Quality Management Plan Guidance For Concrete Used For .
Technical Memorandum No. MERL-2015-073Quality Management PlanGuidance for Concrete used forConstruction of SignificantFeatures1.2.U.S. Department of the InteriorBureau of ReclamationTechnical Service CenterDenver, ColoradoAugust 2015
Mission StatementsThe U.S. Department of the Interior protects America’snatural resources and heritage, honors our cultures andtribal communities, and supplies the energy to power ourfuture.The mission of the Bureau of Reclamation is to manage,develop, and protect water and related resources in anenvironmentally and economically sound manner in theinterest of the American public.Disclaimer: Information in this report may not be used for advertising or promotional purposes. Theenclosed data and findings should not be construed as an endorsement of any product or firm by theBureau of Reclamation, U.S. Department of the Interior, or the Federal Government.
BUREAU OF RECLAMATIONTechnical Service Center, Denver, ColoradoMaterials Engineering and Research Laboratory, 86-68180Technical Memorandum No. MERL-2015-073Quality Management Plan Guidance forConcrete used for Construction ofSignificant Concrete FeaturesbyKurt F. von FayBureau of ReclamationTechnical Service Center, Denver, Colorado3.4.U.S. Department of the InteriorBureau of ReclamationTechnical Service CenterDenver, ColoradoAugust 2015
Technical Memorandum No. MERL-2015-073Quality Management Plan Guidance forConcrete used for Construction of SignificantConcrete FeaturesDate75/z/s-- Peer'·ew: Janet White, PEMaterials Engineering and Research Laboratory, 86-68180j{e; \V:&ott Keim, PE7DateDateMaterials Engineering and Research Laboratory, 86-68180Noted: William F. Kepler, Ph.D., P.E.Materials Engineering and Research Laboratory, 86-68180DateAcknowledgmentsCredit is due Tim Dolen who prepared a draft quality management document several years ago.In addition, Katie Bartojay prepared a Quality Management plan for the concrete features of theWanen H. Brock Reservoir in Arizona. This document relies on those documents and the workof the authors is greatly appreciated.
FOR OFFICIAL USE ONLYTechnical Memorandum No. MERL-2015-073Quality Management Plan Guidance for Concreteused for Construction of Significant FeaturesAcronymsAASHTOAmerican Association of State Highway and TransportationOfficialsACIAmerican Concrete InstituteASTMAmerican Society for Testing and MaterialsCCRLCement and Concrete Reference LaboratoryCDTMconcrete materials design team membercmcementitious materialsCORContracting Officer’s RepresentativeEREngineer RegulationFARFederal Acquisition RegulationF/Tfreezing and thawingf’cdesign strengthIBCInternational Building CodeJHAJob Hazard AnalysisPCQASProject Concrete Quality Assurance SystemPsipounds per square inchQAquality assuranceQCquality controlQMPquality management planReclamation Bureau of ReclamationRCCroller compacted concreteRSHAReclamation Safety and Health StandardsiiiFOR OFFICIAL USE ONLY
Technical Memorandum No. MERL-2015-073Quality Management Plan Guidance for Concreteused for Construction of Significant FeaturesRSNRequired submittal numberVebeVibratory consistencywwaterWRAwater-reducing, set-controlling admixturesiv
FOR OFFICIAL USE ONLYTechnical Memorandum No. MERL-2015-073Quality Management Plan Guidance for Concreteused for Construction of Significant FeaturesContentsI.Project Quality Management Plan Summary .1A. Quality.1B. Quality Management.1II. Roles and Responsibilities .2A. Quality Assurance .21. Joints .6B. Quality Testing.8C. Quality Control .12D. Quality Submittals by the Contractor .13E. Contractor Quality Testing .131. Contractor Batch Plant Quality Testing .142. Contractor Field Quality Testing .14III. Quality Related References .15IV. Personnel Requirements .16A. Reclamation Concrete Materials Design Team Member Requirements.16B. Reclamation QA Personnel Requirements.171. Reclamation Construction Laboratory (Field Laboratory) .172. Reclamation Construction Inspection .19C. QA/QC Coordination Meetings .21D. Contractor QC Personnel Requirements .21V.Material Requirements .22A. Strength and Durability Requirements.221. Strength Requirements .222. Durability Requirements .233. Procedures for Evaluation of the Starting Concrete Mixture.24B. Requirements for Documentation of Concrete Mix Design .261. Example Requirements for Materials .26VI. Inspection and Testing Requirements .27A. Quality Assurance Testing Requirements – Structural Concrete .271. Quality Assurance Testing – Minimum Requirements for StrengthTesting (one set consists of 2 cylinders tested at indicated test age) .282. Quality Assurance Testing – Typical Requirements and Reporting.283. Independent Quality Assurance Testing Laboratory Requirements .29vFOR OFFICIAL USE ONLY
Technical Memorandum No. MERL-2015-073Quality Management Plan Guidance for Concreteused for Construction of Significant FeaturesB. Quality Assurance Testing Requirements – Mass and RollerCompacted Concrete .301. Quality Assurance Strength Testing – Minimum Requirements forStrength Testing .302. Quality Assurance Testing – Typical Requirements and Reporting.30C. Reporting Format and Routing .32VII. Major Quality Assurance Activities .32A. Division 1.0.331. Quality Procedures .332. Testing Agency Services.33B. Division 3.0.341. Epoxy Grouted Anchor Bars.342. Concrete .34VIII. Summary Table of Testing Activities .36FiguresFigure 1.—Example mix design requirement – strength and durability criteria .25TablesTable 1.—Batch Plant Testing .9Table 2.—Field Testing .10Table 3.—Example Checklist for Documenting Concrete Materials .23Table 4.—Example Checklist for Concrete Mixture Proportions .25Table 5.—Summary Table of Testing Activities .37vi
Technical Memorandum No. MERL-2015-073Quality Management Plan Guidance forConcrete used for Construction ofSignificant Concrete FeaturesI.Project Quality Management Plan SummaryThis project quality management plan (QMP) guidance document providesinformation about concrete material related quality assurance (QA) and qualitycontrol (QC) practices for the Bureau of Reclamation (Reclamation) constructionprojects with significant concrete features. It is intended to serve as a guide fordeveloping a QMP for concrete used for construction of significant concretefeatures of a project. It is up to the design and project management team todetermine when to use this document; they must decide when the concretestructure is significant and when QMP documents (project-specific QC and QAprocedures) are appropriate for a project. This document provides informationabout what to include and items to consider for QC and QA planning.Generally speaking, QC activities are those actions performed by the contractor toensure that the product meets specification requirements. QA activities are thoseactions performed by the Government to ensure that the contractor is followingspecification requirements.A.QualityQuality is the adherence and conformance to properly developed requirements.Requirements for quality design in concrete construction include conformance withapplicable codes, standards, guidance, regulations, laws, and statues referenced inthe specifications.Requirements for quality construction include compliance with contractprovisions, clauses, and specifications. These contract documents establish thequality requirements for construction by defining the standards, including salientand essential characteristics, of concrete materials and the acceptance criteria andnecessary testing inspection of concrete construction.B.Quality ManagementQuality management is the combination of all QA and QC activities used to attainthe quality required for the contract deliverables. Quality management includes1FOR OFFICIAL USE ONLY
FOR OFFICIAL USE ONLYTechnical Memorandum No. MERL-2015-073Quality Management Plan Guidance for Concreteused for Construction of Significant Featuresall planned and systematic actions necessary to provide confidence that allproducts and constructed works will meet established parameters and performsatisfactorily in service.Quality management is the responsibility of Reclamation and the contractor;quality management must be achieved through cooperation and collaboration.The QMP will depend on the type of concrete structure being built. As thecomplexity and uniqueness of the feature being constructed increases, thespecifications may need to be more prescriptive rather than performance based.More prescriptive specifications may require that the Government, for example,design the concrete mixture, and determine how and when the concrete will beplaced and cured. Many times, for these specifications, the cementitious materials(cm, cement plus pozzolan) are paid for separately from other concreteingredients, allowing for QA staff to adjust concrete mixture proportions withoutundue impacts on the contractor concrete costs. A more prescriptive concretespecification lowers the risk for the contractor, perhaps lowering their concretecosts, but will also require additional QA staff for the Government.On the other hand, a performance based specification provides details about therequired concrete product, and allows the contractor greater latitude in developingthe concrete mixture, placing plan, schedule, etc. This may result in savings,since the contractor will be motivated to produce and place the concrete at as lowa cost as possible. This type of specification requires a higher level of effort bythe contractor for QC. This contract type is also somewhat riskier for thecontractor, since they have much more responsibility for the final product.II.Roles and ResponsibilitiesA.Quality AssuranceThis document is intended to provide guidance for project QA operations relatedto concrete production performed by or for the Government. The QMP shouldinclude a listing of the work requiring surveillance (inspection and testing),requirements, methods, and frequencies of surveillance, along with workload,staffing, job responsibilities, qualifications, training, certifications, inspection,testing, and documentation. No document, however, can take the place of properfield and laboratory training.Numerous activities are required as a part of a comprehensive concrete QAprogram. Prior to the start of design and construction, the QA involves locatingsources of materials suitable for use for the construction and performing the2
FOR OFFICIAL USE ONLYTechnical Memorandum No. MERL-2015-073Quality Management Plan Guidance for Concreteused for Construction of Significant Featuresnecessary investigations to evaluate the durability exposure conditions of theconcrete, such as sulfate attack, freezing and thawing exposure, and potential foralkali-aggregate reaction. The design engineer, in consultation with the areaoffice representative and the contracting officer, is responsible for developingdesigns and specifications in accordance with industry standards. For concretedesign, the American Concrete Institute (ACI) 318-141 includes requirements forassuring concrete mixtures meet both minimum strength and durability criteria asa part of the design process.After the contract award, Reclamation or the owner’s representative is responsiblefor QA to the extent required to determine whether the contractor has fulfilled thecontract requirements, and will confirm that the specified deliverables areobtained. QA may include inspection, monitoring, sampling, checking,destructive and non-destructive testing, peer and independent reviews, third partyverification, and may be based on statistical methods, empirical observations,and/or other specification requirements.Reclamation QA is for the sole benefit of Reclamation and does not: Relieve the contractor of responsibility for providing minimum requiredQC throughout the construction period, Relieve the contractor of responsibility for damage or loss of suppliesbefore acceptance under the terms of the contract, or Affect the continuing rights of Reclamation after acceptance of thecompleted work as stipulated in the contract requirements.Reclamation is required, as part of its QA responsibilities, to monitor and assurethat the contractor is in compliance with contract documents and fulfillingcontractual responsibilities in performance of QC, as defined by contract.Federal Acquisition Regulation (FAR) 46.4 defines Government contract qualityassurance as “the various functions, including inspection, performed by theGovernment to determine whether a contractor has fulfilled the contractobligations pertaining to quality and quantity.” Section 46.401 (e) goes on tostate that “Government inspection shall be performed by or under the direction orsupervision of Government personnel.”21ACI 318-14 Building Code Requirements for Structural Concrete and Commentary,American Concrete Institute, Farmington Hills, MI, 2014.2Federal Acquisition Regulation (FAR), Volume I, Part 46, March 2015.3
FOR OFFICIAL USE ONLYTechnical Memorandum No. MERL-2015-073Quality Management Plan Guidance for Concreteused for Construction of Significant FeaturesFAR 52.246-123 states that “Government inspections and tests are for the solebenefit of the Government and do not relieve the contractor of responsibility forproving adequate quality control measures.”For civil works structures, the United States Army Corps of Engineers regulationsrequire the use of Government personnel to perform QA activities:“The inclusion of quality control requirements for the contractor does not relievethe Contracting Officer of the responsibility for safeguarding the Government’sinterests . The GQA [Government Quality Assurance] responsibility is not tobe imposed on the construction contractor. If personnel shortages preclude theuse of government personnel to accomplish GQA, it should be done by acommercial testing organization under contract to the Government.”4“Subsequent to contractor quality control completion inspections, acceptanceinspections of completed construction are a government responsibility.”5For commercial projects, the International Building Code (IBC)6 also requires QAinspection and testing for critical building infrastructure to be the responsibility ofthe owner. “The owner or the registered design professional in responsible chargeacting as the owner’s agent shall employ one or more special inspectors toprovide inspections during construction.”The ACI 318-14 Building Code1 requires inspection of concrete structures andreferences ACI 311 “Guide for Concrete Inspection” which includes specificrequirements for acceptance testing as a part of the overall QA program. ACIrecommends that acceptance testing be performed by the owner or engineer as apart of the overall QA program, and goes as far as saying “[t]he owner or engineershould avoid the undesirable practice of arranging payment for acceptanceinspection and testing services through the contractor. Such practice is not in theowner’s interest.” 7Although the IBC6 and ACI 318-141 codes contain standards for buildings, mostlarge civil projects designed and built in the private sector follow these standards.The ACI 318-14 Building Code1 specifies minimum criteria for frequency oftesting of structural concrete. Industry standards provide additional guidance for3Federal Acquisition Regulation (FAR), Volume I, Part 52, July 2015.U.S. Army Corps of Engineers, Engineering Manual (EM) 1110-2-2000, “StandardPractice for Concrete for Civil Works Structures,” February 1, 1994.5U.S. Army Corps of Engineers, Regulation ER 1180-1-6 Construction QualityManagement dated September 30, 1995.6International Building Code, International Code Council, 2012.7ACI 311.4R-05, “Guide for Concrete Inspection,” American Concrete Institute.44
FOR OFFICIAL USE ONLYTechnical Memorandum No. MERL-2015-073Quality Management Plan Guidance for Concreteused for Construction of Significant Featuresrecommended tests and frequency of testing for structural and other concretes.Normally, this includes daily sampling and testing of each class of concrete. Theextent of QA needs to be commensurate with the value, complexity, sensitivity,criticality, and other factors of the contract requirements.Contract specifications detail the level of quality necessary to achieve theminimum standards for meeting the design requirements. The project team willassure these standards are met and that the contractor uses standard and/orspecified methods to produce satisfactory results, or that if unusual methods areused that these methods achieve satisfactory results.Much of Reclamation’s specification for concrete deals with testing materials andensuring the properties meet specification requirements. However, beforeconcrete is placed, the specification requirements regarding excavation,formwork, steel reinforcement, and construction joints must be inspected.Inspectors must familiarize themselves with the specifications, including relevantdrawings. Daily reports should be prepared that document observations madeduring the inspection of the placement of steel reinforcement and formwork.Required excavations should be verified by inspection and testing, andappropriate reports prepared.Excavate
Materials Engineering and Research Laboratory, 86-68180 . . PCQAS Project Concrete Quality Assurance System . Psi pounds per square inch . QA quality assurance . QC quality control . . Structural Concrete .27 Quality Assura
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