tech talk

How good is your QC?

Part I of Concrete Quality Control Series
By Karthik Obla, Ph.D., P.E., Vice President, Technical Services, NRMCA

Q
uality Control (QC), also called Process Control, is defined tor quality level a better
as those actions and considerations necessary to control the quality producer is still
level of quality being produced in the end product. Regu- likely to have a lower
larly measuring aggregate moistures and correcting batch water is amount of rejected con-
one such action; regularly verifying accuracy of measuring devices crete and lower costs to
is another. A large number of ready mixed concrete companies are deal with hardened concrete issues on an annual basis.
making significant efforts in QC. However, with Quality Control The third question is also very important and should be carefully
there is always room for improvement. Most companies probably monitored by every company for at least its 5 largest volume mixtures.
feel that they have a good QC program. But how does a company Variability in compressive strength as measured by standard devia-
know for certain? For example, to evaluate a company’s operational tion (s) is an excellent measure of a company’s QC. Table 1, which is
efficiencies there are several benchmarks such as yards/hour, deliv- a reproduction of Table 3.2 from ACI 214R-021, shows that the stan-
ery costs for fleets, safety statistics that a company can measure and dards of concrete control based on general construction testing can
compare to industry averages. There are similar financial bench- vary from Excellent (s < 400 psi) to Poor (s > 700 psi). This applies to
marks developed by the NRMCA Business Administration Com- typical concrete strengths in the range of 3000 to 5000 psi.
mittee. Are there benchmarks specific to quality of ready mixed A low s is desirable because it will result in a lower required aver-
concrete? A start can be made by the company by annually monitor- age strength (ƒ´cr) that a producer needs in a mix submittal for a speci-
ing its cost that can be attributed to poor quality. For some compa- fied strength (ƒ´c). A lower required average strength will reduce the
nies this may be a paradigm shift because they currently think in material costs for each class of concrete. ACI 318-082 requires that the
terms of the cost of their QC program. The cost due to poor quality required average strength (for ƒ´c<5000 psi) should be the higher of
may be measured by monitoring the following: the following two equations:
• Amount of rejected concrete (as a percent of the concrete pro- ƒ´cr = ƒ´c + (1.34 x s)
duced) for non-compliance with project specifications such as ƒ´cr = ƒ´c + (2.33 x s) – 500
slump, air content, etc. These equations are based on a one in 100 chance of the
• Cost to repair, replace or mitigate hardened concrete issues (cores strength results falling below the two ACI 318 standard acceptance
etc.) because concrete did not meet purchaser’s or specification requirements.
requirements, expectation, etc. Table 2 shows the target average strength calculated for ƒ´c = 4000
• Variability in compressive strength as measured by standard devi- psi for different levels of QC. Assuming that for each 200 psi increase
ation of the 5 top selling mixtures in ƒ´cr results in an increase in concrete materials cost of $1/yd3, the
• Perception of company’s quality by customer through an annual cost savings due to the lower ƒ´cr can be estimated. It is instructive
customer survey – Excellent, Very Good, Good, Fair, Poor to note that improving QC, i.e. reducing “s” from 750 psi to 350 psi
The NRMCA Research Engineering and Standards Committee can result in a saving of $3.9/yd3 in concrete materials cost due to a
has developed the NRMCA Quality Measurement and Bench- reduction in ƒ´cr from 5250 psi to 4470 psi! Another way to look at
marking survey to develop QC metrics or benchmarks for the indus- this is with poor QC (“s” of 750 psi as compared to 350 psi) one may
try. This survey will be initiated in 2010 and it includes the above have to add more cement at a cost of $3.9/yd3 to avoid low strength
questions as part of the survey. Any company or division can partici- test results. But unfortunately that will result in highly un-optimized
pate in this survey and compare its QC metrics to industry averages. mixtures and therefore is not a cost effective practice. Poor testing
As with all NRMCA surveys, confidentiality of individual company quality can also increase the “s”. There are ways to help improve test-
information will be maintained. ing quality and that will be a subject of a different article. However,
The first two of the above questions are fairly obvious. Rejected for the same level of testing quality the producer with better QC will
concrete even if it is beneficially reused is still money lost in terms still have a lower “s” and is therefore still in a better position.
of truck time and man hours. Cost to repair hardened concrete can The final question, which is the perception of a company’s qual-
involve core tests, evaluating cracking etc. and can become very ity in the eyes of the customer, is also very important and should
expensive, even if it does not go to litigation. It is realized that con- be monitored annually by concrete producers. A customer’s percep-
crete could be rejected or the producer could be asked to provide costs tion of a company’s quality is formed by a number of factors such as
to address a hardened concrete issue for reasons that are not within personnel, facilities etc. If the customer believes he will get a better
the control of the concrete producer, such as delays in pour at the job- product he will pay more for it. When the inevitable problems do
site and jobsite mixture adjustments. However for the same contrac- occur the customer is more willing to look at himself, the lab or other

CONCRETE in focus ı 17
 factors beyond the concrete producer. The likely to command a better profit. So if References
owner, engineer and architect are more will- the company primarily supplies to applica- 1. ACI Committee 214, “Evaluation of
ing to trust and even take the advice of the tions where there are no jobsite testing and Strength Test Results of Concrete (ACI
concrete producer when problems do occur. acceptance requirements then the value of 214R-02),” American Concrete Institute,
They may even consult and seek the help of improved QC may not be so obvious. But Farmington Hills, MI, 2005, 20 pp.
the concrete producer on matters of speci- if that company starts supplying to proj- 2. ACI Committee 318, “Building Code
fication and desired concrete performance. ects involving jobsite testing and accep- Requirements for Structural Concrete (ACI
The bottom line is a happier, satisfied cus- tance requirements then they are likely 318-08) and Commentary,” American
tomer which will inevitably lead to more to start seeing significant costs resulting Concrete Institute, Farmington Hills, MI,
business and a higher profit. from their lower level of QC. ■ 2008, 471 pp.

Is it worthwhile not to invest

in improved QC under certain Table 1. Standards of Concrete Control (adapted from ACI 214R-02 Table 3.2)
circumstances? Overall Variation
Let us say a company primarily supplies Standard Deviation for Different Control Standards, psi
Class of Operation
to applications where there are no jobsite Excellent Very Good Good Fair Poor
testing and acceptance requirements. General
< 400 400 to 500 500 to 600 500 to 700 > 400
Then the amount of rejected concrete Construction Testing
related to testing will be negligible. Even
though there will be no strength results to
deal with the cost to repair will be slightly Table 2. Cost Savings Due to Improved QC for ƒ´c = 4000 psi
higher for the producer at a lower level of QC Standards (ACI 214) Excellent Very Good Good Fair Poor
quality as he will incur greater call back s, psi 350 450 550 650 750
costs due to aesthetics such as cracking ƒ´cr , psi 4470 4600 4780 5020 5250
etc. Compressive strength is not even mea-
Cost Savings, $/yd3 3.9 3.2 2.3 1.2 0.0
sured so there is no advantage in reducing
standard deviations. Finally, companies
with an excellent quality perception are For more information, contact Dr. Obla at [email protected] or 240/485-1163.

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