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Quality Control for the Construction Materials Industry

Quality Control for the Construction Materials Industry. Jay Shilstone jshilstone@commandalkon.com Tel: 205-879-3282 x2320. Session Objective. Computerized QC systems are valuable and indispensable Why should your company have a QC system 4 Major Trends in QC and the Industry.

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Quality Control for the Construction Materials Industry

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  1. Quality Control for the Construction Materials Industry Jay Shilstone jshilstone@commandalkon.com Tel: 205-879-3282 x2320

  2. Session Objective • Computerized QC systems are valuable and indispensable • Why should your company have a QC system • 4 Major Trends in QC and the Industry Quality Control for the Construction Materials Industry

  3. Quality Control is for Everyone • Public Works • Industrial • Commercial • Residential • Agricultural Farmers need good concrete, too! Quality Control for the Construction Materials Industry

  4. Basic Tasks for QC • Avoid low strengths • Get the right slump • Respond to problems • Make the customer happy Quality Control for the Construction Materials Industry

  5. Know your “cost of quality” • Cost of your QC department • Cost of lack of quality • Chargebacks • No-pays • Removal/replacement • Insurance • Lost sales • Lawsuits • Know your cost of quality and you will know your QC priorities • $1 spent on quality provides a $3 payback Quality Control for the Construction Materials Industry

  6. Hard Returns

  7. Hard Returns • Reduced materials cost • Total Materials • Reduced production variance • Cement • Fewer problems • Assignable causes of variation • Reduced variation • Greater operational efficiency • Mix adjustments • Submittals • Rapid response to changes Quality Control for the Construction Materials Industry

  8. Reduced Materials Cost – Total Materials

  9. Yield - The Unobvious Opportunity (10,000 cyd) / year x (0.51 cft) / (27 cft/cyd) = 189 cyd not sold189 cyd x $60/cyd = $11,340 / yr lost Quality Control for the Construction Materials Industry

  10. Mix List by Yield Quality Control for the Construction Materials Industry

  11. Mix Mass Update for Yield Quality Control for the Construction Materials Industry

  12. Reduced Materials Cost – Production Variance

  13. Production Analysis Quality Control for the Construction Materials Industry

  14. Production Analysis (con’t) Admix- $1200 in 3 months Quality Control for the Construction Materials Industry

  15. Reduced Materials Cost – Cementitious

  16. Production Analysis Quality Control for the Construction Materials Industry

  17. Strength Overdesign Reporting 5900 psi – 5070 psi = 830 psi  80 lbs of cement x $.05 = $4.00 Quality Control for the Construction Materials Industry

  18. w/c Ratio Curves 5700 psi – 5070 psi = 630 psi  63 lbs of cement x $.05 = $3.15 Quality Control for the Construction Materials Industry

  19. ACI 318 - 11 Quality Control for the Construction Materials Industry

  20. Fewer Problems– Assignable Causes

  21. Evaluate Testing Variation • Monitor labs and technicians for testing variation • Determine causes of concrete changes • Provide backup information during investigations Cylinder difference CuSum Analysis Quality Control for the Construction Materials Industry

  22. Production Analysis Quality Control for the Construction Materials Industry

  23. Greater Operational Efficiency

  24. Mix Mass Update Quality Control for the Construction Materials Industry

  25. Concrete Submittals Quality Control for the Construction Materials Industry

  26. Soft Returns • Improved ability of sales to back up bids • Increased confidence by customers • Increased confidence by producer • Ability to negotiate with Engineers • Ability to negotiate with Material Suppliers • Industry recognition

  27. NRMCA 2010 Quality Survey(InFocus Jan. 2011)

  28. Concrete Rejected Quality Control for the Construction Materials Industry

  29. Reasons for Rejection at Job Quality Control for the Construction Materials Industry

  30. Cost of Rejected/ cyd Produced Quality Control for the Construction Materials Industry

  31. # Core Sets / 100K cyd Quality Control for the Construction Materials Industry

  32. Hardened Concrete Callbacks Quality Control for the Construction Materials Industry

  33. 4 Major Trends Affecting QC • Sustainability – requires ability to work with supplementary cementious materials, reduce cement content and work with locally available materials • Fly ash restrictions – EPA’s efforts will make fly ash more difficult or impossible to obtain • Depletion of resources – new materials may have to be imported from great distances • Performance specifications – Performance specifications will place greater demand on QC departments Quality Control for the Construction Materials Industry

  34. Please Complete Your Evaluation • Be sure to circle the session you are evaluating on the back of your card • QC (Track Name) • QC-001 (session code) • Quality Control for the Construction Materials Industry (session title) • All breakout session materials can be accessed at: www.commandalkon.com/cc2011/update/index.htm • jshilstone@commandalkon.com • Thank You! Quality Control for the Construction Materials Industry

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