its unannounced audit.
5.3.1.10 Plants that do not appeal the results of a failed audit are not eligible
for Provisional Certification.
5.4 Corrective Actions
5.4.1 All plants passing their audit (regardless of score) must respond in writing
indicating corrective action taken for all deficiencies noted in their report.
All plants failing to submit a written response with documented evidence
within 45 days of the plant audit shall receive and be subject to the
conditions set forth in section 5.2.1; Probationary Certification Status.
Documented evidence shall be supplied (photographs, completed

152
inspection forms, test results, copies of material certifications) to illustrate
compliance to requirements and of the corrective action taken to both
NPCA and the agency.

153
PART 6
APPEAL PROCEDURE
6.1 If plant management disagrees with the grade resulting from a plant audit, the
approval of a product submittal or decision on product listing, management may file
an appeal for review by the NPCA Quality Assurance Review Subcommittee, or their
designees. See section 5.2, Probationary Certification Status or section 5.3,
Provisional Plant Certification Status for information on the appeal process.
6.2 Plants wishing to file a formal appeal of their audit must do so within 45 calendar
days of the plant audit. A complete appeal shall be submitted in the form of a letter
or email addressed and sent to the program Administrator. A copy of the Preliminary
or Final Report grading schedule shall accompany the letter or email. Individual
grades on specific sections with which management disagrees shall be cited and all
supporting documentation (photographs, completed inspection forms, test results,
copies of material and certification to illustrate compliance to requirements along
with corrective action responses to all deficiencies noted in the inspection report)
shall be provided along with reasons why management believes each cited grade
should be changed. If the plant fails to provide a complete written appeal and all
relevant documentation the appeal will be denied.
6.3 If necessary, the Review Subcommittee shall request a response from the inspection
agency. The agency will respond in writing to the Administrator within 21 calendar
days of receipt of notice of appeal by the Administrator.
6.3.1 If the agency agrees with the appeal and agrees that the grade should be
changed as requested in the appeal, the agency will prepare a revised report
and grading schedule.
6.3.2 If the inspection agency disagrees with the appeal and believes that the
grades originally assigned are appropriate and the plant wishes to have the
appeal heard by the Quality Assurance Review Subcommittee (which acts
as the appeals board), the chairman (or designated program administrator )
of the NPCA Quality Assurance/Quality Control Committee will poll the
Review Subcommittee members to determine if they (a) agree with the
appeal and disagree with the agency’s response, or (b) disagree with the
appeal and agree with the agency’s response. The chairman (or
designated program administrator) shall poll the members to determine if a
hearing of the appeal is needed and if so, to establish a date for the
hearing. Subcommittee members who have a conflict of interest with
regard to the plant must excuse themselves from the polling.
6.5 Hearings for appeals will usually be scheduled to coincide with the regularly
scheduled monthly meetings of the NPCA Quality Assurance Review
Subcommittee, but hearings may be held at other times which are mutually

154
convenient for the Review Subcommittee, management of the plant which filed the
appeal, and the inspection agency and may consist of a conference call. Hearings
may also be conducted via email poll at the discretion of the chairman (or designated
program administrator) of the NPCA Quality Assurance/Quality Control Committee.
6.6 Hearings for appeals will be closed meetings with only the Quality Assurance
Review Subcommittee, the Administrators, management of the appealing plant, and
if required the agency representative. The management of the plant which filed the
appeal will first present its case orally and the committee may ask questions of the
speaker. The agency representative will then orally present its case followed by
answering questions raised by the committee. Management of the appealing plant
then will make its closing statement and that will be followed by the closing statement
of the agency representative. Representatives of the appealing plant and the
agency will then be excused so that the Subcommittee can deliberate in executive
session.
6.7 If a member of the Quality Assurance Review Subcommittee is a representative of

the appealing plant, or it is determined that they have a conflict of interest, that
Subcommittee member shall excuse themselves from the deliberations in executive
session.
6.8 Decisions of the Quality Assurance Review Subcommittee will be sent to both the
plant management and the agency within ten calendar days of the hearing. The
Quality Assurance Review Subcommittee’s decision(s) will be final and no further
appeals will be considered.

155
PART 7
7.1 Applicable Plant
The NPCA Plant Certification Program Contracts and Product Listing Application
apply only to the plant described in the Plant Profile Information supplied by the
plant. However, in cases where a plant operates two production facilities at separate
physical locations and they are within a 20-mile driving distance of each other, the
plant may elect to include both of these production operations under one contract
and be inspected during the same audit visit. A single report will be issued by the
agency for both production locations. This means that the success of either plant is
dependent on the other plant – if one fails, they both fail. In addition, in such
instances, it may be necessary for the program fee to be increased, because the
production operations are too large and/or too complex to adequately audit during a
normal-length (one-day) period and an additional audit day shall be required. Such
instances will be judged on a case-by-case basis jointly by the agency and NPCA.
In all other cases, each production operation must use separate NPCA contracts for
each production operation, if so desired. Multiple physical plant location option does
not apply to NPCA Product Listing.
7.2 Audits and Certification
7.2.1 Audits will be conducted by an approved, accredited, and independent

audit agency or agencies appointed by NPCA. NPCA retains sole authority
in the appointment of one or more audit agencies. Certification of the plant
shall be established on the basis of the plant’s satisfactory performance
during these audits, as described in the Program and the QC Manual,
which are incorporated herein by reference.
7.2.2 Scheduling of first time, announced (initial) and subsequent unannounced

annual audit shall be at the sole discretion of the audit agency once
released by NPCA. However, the audit agency shall contact the plant in
an effort to determine a date for the first time, announced audit that is
mutually agreeable.
7.2.3 The plant must agree to schedule the first-time, announced audit within
three-months (90 days) of signing the program Contract; otherwise the
plant agrees to forfeit the entire certification fee.
7.2.4 Plants that apply to the program, pay applicable fees, receive their initial
inspection after September 30 will be granted certification through
December 31st of the following calendar year (15 months). Certification
fees beyond year one are due on or before December 31st of each year.

156
7.2.5 First time (initial) plant audits will be announced to the plant in advance.
Advance notice will typically be approximately two (2) to four (4) weeks.
For the plant’s initial audit, the plant shall have records required by the
program for a minimum of thirty (30) calendar days of production
immediately prior to the audit date.
7.2.6 Subsequent annual audits will be unannounced.
7.2.7 Inspections, grading and certification shall be conducted as described in

the program.
7.2.8 The plant agrees to cooperate fully with the audit agency and its
employees. The plant shall allow the auditor access to the facilities internet
connection and printer for generating the close-out interview documents.
7.2.8.1 The plant agrees to cooperate fully in the situation that the audit
agency is being audited by NPCA while performing a plant audit.
7.2.8.2 The plant agrees to cooperate fully in the situation that the audit
agency auditor is being audited by NPCA who is being audited by the ANSI
auditor when performing a plant audit.
7.2.8.3 The plant agrees to comply fully with the program contract
document.
7.2.9 In Non-English speaking locations, the plant agrees to provide an English-

speaking liaison to the auditor to interpret communications between the
auditor and plant representatives.
7.2.10 Immediately following the audit, the auditor will hold a closeout interview
and be available for discussion and questions about the inspection with
plant representative and/or management.
7.2.11 The audit agency will audit the plant for the sole purpose of assessing the
plant’s compliance with the standards outlined in the most current edition
of the NPCA QC Manual, unless otherwise directed by NPCA. NPCA
reserves the right, at its sole discretion, to periodically update and modify
the QC Manual.
7.2.12 No audit or observation will be made of safety, environmental or other

conditions, and NPCA and the audit agency disclaims responsibility to the
plant and any third party for such conditions.
7.2.13 The programs do not certify products, or the company as a whole. The
programs instead confirm the capability of the audited plant, in which
products are produced to meet the minimum requirements of the Program.

157
This confirmation includes, but is not limited to; the plant’s manufacturing
processes, production procedures and quality control operations.
7.2.14 Active production operations must be observed by a representative of the

audit agency during all inspections. When awaiting an unannounced audit,
the plant shall provide accurate production schedule information to NPCA.
This information is then used by the inspection agency to schedule
unannounced inspections appropriately.
7.2.14.1 The plant shall notify NPCA in writing of dates when

production will not take place as far in advance as possible,
but not later than 14 calendar days prior to any date in which
production operations will not take place during normal
production days. For the purposes of the program Contract,
normal production days are defined as Monday through
Friday.
7.2.14.2 Plants will be charged for the audit agency’s time and
expenses if they fail to notify NPCA in writing of a date in
which production operations did not occur AND the audit
agency attempts to perform an unannounced audit at the
plant on that date, but is unable to do so because of a lack of
observable production operations. This fee is payable and
subject to the provisions set forth in the applicable Program
Fee Schedule.
7.2.14.3 Instances of unforeseen production stoppage caused by

conditions beyond the plant’s control (such as inclement
weather, unexpected equipment breakdown, third-party raw
material delivery delays, etc.) shall NOT be cause for this
extra charge. However, the plant shall practice due diligence
and notify NPCA in writing when such unforeseen production
stoppages occur. If it is deemed that the plant did not put
forth a good faith effort to notify NPCA, the plant will be
charged for the audit agency’s time and expenses associated
with the attempted audit.
7.2.14.4 Plants refusing an unannounced audit for reasons other than

those stated in Subsection 7.2.14.3 above constitute grounds
for the plant to be decertified.
7.2.14.5 The NPCA Quality Assurance Review Subcommittee will

resolve any disputes that may arise regarding interpretation

158
of this section of the contract. The decision of the NPCA
Quality Assurance Review Subcommittee will be final.
7.2.15 In the process of promoting the NPCA Plant Certification and/or Product
Listing Programs to various specifying agencies, from time to time,
representatives from these agencies may request to observe an actual
inspection. The plant agrees to cooperate fully in good faith with this
process and, in case of such a request from a specifying agency
representative, the plant agrees to allow the representative to observe an
audit at their facility, whether or not the audit is announced or
unannounced.
7.2.16 The plant must notify NPCA, in writing, of any materially changed condition,
as defined in the following, within 30 calendar days of the change. Failure
to do so may result in decertification.
7.2.16.1 Change in plant ownership.
7.2.16.2 Change in the type or capability of operations, equipment

or facilities, or the physical location of the facility in relation
to the requirements of the program. If the reported change
is judged jointly by the NPCA Quality Assurance Committee,
NPCA and the Audit Agency to substantially affect or
influence the plant’s capabilities of adhering to the
requirements of the program, the plant shall receive an
additional, unannounced audit. The cost of such an audit
shall be borne by the plant in the amount of the standard
program fee.

159
PART 8
8.0 Additional Random Unannounced Audits
8.0.1 The frequency of unannounced additional random unannounced audits

shall be determined by the NPCA QA/QC Committee, and/or NPCA, at its
sole discretion, and shall not occur in less than 90 days from the previous
plant audit.
8.0.2 If NPCA receives written evidence from a credible authority that asserts
that an NPCA certified plant is not in substantial compliance with the
requirements of the applicable program, the NPCA QA/QC Committee,
and/or NPCA at its sole discretion, shall determine if there is sufficient
cause to conduct an unannounced re-audit at the plant. The cost of such
an audit shall be borne by the plant and subpart 8.0.1 above shall be
satisfied unless otherwise negotiated between the credible authority and
NPCA.
8.0.3 Should a plant fail an audit, the plant must follow the procedures set forth
in Section 5.3.
8.1 Confidentiality
8.1.1 Except as required by legal order or otherwise required by law, neither

NPCA nor the audit agency nor any of their employees shall reveal any
specific data or grading with respect to the plant audited, other than to the
plant’s authorized representative, except with the plant’s written consent.
8.1.2 Specifying agencies may, on occasion, request copies of certification

reports and/or grading information for review. NPCA will not provide this
information, unless specifically directed to do so in writing from the plant.
An individual plant may elect, at its own discretion, to provide this
information directly to a specifying agency to satisfy such a request.
8.2 Plant Certification
The NPCA Plant Certification is envisioned to be the foremost management tool for
precast concrete manufacturing. The certification process furnishes a framework for
management decisions in making changes in equipment and procedures to create
a quality manufacturing environment. Upon Certification:
8.2.1 The plant shall receive a Certification Plaque, supplied by NPCA. For
plants that choose to certify two production locations under the provisions

160
of the program Contract, each location shall receive a separate plaque,
noting the location or each.
8.2.2 NPCA will grant the plant the right to use, in conformance with the program
guidelines and contract, the appropriate Certification seal, emblem, logo,
etc. (Symbol) for use on stationery and for advertising purposes for as long
as the plant’s Certification is in effect and provided such use is only in
reference to the plant covered by the program contract, and not the
company as a whole nor any other non-certified branch locations.
Additionally, the plant may only place NPCA Plant Certification Symbol or
any other reference to the program on products produced at the plant
location(s) covered under the NPCA Plant Certification Program Contract.
8.2.3 Certified plants are registered with NPCA and are added to the NPCA
published list of certified precast concrete plants. This listing is included in
the NPCA Annual Membership Directory and on the NPCA Web site. In
cases where two production locations are covered by this contract, both
shall be listed separately.
8.2.4 It is understood that in issuing a certification plaque and Symbol, and

authorizing its use, NPCA does not approve, endorse or guarantee any
inspection, product, system or construction, or in any way make any
expressed or implied warranties in connection with any inspection, product,
system or construction.
8.2.5 The certification plaque and Symbol remain the property of NPCA and must
be surrendered by the plant immediately in the event of expiration,
decertification, termination of this contract, or withdrawal from the program,
and any use of NPCA Plant Certification Program literature, advertising, or
stationery or any other materials referencing the program must immediately
cease.
8.2.6 In the event that NPCA becomes aware of evidence that the
Certification seal, emblem, logo, or other symbol of or reference to
certification is being used by an unauthorized person or organization,
NPCA shall ask its General Counsel to assess whether the evidence is
sufficient to issue a letter instructing the misappropriating person to cease
and desist from the misappropriation. If the evidence is deemed sufficient,
the General Counsel shall issue a letter to the misappropriating person or
organization based upon whether the misappropriating person is an
applicant or member of the Certification Program, or not involved in the
program.
If the evidence is not deemed sufficient for a “cease and desist” letter, the
President may issue a letter to the misappropriating person expressing
NPCA’s concern and asking for an assurance that symbols and
references to certification are not being misused.

161
If the misappropriating person continues in the misconduct, the President
shall take such action as is deemed necessary to protect the integrity of the
Certification Program, including without limitation further oral and written
contacts with the misappropriating person, suspension of membership in
NPCA, and appropriate remedies through legal action, including litigation
to obtain a cease and desist order and/or monetary damages. Further,
NPCA shall seek the court’s order that the Plant shall reimburse NPCA for
all expenses incurred in obtaining judicial relief.
8.3 Product Listing
8.3.1 Plants participating in the NPCA Product Listing Program are

required to pass a watertighness test on a tank model chosen at
random by the inspector on the day of the plant’s inspection each
program year to maintain listing.
8.3.2 Upon successful completion of their inspection and approval of submittal,

the plant shall receive a Product Listing Certificate, supplied by NPCA.
8.3.3 NPCA will grant the plant the right to use, in conformance with the program
guidelines and contract, the appropriate Product Listing seal, emblem,
logo, or stencil (Symbol) for product marking purposes for as long as the
plant’s Certification is in effect and provided such use is only in reference
to the plant covered by the program contract, and not the company as a
whole nor any other non-certified branch location. Additionally, the plant
may only place the NPCA Product Listing Symbol or any other reference
to the program on listed products produced at the plant location (s) covered
under the NPCA Product Listing Program Application.
8.3.4 Listed products are registered with NPCA and are added to the NPCA
published list of certified precast concrete plants. This listing is included in
the NPCA Annual Membership Directory and on the NPCA website.
8.3.5 It is understood that in issuing a product listing certificate and Symbol, and
authorizing its use, NPCA does not approve, endorse, or guarantee any
inspections, product, system, or construction, or in any way make any
expressed or implied warranties in connection with any inspection, product,
system, or construction.
8.3.6 The product listing certificate and Symbol remain the property of NPCA and
must be surrendered by the plant immediately in the event of expiration,
probationary status, failure, decertification, termination of this contract, or
withdraw from the program and any use of NPCA Product Listing Program
literature, advertising, or stationery or any other materials referencing the
program must immediately cease.
8.3.7 In the event that NPCA becomes aware of evidence that the Product Listing
seal, emblem, logo, stencil or other Symbol or reference to certification is
being used by an unauthorized person or organization, NPCA shall ask its
General Counsel to assess whether the evidence is sufficient to issue a
letter instructing the misappropriating person or organization to cease and

162
desist from the misappropriation. If the evidence is deemed sufficient, the
General Counsel shall issue a letter to the misappropriating person or
organization.
If evidence is deemed not sufficient for a “cease and desist” letter, the
President may issue a letter to the misappropriating person or organization
expressing NPCA’s concern and asking for an assurance that Symbols and
references to certification are not being misused.
If the misappropriating person or organization continues the misconduct,

the President shall take such action as is deemed necessary to protect the
integrity of the Product Listing Program, including without limitation further
oral and written contacts with the misappropriating person or organization,
suspension of membership in NPCA, and appropriate remedies through
legal action, including litigation to obtain a cease and desist order and/or
monetary damages. Further NPCA shall seek the court’s order that the
person or organization shall reimburse NPCA for all expenses incurred in
obtaining judicial relief.
8.4 Renewal and Expiration
8.4.1 The plant’s certification status shall be effective starting on the date of the
initial audit, pending successful performance during the initial audit and
subsequent re-audit, as detailed in the final audit report prepared by the
audit agency. For NPCA Product Listing status shall be effective starting
on the date of the passed plant audit and approval of the submittal package.
8.4.2 Upon renewal of NPCA certification each year, the plant gives NPCA
permission to send electronic copies of plant inspection documents
(reports, corrective actions to all deficiencies, and addendums) to a
Department of Transportation (DOT) if so required by the DOT. NPCA will
notify the plant of any request.
8.4.3 If the plant has not submitted payment of the program fees and any other
paperwork required by the applicable program by January 1st each year,
the plant’s certification shall automatically expire.
8.4.4 If the plant that has been decertified for any reason in the past, the plant
shall agree to the following:
8.4.4.1 If the plant is decertified the plant is responsible for all

applicable fees required to reenter the program as a new
plant to the program. Additionally, plants that have been
decertified will have their anniversary dates reset to the date
of when they reentered the program.

163
8.4.4.2 Payment of all prior financial obligations must be made prior
to renewal of this agreement or any other agreement
regarding NPCA Plant Certification.
8.4.4.3 If a plant is decertified, all product listings are terminated.
8.5 Violation of Contract
The plant agrees to abide by the terms of this contract. The plant understands that
NPCA reserves the right to change the terms and conditions governing certification,
including the NPCA Plant Certification Program Contract, the NPCA Product Listing
Program Contract, the requirements set forth in the QC Manual, and use of Symbols,
from time to time, and the plant shall abide by such changed provisions upon receipt
of notice thereof, or otherwise withdraw from the program by surrendering its plaque
and foregoing use of the certification Symbol. Violation of this contract, or any part
thereof, including, without limitation, any misrepresentation in the NPCA Plant
Certification Program Contract, the NPCA Product Listing Program Contract or
elsewhere by the plant or misuse of the Symbol, constitutes grounds for the plant to
be decertified. In the event that the plant is notified in writing by NPCA of such
decertification, the plant shall immediately surrender its plaque and cease using the
certification Symbol or facsimile thereof in any way. NPCA may obtain, if necessary,
specific enforcement of plant’s obligations described in the applicable program
contract by seeking the injunction of any court having jurisdiction.
8.6 Hazardous Materials
If NPCA or its audit agency encounters, or reasonably suspects that it has

encountered, hazardous materials in a plant under audit, NPCA or its agency shall
cease activity at the plant and promptly notify the plant’s management. The plant
shall initiate action, where appropriate, to identify and investigate the nature and
extent of hazardous materials in the plant and to abate and/or remove the same as
may be required by federal, state or local statute, ordinance, code, rule, or regulation
now existing or hereinafter enacted or amended. The services to be provided by
NPCA and its audit agency do not include identification of hazardous materials, and
NPCA and its audit agency have no duty to identify or attempt to identify the same
within the area of the plant. NPCA and /or the audit agency representative need not
re-enter the plant until they, in their sole discretion, are satisfied that hazardous
materials pose no problem to them.

164
NEW PLANT – Certification Process Logic
Plant No Plant must respond with

Decertified corrective action to all
deficiencies within 45 days
of plant inspection
Plant
Certified
Paid Plant Inspection Yes

Application Agency
Notified Announced
Plant Inspection Pass
No
Plant Must
Re-apply
QMF-022, New Plant Certification Process Logic Diagram Rev. 7 10-29-18 (15.0)
165
EXISTING CERTIFIED PLANT – Process Logic Corrective
Action Yes
Paid Member Yes Yes Response Plant
Yes
& Certification Inspection Agency Unannounced 45 days from Certified
Assignment Inspection Pass
Annual Dues Inspection
No
Plant Provisional No
Plant Must Yes
Re-apply Status Section 5.3
Fail Plant Considered for Plant Must
No Probationary Status Re-apply
No Section 5.2
Plant is Plant Appeal
Decertified Section 6 Plant Yes
Appeal Paid No Plant is
Yes Section 6 Reinspection Decertified
No Written Notification and Fee
Documentation Received from No
Plant within 45 days from
Unannounced Inspection
Plant
Yes Unannounced Yes – see next page
Reinspection
Plant Inspection Within 90 Days
Agency Response
within 21 days
No Plant Must
Plant is
No Pass Decertified Re-apply
Agency Agrees
No Plant Requests QA
Review Hearing Yes
Yes
Yes Plant
Plant Certified
QA Review Hearing Certified
Corrective Action
Response
No Corrective Action 45 days from
Report Revised Response to all Unannounced
QA Final Decision by Agency Deficiencies Reinspection
In Favor of Plant
Yes
QMF-023, Existing Certified Plant Process Logic Diagram Rev. 5; Page 1 of 2 10-29-18 (15.0)
166
EXISTING CERTIFIED PLANT – Process Logic
Plant Yes Written Notification and Documentation

Appeal Received from Plant within 45 days
Section 6 from Inspection
Report Revised
Yes by Agency
Plant Must
Re-apply
Plant Inspection
Agency Response Yes
within 21 days
Plant is
Decertified Yes Plant
Certified
Corrective
Action Agency Agrees Yes
Response Yes
45 days
from audit No
Plant Refund
of
Plant Requests QA
Reinspection
Yes Review Hearing Fee
No
Plant Yes
Certified Yes
QA Review
Hearing
Corrective
Yes Yes Action
Yes Response
Plant Unannounced No QA Final Decision 45 days
No
Reinspection within In Favor of Plant from audit
Pass 90 Days of Previous
Inspection
QMF-023, Existing Certified Plant Process Logic Diagram Rev. 5; Page 2 of 2 10-29-18 (15.0)
167
PORTAL.PRECAST.ORG
Grading Schedule
Base Score: 90.7/92 Final Score:

Continuous Improvements: 0/8
Deductions From Repeat Deficiencies: -0.25 90.45%
Chapter 1: General (Chapter 1) Summary Score
Plant Quality Control Procedures and Management Policies

1.1.1 Plant Management & Personnel
1.1.2 Plant Specific Quality Control Manual
1.1.5 Plant Requirements
0 0 2 3/3
Deficiencies Improvements Comments
1.1.1, 1.1.2, & 1.1.5 Auditor improvements
1.1.2 Plant-Specific Quality Control Manual
QC Personnel Training
1.1.3 QC Personnel Training 0 0 1 6/6
1.1.3 QC Personnel Training Deficiencies Improvements Comments
1.1.3 QC Personnel Training
Plant Safety
1.2.1 Plant Safety Program
1.2.2 Plant Requirements 0 0 1 1/1
1.2.1 Safety Program Deficiencies Improvements Comments
1.2.1 Safety Program
Drawings and Mock-Ups

1.3 Drawings & Mock-Ups –/–
1.3 Drawings & Mock-Ups
1.3.1 Drawings
CHAPTER 1 SCORE 10
10 possible
Chapter 2: Materials (Chapter 2) Summary Score
Concrete
2.0 Buy America Provisions
2.1.2 Blended Cement
2.1.3 Aggregates
2.1.4 Lightweight Aggregates
2.1.5 Mixing Water
2.1.7 Supplementary Cementitious Materials
0 0 3 3/3
2.1 Concrete
2.1.2 Blended Cement
2.1.3 Aggregates
2.1.4 Lightweight Aggregate
2.1.5 Mixing Water
2.1.7 Supplementary Cementitious Materials
PBC Precast
March 07, 2022 QMF-021 15th Edition
Rev. 6 Page 168
PORTAL.PRECAST.ORG
Chapter 2: Materials (Chapter 2) Summary Score
Reinforcement
2.2.2 Reinforcing Wire
2.2.3 Bar Mats and Welded-Wire Reinforcement
2.2 Reinforcement Deficiencies Improvements Comments
2.2.2 Reinforcing Wire
2.2.3 Bar Mats and Welded-Wire Reinforcement
Miscellaneous Materials
2.3.2 Embedded Steel Shapes and Plates
2.3.3 Headed Studs and Deformed Anchors
0 0 2 2/2
CHAPTER 2 SCORE 8
8 possible
Chapter 3: Concrete (Chapter 3) Summary Score
Concrete Mixes
3.1.1.1 Normal, Heavyweight, and Mass Concrete
3.1.1.3 Dry-Cast / Zero Slump Concrete
3.1.1.4 Ultra High Performance Concrete (UHCP)
3.1.1.5 Mix Compatibility When Using Face Mix
3.1.2 Water-Cementitious Materials Ratio
3.1.3 Air Content (Plastic)
0 0 4 5/5
3.1.5 Admixtures
3.1 Concrete Mixes
3.1.2 Water-Cementitious Ratio
3.1.3 Air Content
3.1.5 Admixtures
PBC Precast
03-07-22 15th Edition
PORTAL.PRECAST.ORG
Chapter 3: Concrete (Chapter 3) Summary Score
Batching and Mixing

3.2.2 Storage of Cement and Supplementary Cementitious Materials
3.2.6 Mixers
3.2.7 Mixing
3.2 Batching and Mixing Deficiencies Improvements Comments
3.2.2 Storage of Cement and Supplementary Cementitious Materials
3.2.6 Mixers
3.2.7 Mixing
CHAPTER 3 SCORE 15
15 possible
Chapter 4: Production Practices (Chapter 4) Summary Score
General
4.1.1 Plant Layout
4.1.2 Housekeeping
4.1.6 Architectural Precast
0 0 4 10/10
4.1 Production Practices - Forming Equipment Maintenance
Architectural Precast Concrete

4.1.6 Architectural Precast Concrete - Surface Finishes –/–
4.1.6 Architectural Precast Concrete
4.1.6.1 Surface Finishes
Fabrication of Reinforcement and Blockouts

4.2.1 Fabrication of Reinforcement
0 0 0 8/8
4.2 Fabrication of Reinforcement and Blockouts
PORTAL.PRECAST.ORG
Fabrication of Reinforcement (CRITCAL SECTION) 1 3.4/4

4.2.1 Fabrication of Reinforcement Deficiencies
Pre-Pour Operations
4.3.1 Cleaning of Forms
4.3.3 Positioning of Reinforcement
4.3.1 Cleaning of Forms Deficiencies Improvements Comments
Positioning of Reinforcement (CRITICAL SECTION) 0 10/10

4.3.3 Positioning of Reinforcement Deficiencies
Casting Concrete
4.4.6 & 4.4.7 Hot & Cold Weather Precautions
4.4.4 Finishing Unformed Surfaces 0 0 4 8/8
4.4.5 Secondary Pours Deficiencies Improvements Comments
4.4.6 Hot Weather Precautions
4.4.7 Cold Weather Precautions
Curing Concrete
4.5.1 General
4.5 Curing Concrete Deficiencies Improvements Comments
4.5.1 General
PORTAL.PRECAST.ORG
Stripping Products from Forms

4.6.2 Products Damaged During Stripping
4.6.4 Post-Pour Inspections
4.6 General Deficiencies Improvements Comments
4.6.2 Product Damaged During Stripping
4.6.4 Post-Pour Inspection
Repairing Concrete
Marking, Storage and Shipment of Products

4.8.2 Storage Areas
4.8.2 Storage Areas
CHAPTER 4 SCORE 65.4

66 possible
PORTAL.PRECAST.ORG
Chapter 5: Quality Control Operations (Chapter 5) Summary Score
Summary of Required Records

5.1.5 Concrete Batching Records
5.1.6 General Plant and Product Inspection Records
5.1 Concrete Mixing - Equipment Deficiencies Improvements Comments
5.1.5 Concrete Batching Reports
5.1.6 General Plant and Product Inspection Reports
Aggregate Testing
Concrete Testing
5.3.1 Slump, Slump Flow, and Visual Stability Index
5.3.2 Temperature
5.3.3 Density (Unit Weight) 0 4 0/0
5.3.4 Air Content Improvements Comments
5.3 General
Concrete Testing (CRITICAL SECTION)

5.3.1 Slump, Slump Flow and Visual Stability Index
5.3.2 Temperature
5.3.3 Density (Unit Weight) 1 7.5/9
Repeat Deficiency Deficiencies
5.3.4 Air Content
CHAPTER 5 SCORE 19.5

21 possible
PORTAL.PRECAST.ORG
Chapter 6: Special Requirements for Specific Products (Chapter 6)

Summary Score
Products Manufactured According to ASTM International and Other

Industry Standards
6.1 General
Stormwater Concrete Pipe

6.2.1.1 Reinforcing Steel Inspection
6.2.1.2 Three-Edge Bearing Testing
6.2.1.3 Absorption Testing
6.2.1.7 Watertightness Vacuum Testing
6.2.1.8 Gasket Quality Control –/–
6.2.1.9 Plant Requirements
6.2.1 General
6.2.1.5 Joint Design Testing
6.2.1.7 Watertighness Vacuum Testing
Reinforcing Steel Inspection (CRITICAL SECTION)

–/–
Three-Edge Bearing Testing (CRITICAL SECTION)

–/–
Absorption Testing (CRITICAL SECTION)

–/–
PORTAL.PRECAST.ORG
Chapter 6: Special Requirements for Specific Products (Chapter 6)

Summary Score
Sanitary Concrete Pipe Requirements

6.2.2.7 Watertightness Requirements
6.2.2.8 Off-Center Joint Proof of Design Testing
6.2.2.9 Joint Shear Proof of Design Testing
6.2.2.11 Gasket Quality Control –/–
6.2.2 General
6.2.2.7 Watertightness Requirements
6.2.2.8 Off-Center Joint Proof of Design
6.2.2.9 Joint Shear Proof of Design

–/–
Three-Edge Bearing Testing (CRITICAL SECTION)

–/–

–/–
Round Manhole Component Requirements

6.3.1 Reinforcing Steel Inspection
6.3.2 Flat Top Slabs
6.3.4 Joint Design
–/–
6.3 General
6.3.2 Flat Slab Tops
6.3.4 Joint Design

–/–
6.3.1 Reinforcing Steel Inspection

–/–
PORTAL.PRECAST.ORG
Chapter 6: Special Requirements for Specific Products (Chapter

Summary Score
6)
Box Culvert Requirements

6.4.2 Joint Design
6.4.3 Pre-Pour Inspections
6.4.4 Dimensional Checks –/–
6.4 General
6.4.2 Joint Design
Pre-Pour Inspections (CRITICAL SECTION)

–/–
6.4.3.1 Pre-Pour Inspections (Form Dimensions)
Pre-Pour Inspections - Reinforcing Steel (CRITICAL SECTION)

–/–
6.4.3.2 Pre-Pour Inspections (Reinforcing Steel)
Dimensional Checks (CRITICAL SECTION)

–/–
6.4.4 Dimensional Checks
Septic Tank Requirements

6.5.1 Structural Proof of Design
6.5.2 Watertightness Testing
0 0 0 3/3
6.5 General
6.5.3 Septic Tank
Watertightness Testing (CRITICAL SECTION) 0 10/10

6.5.2 Watertightness Testing Deficiencies
Grease Interceptor Requirements

6.6.1 Structural Proof of Design
6.6.2 Watertightness Testing 0 0 3/3
6.6.3 Plant Requirements Deficiencies Comments
Watertightness Testing (CRITICAL SECTION) 0

6.6.2 Watertightness Testing
Deficiencies 10/10
CHAPTER 6 SCORE 29
29 possible
NPCA Quality Control Manual for Precast Concrete Plants
Standardized Grading System for Critical Requirements, 14th Edition
General Grading Philosophy
- If the plant is meeting all the requirements at the proper frequencies, the
records are well organized and easily retrieved, and no problems with that
item are noted, they should be given a score of 100 percent for that item.
- Double deductions for major infractions / deficiencies
- The lowest possible score for each section is zero
- The following standard deductions should be subtracted from a grade of 100% for the particular section, assuming that no other deficiencies are noted.
Section Subsection General Comments & Grading Common Deficiencies Deduction(s)

4.2 Fabrication of Reinforcement 4.2.1 Fabrication of Reinforcement
and Blockouts
All reinforcing steel shall be fabricated to a detailed reinforcing
steel plan document in conformance with the precast concrete
product tolerances and / or tolerances provided in the project
Detailed reinforcing steel plan documents are not available for precast products produced 100%
specifications or plans. If no dimensional tolerances have been Some detailed reinforcing steel plan documents do exist but not for all precast products produced {if
established, or reference given, the plant shall specifically state less than 75% of products 100% deduction} Estimate %
on the plan documents or in the plant specific quality control Detailed reinforcing steel plan documents do not specifiy applicable tolerance information 10%
manual, the dimensional tolerance scheme that will govern for Required information is missing from the plan documents; deduct 20% per element missing Estimate %
the product; such as but not limited to the Concrete Reinforcing
Steel Institute (CRSI) publication, “Placing Reinforcing Bars,”
and / or the Reinforcing Steel Institute of Canada / Institut
D'acier du Canada (RSIC / IAAC) publication, "Reinforcing Steel,
Manual of Standard Practice". Reinforcing steel cages shall be
inspected for conformance to approved design requirements and
documented with the pre-pour inspection. The inspection
requirements are detailed in Section 4.3.3 Positioning of
Reinforcement.
4.3 Pre-Pour Operations 4.3.3 Positioning of Reinforcement
Plants shall maintain a documented process of reinforcing steel /
cage inspections including information on the required cage
design vs the actual cage used; including the following:
Bar size and/or WWR bar diameter;
Bar spacing and/or WWR style;
The quantity of bars; Reinforcing steel checks are not performed at all [or one or more of the following] 100%
(Inspections may include one or more of the above per detailed Reinforcing steel checks are performed, but not consistently [deduction based on estimated % of
reinforcing steel plan documents); checks not performed] {if less than 75% of products 100% deduction} Estimate %
The effective depth (d), (the distance from the compressive face
to the centroid of the tensile reinforcement member); Reinforcing steel checks performed incorrectly / measurements not accurate 100%
Required data is missing from documentation, or is not measured {if less than 75% of products 100%
The concrete cover, never less than ½” clear; deduction} Estimate %
Reinforcing steel inspection documentation is missing from the file {if less than 75% of products
The development length; 100% deduction} Estimate %
Cage dimensions: length, width, height, and/or diameter, as
applicable; Welded reinforcing steel does not follow 4.2.2 100%
Reinforcing steel condition: Reinforcing steel is dirty, oily, or has pitted or flaking rust 25%
Clean or light red rust, not flaking or pitted; Reinforcing steel hooks and / or bends are not correct 100%
Free from oils, dirt, or other contaminants; Insufficient quantity of reinforcing steel inspections {if less than 75% of products 100% deduction} Estimate %
If welded, meets the requirements of section 4.2.2;
If welded, does not contain any damage, such as gouges and
undercut;
Reinforcement hooks and bends (90° and 180°). If design,
project specifications, and/or detailed reinforcing steel plans
require a bend in reinforcing steel around a corner, substitution
of straight sections tied together shall not be acceptable
practice.
A detailed inspection is required on one piece or 3% produced

unless the product is machine-cast or dry-cast. (See section
4.1.5 for reinforcement in machine-cast or dry-cast products).
Documentation of the inspection can be on a piece or production
shift basis and must be documented daily.
Rev. 6
QMF-001, Standardized Grading Table 177 10-29-18 (15.0)
- The following standard deductions should be subtracted from a grade of 100% for that particular section, assuming that no other deficiencies are noted.

5.3 Concrete Testing 5.3.1 Slump, Slump Flow, and VSI Fresh concrete tests should be performed at the required
frequencies for each mix design used at the plant.
Upon discovering a test result that is out of tolerance, the plant
must take action to correct the non-conformance. Testing not performed at all [choose this option or one or more of the following] 100%
Testing not performed at proper frequency % of sample
Testing not performed correctly 100%
Measured test results out of tolerance - no corrective action taken { no action taken 25% deductions} 25.0%
Slump or slump flow test documentation is missing from files % of sample
5.3.2 Temperature Upon discovering a test result that is out of tolerance, the plant
must take action to correct the non-conformance. Temperature testing not performed at all [or one or more of the following] 100%
Temperature testing not performed at proper frequency % of sample
Temperature testing not performed correctly 100%
Measured temperature out of tolerance - no corrective action taken {no action taken 25% deductions} 25.0%
Temperature testing documentation missing from file % of sample
5.3.3 Density (Unit Weight) Upon discovering a test result that is out of tolerance, the plant
must take action to correct the non-conformance. Density testing not performed at all [or one or more of the following] 100%
Density testing not performed at proper frequency % of sample
Density testing not performed correctly 100%
Measured test results out of tolerance - no corrective action taken { no action taken 25% deductions} 25.0%
Density testing documentation missing from file % of sample
5.3.4 Air Content Upon discovering a test result that is out of tolerance, the plant
must take action to correct the non-conformance. Air content testing not performed at all on air entrained concrete [or one or more of the following] 100%
Air content testing not performed at proper frequency % of sample
Air content testing not performed correctly 100%
Measured air content out of tolerance - no corrective action taken {no action taken 25% deductions} 25.0%
Air content testing documentation missing from file % of sample
5.3.5 Compressive Strength Compressive strength testing may be stopped upon reaching the
design strength plus 10 percent. Testing to cylinder failure
(crushing) must be performed at least once per month. Compressive strength testing not performed at all [or one or more of the following] 100%
Compressive strenght testing not performed at proper frequency % of sample
Compressive strength specimen not cast or cured correctly 100%
Compressive strength specimen not tested correctly 100%
Measured compressive strength out of tolerance - no corrective action taken { no action taken 25%
deductions} 25.0%
Number of specimen cast insufficient 100%
Compressive strength testing documentation missing from file {if less than 75% of products 100%
deduction} Estimate %
Rev. 6

6.2.1 Stormwater Concrete Pipe This section does not apply to sanitary pipe
Requirements 6.2.1.1 Reinforcing Steel Inspection All reinforcing steel cages should be checked by plant personnel Reinforcing steel checks are not performed at all [or one or more of the following] 100%
for conformance to the design. For the sake of simplicity, 1 Reinforcing steel checks are performed, but not consistently [deduction based on estimated % of
reinforcing steel cages or 3% of each production run should be checks not performed] {if less than 75% of products 100% deduction} Estimate %
checked on a random basis, regardless of whether or not they Reinforcing steel checks performed incorrectly / measurements not accurate 100%
are fabricated with mechanized equipment. Required data is missing from documentation, or is not measured 20% / element
Reinforcing steel inspection documentation is missing from the file {if less than 75% of products 100%
6.2.1.2 Three-Edge Bearing Testing Testing should be performed on each size and class of pipe TEB testing not performed at all [or one or more of the following] 100%
produced at the plant, up to 60 inches in diameter. Unless TEB testing not performed at proper frequency [deduction based on estimate % of TEB testing not
testing to ultimate strength, it is not necessary to load the pipe performed] {if less than 75% of products 100% deduction} Estimate %
beyond the ASTM-specified D-Load to produce a 0.01-in. crack. TEB testing not performed correctly 100%
TEB test documentation incomplete 100%
The plant is unable to test large diameter pipe due to the physical limitations of the test equipment 100%
6.2.1.3 Absorption Testing Absorption testing should be performed on both wet- and dry- Absorption testing is not performed at all [or one or more of the following] 100%
cast mixes, with the lowest amount of cementitious material. Absorption testing is performed, but not at the required frequency {if less than 75% of products 100%
Absorption testing is not performed correctly 100%
Absoption testing documentation is incomplete or missing from the plant files 100%
6.2.2 Sanitary Concrete Pipe
Requirements 6.2.2.1 Reinforcing Steel Inspection All reinforcing steel cages should be checked by plant personnel Reinforcing steel checks are not performed at all [or one or more of the following] 100%
for conformance to the design. For the sake of simplicity, 1 Reinforcing steel checks are performed, but not consistently [deduction based on estimated % of
reinforcing steel cages or 3% of each production run should be checks not performed] {if less than 75% of products 100% deduction} Estimate %
checked on a random basis, regardless of whether or not they Reinforcing steel checks performed incorrectly / measurements not accurate 100%
are fabricated with mechanized equipment. Required data is missing from documentation, or is not measured 20% / element
Reinforcing steel inspection documentation is missing from the file {if less than 75% of products 100%
6.2.2.2 Three-Edge Bearing Testing Testing should be performed on each size and class of pipe TEB testing not performed at all [or one or more of the following] 100%
produced at the plant, up to 60 inches in diameter. Unless TEB testing not performed at proper frequency [deduction based on estimate % of TEB testing not
testing to ultimate strength, it is not necessary to load the pipe performed] {if less than 75% of products 100% deduction} Estimate %
beyond the ASTM-specified D-Load to produce a 0.01-in. crack. TEB testing not performed correctly 100%
TEB test documentation incomplete 100%
The plant is unable to test large diameter pipe due to the physical limitations of the test equipment 100%
Rev. 6

- If the plant is meeting all the requirements at the proper frequencies,
the records are well organized and easily retrieved, and no problems
with that item are noted, they should be given a score of 100 percent for

6.3 Round Manhole Component 6.3.1 Reinforcing Steel Inspection All reinforcing steel cages should be checked by plant personnel
Requirements for conformance to the design. For the sake of simplicity, 1
reinforcing steel cages or 3% of each production run should be
checked on a random basis, regardless of whether or not they
are fabricated with mechanized equipment. Reinforcing steel checks are not performed at all [or one or more of the following] 100%
Reinforcing steel checks are performed, but not consistently [deduction based on estimated % of
checks not performed] {less than 75% of product then 100% deduction} Estimate %
Reinforcing steel checks performed incorrectly / measurements not accurate 100%
Required data is missing from documentation, or is not measured 20% / element
Reinforcing steel inspection documentation is missing from the file {less than 75% of product then
100% deduction} Estimate %
6.4 Box Culvert Requirements
6.4.3 Pre-Pour Inspections Critical form dimensions, including top, bottom and wall Form dimensions are not measured / checked at all on box culverts [or one or more of the following] 100%
thicknesses, should be measured and documented for both wet - Form dimensions are measured, but not at required frequency [deduction based on estimated % of
and dry-cast box culverts. In addition, reinforcing steel checks not performed] {less than 75% of product then 100% deduction} Estimate %
inspections should be performed and documented. Required form dimension data is missing from documentation, or is not measured 20% / element
Form dimension documentation is missing from the file 20% / element
Reinforcing steel checks are not performed at all [or one or more of the following] 100%
Reinforcing steel checks are performed, but not consistently [deduction based on estimated % of
checks not performed] {less than 75% of product then 100% deduction} Estimate %
Reinforcing steel checks performed incorrectly / measurements not accurate 100%
Required data is missing from documentation, or is not measured 20% / element
Reinforcing steel inspection documentation is missing from the file {less than 75% of product then
100% deduction} Estimate %
6.4.4 Dimensional Checks These dimensional checks should be performed at the same time following] 100%
as the post-pour inspection Product dimensions are measured, but not at required frequency [deduction based on estimated % of
checks not performed] {less than 75% of product then 100%} Estimate %
Required product dimension data is missing from documentation, or is not measured 20% / element
Product dimension documentation is missing from the file {less than 75% of product then 100% Estimate %
deduction}
Rev. 6

- If the plant is meeting all the requirements at the proper frequencies,
the records are well organized and easily retrieved, and no problems
with that item are noted, they should be given a score of 100 percent for

6.5 Septic Tank Requirements The plant should have a listing of all forms that are used for
casting onsite wastewater tanks. The listing should include
information on the various design options the plant is capable of
producing with each form. This listing will be used by the
inspector to ensure that tanks from each of the forms have been
tested and have the required documentation associated with
them. In cases when multiple tank sizes are manufactured using
the same form, structural testing should be performed on the
largest (tallest) structure, as long as the same reinforcement
design and concrete strength are used. Otherwise, testing
should be performed on each tank design.
6.5.2 Watertightness Testing No watertighness testing is performed at the plant or no documentation exists on file [or one or more
of the following] 100%
Watertightness testing should be performed according to ASTM Watertighness testing documentation is available, but it is not available for all designs [deductions is
C1227, as a minimum. More stringent test protocol is based the % of documentation missing, as compared to the listing of forms and designs] {less than
acceptable, when required by the authority or authorities having 75% of product then 100%} Estimate %
Watertighness testing documentation is missing information, such as dates, test values, etc. 20% / element
6.6 Grease Interceptor The plant should have a listing of all forms that are used for
Requirements casting grease interceptors. The listing should include
information on the various design options the plant is capable of
producing with each form. This listing will be used by the
inspector to ensure that grease interceptors from each of the
forms have been tested and have the required documentation
associated with them. In cases when multiple interceptor sizes
are manufactured using the same form, structural testing should
be performed on the largest (tallest) structure, as long as the
same reinforcement design and concrete strength are used.
Otherwise, testing should be performed on each interceptor
design.
6.6.2 Watertightness Testing No watertighness testing is performed at the plant or no documentation exists on file [or one or more
of the following] 100%
Watertightness testing should be performed according to ASTM Watertighness testing documentation is available, but it is not available for all designs [deductions is
C1613, as a minimum. More stringent test protocol is based the % of documentation missing, as compared to the listing of forms and designs] {less than
acceptable, when required by the authority or authorities having 75% of product then 100%} Estimate %
Watertighness testing documentation is missing information, such as dates, test values, etc. 20% / element
Rev. 6

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“Dedicated to expanding the use of quality precast concrete”

NPCA QUALITY CONTROL MANUAL

No part of this manual may be reproduced

TABLE OF CONTENTS …………………………………………………………………………………..i

CHAPTER 1- GENERAL .............................................................................................................6

CHAPTER 2 – MATERIALS ....................................................................................................................... … .13

QCM-001, Table of Contents Rev. 0 09-12-22 (16.0)

CHAPTER 4 - PRODUCTION PRACTICES ............................................................................. 37

QCM-001, Table of Contents Rev. 0 09-12-22 (16.0)

CHAPTER 5 - QUALITY CONTROL OPERATIONS ................................................................ 70

QCM-001, Table of Contents Rev. 0 09-12-22 (16.0)

CHAPTER 6 – SPECIAL REQUIREMENTS FOR SPECIFIC PRODUCTS ……………………..86

QCM-001, Table of Contents Rev. 0 09-12-22 (16.0)

APPENDIX A – STANDARDS CITED IN THE MANUAL AND REFERENCES ………………..108

APPENDIX B – SAMPLE FORMS…………………………………………………………………...119

NPCA PLANT CERTIFICATION TERMS AND CONDITIONS……………………………………141

NPCA PRECAST PLANT CERTIFICATION PROGRAM GRADING SCHEDULE.….…………168

STANDARDIZED GRADING TABLES……………………………………………………………....177

QCM-001, Table of Contents Rev. 0 09-12-22 (16.0)

NPCA Quality Assurance/Quality Control Committee Members (2021 - 2022):

• Richard Alvarado, Western Precast Concrete Inc. (Chairman)

QCM-001 Rev 0 09-12-22 (16.0)

Reference is made to many standards of the American Concrete

Technical terms used in this manual are defined in ACI 116,

Quality control requires the attention and cooperation of all

QCM-001 Rev 0 09-12-22 (16.0)

MAJOR FACTORS IN QUALITY CONTROL

The single most important factor in quality control is

Qualified personnel are also required. Qualifications include a

Items that must be monitored and compared with standards

a. Completeness of work orders and product drawings

Another aspect of a successful QC program is the concept of

Quality of products is generally defined to be the consistent

QCM-001 Rev 0 09-12-22 (16.0)

PQS Level I – Basics –

PQS Level II – Safety

PQS Level II – Technical

PQS Level II – QA/QC

PQS Level II - Production

PQS Level III –Leadership

QCM-001 Rev 0 09-12-22 (16.0)

3. This publication is designed to provide accurate and authoritative information in

5. Proprietary products manufactured under Underwriters Laboratories (UL), U.S.

QCM-001 Rev 0 09-12-22 (16.0)

1.1 PLANT QUALITY CONTROL PROCEDURES AND

1.1.1 Plant Management and Personnel

A person not directly

Note: Use of supplementary

QCM-001, Chapter 1 Rev. 0 09-12-22 (16.0)

1.1.2 Plant-Specific Quality Control Manual

QCM-001, Chapter 1 Rev. 0 09-12-22 (16.0)

1.1.3 QC Personnel Training

a) the American Concrete Institute (ACI) Concrete Field

The plant shall engage in continuous improvement activities By definition, ‘continuous

QCM-001, Chapter 1 Rev. 0 09-12-22 (16.0)

In order to be considered for continuous improvement points, the rearrangement of the

1. Maintain a current copy of this NPCA Manual in ready

QCM-001, Chapter 1 Rev. 0 09-12-22 (16.0)

directly to production personnel. In small plants, the

1.2 PLANT SAFETY