Webinar: MNL 116-21 Changes

A webinar summarizing the changes to MNL 116-21 has been scheduled for June 7, 2022, at 2:00 pm central. The PCI Education group will be emailing an announcement with registration details in the coming weeks.

Plant and Erector Certification Renewal for 2022-23

All producers and erectors should have received an email with instructions on how to renew their certifications for 2022-23. These processes are very similar to last year. Completed forms are to be submitted by May 31. Failure to complete these processes on time may result in a lapse in certification status. For any questions regarding your plant’s certification status, please contact qualityprograms@pci.org.

Project Surveys for Categories AA and AB

Effective July 1, producer plants certified in the AA and AB categories are required to submit project information to PCI that will facilitate a PCI-distributed survey to the architect and GC/CM upon completion of a project. This requirement applies to all completed projects that are specified as category AA or AB with more than 5000 ft² (465 m²) of wall panel area.

The Architectural Certification Program Supplemental Requirements describes a paper process for submitting this project information. An online survey system is currently being completed and will be available prior to July 1. This survey will be available through the PCI website. Further information will be provided directly to the AA and AB-certified plants when the software testing process has been completed.

Baseline for Key Feature Points for Recertification

Plants with certification in the architectural group are required to demonstrate continued capability in their certification category by achieving a minimum number of key feature points every two years. The Architectural Certification Subcommittee recently discussed options for how this would be implemented and decided to use a rolling two-year period, based upon the last four audit cycles (semi-annual).

The key features to be demonstrated for each category are listed in the respective chapters of the Architectural Certification Program Supplemental Requirements. During the opening meeting for each audit, the auditor will be discussing current plant production and architectural products in storage, so that the auditor can be aware of the products available for review. The points to be awarded will be discussed during the closing meeting and any questions concerning points can be resolved while the auditor is still on site.

Points will be tracked on a rolling basis rather than for a fixed, defined period. This ensures that plants will have four opportunities to demonstrate the required points, as the regular audits are conducted at approximately 6-month intervals. Special audits, such as those conducted for category changes, etc., are not counted as part of the four audits, although a plant could get points if eligible product was observed during one of these audits

It should be noted that the tracking of points began with audits conducted on October 1, 2021, when the new categories were implemented. Although the auditors were reviewing products and discussing possible points with plant personnel before that date, these discussions were for the purpose of educating plant staff and refining the point tracking system.

Plants that are short of points as their two-year mark is approaching can construct a mockup panel of their own design with appropriate key features to demonstrate their continued capabilities and earn the necessary points. Drawings for these panels must be submitted and approved in advance, as in the process used for the original mockup panels.

T. Henry Clark Award – Last Call for 2022 Nominations

Nominations for the T. Henry Clark Award, to be presented during 2022 PCI Committee Days, must be submitted to qualityprograms@pci.org by June 1, 2022. The T. Henry Clark Award nomination form is available here.

The T. Henry Clark Award was established to recognize an individual, group of individuals, or firm that has delivered a resource that improves or enhances the quality of precast, prestressed concrete products or processes. T. Henry Clark believed in quality and quality processes, and this award is to recognize those who create or promote quality in a way that would have made him proud.

For more information, contact Gary Wildung, the Quality Activities Council chair, at gary.wildung@fdgcolorado.com or Mike Kesselmayer, PCI managing director of quality programs, at mkesselmayer@pci.org.

Exceptional Precast Practices Deadline is July 1

The deadline for submitting completed Exceptional Precast Practices (EPP) Program surveys is July 1, 2022. This voluntary program is specifically designed for continuous quality improvement of precast plants.

Companies that have successfully adopted a path of continuous quality improvement typically exhibit a pattern of reduced costs, improved quality, and expanded capabilities. They show growing sales because they better serve the needs of their clients.

There are a variety of continuous quality improvement tools available, but the EPP program is a tool developed specifically for the precast concrete industry. The EPP program, developed by the Quality Enhancement Committee, offers both a roadmap for improvement efforts and milestones for measuring progress.

Here is how this voluntary program works: Your plant fills out the self-assessment survey for each of the seven sections/modules – Productivity, Personnel, Safety, Field operations, Sales and marketing, Sustainable plant, and Concrete. This process allows your plant to not only benchmark where you are today but also review programs of proven worth that other PCI plants find valuable.

That process allows plant personnel to decide on a roadmap for the future. If this process is managed well, that roadmap becomes the goals and programs for improvement, and it provides the basis for accountability for achievement. Your benchmark score allows your plant to actually measure progress from year to year. There is no minimum score required. This is not a contest. Scores will not be published. There is no overall winner. All participants in this voluntary program seriously win. All participating plants are provided with an annual certificate of participation and are recognized at the PCI Committee Days and Technical Conference.

To participate or to read more about the program, click here to access the Member Resources section of the PCI website. To receive recognition for 2022, completed forms must be returned to PCI by July 1.

PCI Certification Statement for Industry

Although the new architectural certification program categories were effective October 1, 2021, architectural producers report that industry continues to specify category A1 certification for many new projects. In addition to the other resources that have been provided on PCI’s website that are intended to inform and educate specifiers about these changes, a Certification Statement for Industry has been added.

The Certification Statement for Industry serves as a general notice on PCI letterhead informing a specifier about the changes in architectural categories and provides a variety of contacts if they have additional questions. The Statement is intended to serve as an official notice from PCI to reinforce a producer’s communication to a specifier during the bidding process or in a post-bid request for information or qualification submittal.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Quality Talks Series 2 Now Available in Spanish

Series 2 of PCI’s Quality Talks has been translated into Spanish and is now available on the PCI website. Like the safety talks used by many companies in the construction industry, these quality talks provide precast concrete plant personnel a few moments to reflect on the right ways of doing things from a quality perspective. These talks cover a wide range of quality-control-related topics and production best practices that serve as a resource to producers as they work to continually improve the culture of quality at their production facilities.

T. Henry Clark Award Nominations Due June 1

Nominations for the T. Henry Clark Award, to be presented during 2022 PCI Committee Days, must be submitted to qualityprograms@pci.org by June 1, 2022.

T. Henry Clark Award Nomination Form

The T. Henry Clark Award was established to recognize an individual, group of individuals, or firm that has delivered a resource that improves or enhances the quality of precast/prestressed concrete products or processes. T. Henry Clark believed in quality and quality processes, and this award is to recognize those who create or promote quality in a way that would have made him proud.

For more information, contact Gary Wildung, the Quality Activities Council chair, at gary.wildung@fdgcolorado.com or Mike Kesselmayer, PCI managing director of quality programs, at mkesselmayer@pci.org.

PCI Company Audits

Company audits conducted to support PCI’s Erector Certification Program are conducted by a group of experienced Certified Company Auditors trained to conduct these types of audits. The qualifications necessary to perform these audits are outlined in the PCI Company Auditor FAQs. If you are interested in learning more about conducting these audits, please review the FAQ document and contact PCI at QualityPrograms@pci.org.

Structural Grouting of Load-bearing Precast Concrete Elements: Issues and Solutions

The January-February 2022 issue of the PCI Journal includes a white paper from the PCI Erectors Committee on Structural Grouting of Load-bearing Precast Concrete Elements: Issues and Solutions. The purpose of the white paper is to continue to raise construction industry awareness regarding structural grouting of precast concrete projects. The white paper includes a grout quality assurance/quality control checklist and a one-page field grout checklist.

MNL 116-21 (Fifth Edition) Implemented January 1

Implementation of the new MNL 116-21 (Fifth Edition) requirements became effective January 1, 2022. MNL 116-21 is now available in the PCI Bookstore in either a PDF or printed format. A complimentary PDF copy of the new manual was provided to the authorized audit contacts at all plants last July. A presentation outlining the changes is in the committee approval process and is expected to be available in April, which will also be posted on the PCI website. Watch for details about this presentation in My PCI Update, the monthly Education newsletter, and in this certification newsletter.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

MNL 116-21 (Fifth Edition) Implemented January 1

Implementation of the new MNL 116-21 (Fifth Edition) requirements became effective January 1, 2022. MNL 116-21 is now available in the PCI Bookstore in either a PDF or printed format. A complimentary PDF copy of the new manual was provided to the authorized audit contacts at all plants last July. A presentation outlining the changes is in the committee approval process and is expected to be available in March, which will also be posted on the PCI website. Watch for details about this presentation in My PCI Update, the monthly Education newsletter, and in this certification newsletter.

Erector Field Quality Audits

PCI Policy 29, Erector Certification Program, requires that certified erectors conduct a field quality audit for each primary erection crew once each half of the calendar year if that crew erected precast for more than 60 days during the period. Copies of the field quality audits for the second half of 2021 are to be submitted no later than January 15, 2022. If the crew did not meet the 60-day threshold, a letter to that effect must be submitted. All field quality audits and letters should be emailed to audit@pci.org. 

Change in Category AC Mixer Requirements Approved

The Plant Certification Committee recently approved a change in the batching operation requirements for category AC. Previously, concrete face mixtures for category AC-certified plants were required to be plant-batched and mixed; no truck mixing was allowed. With these approved changes, truck mixing of face mixtures is allowed, subject to certain conditions. These were recently posted on the PCI website.

Review the Changes

New PCI CMS Launched

PCI launched its new personnel Certification Management System (CMS) in November, which replaced our prior paper-based system. The PCI CMS is the online system through which all certification activities are administered, from initial application and uploading of documents through exam administration and issuing of certifications. The central hub for accessing these functions and information is the certification dashboard, which also allows an individual to access their unique information.

Concurrent with launching the new PCI CMS, the personnel certification section of the PCI website has been enhanced and greatly expanded. Users will find easier access to the information they need for certification as well as instructions for use of the new CMS.

The goals of the new CMS are to provide easier access to all aspects of the personnel certification system, to streamline processes, and to eliminate the need for paper, including paper exams. This is a major change to the methods we have used for many years, and it will take some time for everyone to become comfortable with them. Please be patient.

The next phase of the CMS will include online CFA and CCA exams, which are currently being developed, as well as certification expiration reminders and a method for online verification of certification status. Planning for this phase is already underway, with implementation planned for 2022.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

New PCI CMS Launched

PCI launched its new personnel Certification Management System (CMS) on November 9. The PCI CMS is the online system through which all certification activities will now be administered, from initial application and uploading of documents through exam administration and issuing of certifications. The central hub for accessing these functions and information is the certification dashboard, which also allows an individual to access their unique information.

Concurrent with launching the new PCI CMS, the personnel certification section of the PCI website has been enhanced and greatly expanded. Users should find easier access to the information they need for certification as well as instructions for use of the new CMS.

The goals of the new CMS are to provide easier access to all aspects of the personnel certification system, to streamline processes, and to eliminate the need for paper, including paper exams. This will be a major change to the methods we have used for many years, and it will take some time for everyone to become comfortable with them. Please be patient.

The next phase of the CMS will include online CFA and CCA exams, which are currently being developed, as well as certification expiration reminders and a method for online verification of certification status, Planning for this phase is already underway, with implementation planned for 2022.

Initial AC157 Accreditation

Redondo Manufacturing in Converse, Texas, recently became the first PCI-certified plant to be accredited to International Accreditation Service (IAS) AC157 “Accreditation Criteria for Fabricator Inspection Programs for Reinforced and Precast/Prestressed Concrete” under PCI’s bilateral agreement with IAS.

Section 1704 of the 2021 International Building Code states that special inspections are required of fabricated structural, load-bearing members unless an approved fabricator is used. Section 1704.2.5.1 states that ”Approval shall be based on review of the fabricator’s written fabrication procedures and quality control manuals that provide a basis for control of materials and workmanship, with periodic auditing of fabrication and quality control practices by an approved agency or the building official.”

AC157 accreditation provides a mechanism to become an approved fabricator without requiring approval of the building official on each project. Through PCI’s agreement with IAS, AC157 accreditation is available to PCI-certified plants for about half of the cost of going through IAS directly and without substantial additional requirements. The process includes completing an application and a cross-reference checklist of the quality system manual to AC157 requirements and submitting the required IAS fee. Minor revisions to the quality system manual will be required to incorporate specific IAS program references.

AC157 also requires two 2-day audits, so additional audit fees may be necessary for plants receiving 1-day audits. More information and an application is available at IAS AC157 Approved Fabricator Accreditation.

The Audit Score

The numerical scores used to grade PCI plant certification audits occasionally raise questions from participants. A new paper, The Audit Score, has been posted on the PCI website. This paper clarifies the significance of the numerical scores and will hopefully eliminate misunderstandings about them.

MNL 116-21 (Fifth Edition) to be Implemented January 1

MNL 116-21 (Fifth Edition) has been released and is now available in the PCI Bookstore in either a PDF or printed format. A complimentary PDF copy of the new manual was provided to the authorized audit contacts at all plants in July. Implementation of the new requirements will be effective January 1, 2022. Watch for details about these changes, including a webinar, in My PCI Update, the monthly Education newsletter, and in this certification newsletter.

QSM Updates for ISO 9001:2015 Requirements

Several plants have expressed concerns regarding QSM reviews indicating that their previously approved QSM does not meet ISO 9001:2015 requirements. These issues have typically been encountered during an audit or when minor updates are made to one section of the QSM, but deficiencies are noted in other sections during the QSM review and approval process. These issues can be understandably frustrating and have resulted from several causes.

These causes include:

1. The current revision of QSM-1, Preparation Guidelines for a Quality System Manual of a PCI-certified Plant, was issued in April 2018 and a compliance deadline of 6/30/19 was established. In spite of the extended implementation period, well over half of the certified plants submitted their QSM for review within the next 2 months, causing a large backlog. Unfortunately, some of the reviews were apparently not as thorough as they could have been during this initial review period.
2. As with any new task, repetition improves proficiency. While the QSM reviewers were trained in the new QSM requirements, they are now more proficient and detailed in their reviews than they were at the very beginning.
3. Reviewers change. A second or third set of eyes may see something that the initial reviewer missed.

We apologize for these situations and continue to work to improve the quality of all services, including the QSM reviews. We appreciate your feedback and understanding.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

New CMS to be Implemented

Implementation of the new personnel certification management system (CMS) is being planned for early November. The new system includes: online application, proctor registration, and proctored exam request processes; convenient links to the exam; and for successful candidates, access to their certificates. Look for more details in coming weeks!

The goals of the new CMS are to provide easier access to all aspects of the personnel certification system, to streamline processes, and to eliminate the need for paper, including paper exams. This will be a major change to the methods we have used for many years and it will take some time for everyone to become comfortable with them. Please be patient. Significant revisions to the website pages and development of user instructions are underway to help ease this transition.

Phase 1 of the CMS, the transition to online exams for level 1, 2, 3 as well as the GFRC QC Technician/inspector certifications, was implemented in November 2020. The Certified Field Auditor (CFA) and Certified Company Auditor (CCA) exams are being revised to be in multiple choice format and will be added to this process once they are completed.

Phase 3, which includes the online CFA and CCA exams, certification expiration reminders, and a method for online verification of certification status, will follow.

MNL 116-21 (Fifth Edition) to be Implemented January 1^st

MNL 116-21 (Fifth Edition) has been released and is now available in the PCI Bookstore in either a PDF or printed format. A complimentary PDF copy of the new manual was provided to the authorized audit contacts at all plants in July. Implementation of the new requirements will be effective January 1, 2022. Watch for details about these changes, including a webinar, in My PCI Update, the monthly Education newsletter, and in this certification newsletter.

2021 T. Henry Clark Award Recipient – Carl L. Harris

Revisions to the PCI Plant Certification Program

Revisions to PCI Policy 20 (Plant Certification Program) were approved by PCI’s Board at their September meeting. A copy of the revised policy has been emailed to all certified and applicant plants

The Policy 20 revisions include the following:

1. Section 20.2.1.2 was revised to clarify this provision applies to new clients with new locations.
2. ISO 9001:2015 was relocated from section 20.6.2 to section 20.6.1. It is one of the program standards that is used during the evaluation of plants and needs to be listed in this section.
3. Section 20.7.1 and the definition of Product Category were revised to reflect A1, CA and BA categories ending and the new categories that were implemented 10/1/21.
4. Section/Table 20.8.8, section/Table 20.8.9 and section 20.8.13 were revised to show that NET fees not GROSS fees are used for determining the certification fee during the annual renewal and sales declaration process. Clarification was added in 20.8.13 to note that the term Net Fees is as defined by the Board in the sales declaration process and not in the traditional sense that a business might define net fees.

Specific questions about these changes can be directed to qualityprograms@pci.org.

AC157 (Approved Fabricator Accreditation) Update

PCI and IAS (International Accreditation Service) have a bilateral agreement that enables a PCI-certified plant to leverage their PCI certification toward accreditation by IAS as an approved structural fabricator, in accordance with the IAS AC 157 program. Information about this program can be found on the new IAS AC157 Approved Fabricator Accreditation page on PCI’s website. 

Under PCI’s agreement with IAS, the accreditation is issued by IAS and IAS retains all approval authority for the accreditations issued. PCI performs many of the administrative functions on behalf of IAS. All accreditation fees, program applications, audit reports, corrective action responses and other program documentation flow through PCI. Direct communication between the plant and IAS will be very limited. Once accredited to AC157, plants will see very little difference in their normal processes to maintain PCI certification.

Accreditation as an approved fabricator under the IAS program provides building owners, specifiers, engineers, and architects with the upmost confidence that the fabricator consistently demonstrates competency in manufacturing the highest-quality precast concrete for a wide variety of building and transportation projects. Accreditation also provides building departments with a means to register and approve fabricators.

The added benefit of approved fabricator accreditation differentiates PCI-certified plants from other suppliers and will allow PCI plants to demonstrate clear compliance with Section 1704 of the IBC. This will eliminate the need for continuous special inspection at the fabrication facility, potentially saving time and reducing project costs.

The Audit Score

The numerical scores used to grade PCI plant certification audits occasionally raise questions from participants. A new paper, The Audit Score, has been posted on the PCI website. This paper clarifies the significance of the numerical scores and will hopefully eliminate misunderstandings about them.

QSM Updates for ISO 9001:2015 Requirements

Several plants have recently expressed concerns regarding QSM reviews indicating that their previously approved QSM does not meet ISO 9001:2015 requirements.  These issues have typically been encountered during an audit or when minor updates are made to one section of the QSM, but deficiencies are noted in other sections during the QSM review and approval process. These issues can be understandably frustrating and have resulted from several causes. 

These causes include:

1. The current revision of QSM-1, Preparation Guidelines for a Quality System Manual of a PCI-certified Plant, was issued in April 2018 and a compliance deadline of 6/30/19 was established. In spite of the extended implementation period, well over half of the certified plants submitted their QSM for review within the next 2 months, causing a large backlog. Unfortunately, some of the reviews were apparently not as thorough as they could have been during this initial review period.
2. As with any new task, repetition improves proficiency. While the QSM reviewers were trained in the new QSM requirements, they are now more proficient and detailed in their reviews than they were at the very beginning.
3. Reviewers change. A second or third set of eyes may see something that the initial reviewer missed.

We apologize for these situations and continue to work to improve the quality of all services, including the QSM reviews. Your feedback and understanding are both appreciated.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

FINAL REMINDER!! - Certified Plant and Certified Erector Renewals

All PCI plant and erector certifications will expire June 30, 2021.  The deadline for all PCI-certified plants and certified erectors to return their annual renewal documentation was May 31, 2021. Failure to complete the renewal process by June 30 will result in a lapse of certification. Reminders have been emailed to the designated contacts for the plants and erectors who have not yet submitted the required documentation. Please do not ignore these reminders.

For certified plants, the renewal information includes returning the signed agreements and completion of the online sales declarations. Certified erectors need to submit their signed agreements and complete the online certification and membership renewal form. Questions about renewal status should be directed to qualityprograms@pci.org.

FINAL REMINDER!! - Exceptional Precast Practices Deadline is July 1

The deadline for submitting completed Exceptional Precast Practices (EPP) Program surveys is July 1, 2021. This is a voluntary program specifically designed for continuous quality improvement of precast plants.

Companies that have successfully adopted a path of continuous quality improvement typically exhibit a pattern of reduced costs, improved quality, and expanded capabilities. They show growing sales because they better serve the needs of their clients.

There are a variety of continuous quality improvement tools available, but the EPP program is a tool developed specifically for the precast concrete industry. The EPP program, developed by the Quality Enhancement Committee, offers both a roadmap for improvement efforts and milestones for measuring progress.

Here is how this voluntary program works: Your plant fills out the self-assessment survey for each of the seven sections/modules – Productivity, Personnel, Safety, Field operations, Sales and marketing, Sustainable plant, and Concrete. This process allows your plant to not only benchmark where you are today but also review programs of proven worth that other PCI plants find valuable.

That process allows plant personnel to decide on a roadmap for the future. If this process is managed well, that roadmap becomes the goals and programs for improvement, and it provides the basis for accountability for achievement. Your benchmark score allows your plant to actually measure progress from year to year. There is no minimum score required. This is not a contest. Scores will not be published. There is no overall winner. All participants in this voluntary program seriously win. All participating plants are provided with an annual certificate of participation and are recognized at the PCI Committee Days and Technical Conference.

To participate or to read more about the program, click here to access the Member Resources section of the PCI website. To receive recognition for 2021, completed forms must be returned to PCI by July 1.

Audit Update – Architectural Certification Program

The schedule for the next plant audit cycle (July to December) has been completed, and notification of assigned audit windows is being provided to architectural program producers who have not successfully completed the assessment of their mockup panels to the new program requirements. The schedule has prioritized architectural plants that have not yet met the requirements for the new categories, especially those that were not able to have onsite audits during previous audit cycle(s) due to COVID restrictions.    

PCI-certified plants should be aware of the following:

1.     Renewal certificates issued effective 7/1/21 will still reflect the current categories. The certificates for plants with architectural group certification will be effective for three months, through 9/30/21. New certificates will be issued for the architectural plants reflecting their new categories achieved, effective October 1^st through the balance of the certification year (6/30/22).

2.     Plants that have not met the requirements for the new categories by 10/1/21 will not have certification in the architectural group after that date. This lapse in group certification will last until all requirements are met. Therefore, it is important that plants have the mockup panels ready for the auditor’s review during their audits. As previously outlined, two of these panels can be constructed prior to the audit and one must be completed during the audit (pre-pour inspection, cast, cured, stripped and finished).

3.     If an onsite audit and review of the panels in the producer’s facility is not feasible due to COVID-19 concerns, panels can be made available to the auditor at a mutually agreeable onsite or offsite location that is accessible to the producer and auditor, at the producer’s expense.  The producer will notify PCI and RBA in advance of the audit if they are not accepting visitors and need to coordinate an offsite review.

QSM Updates for ISO 9001:2015 Requirements

Several plants have recently expressed concerns regarding QSM reviews indicating that their previously approved QSM does not meet ISO 9001:2015 requirements.  These issues have typically been encountered during an audit or when minor updates are made to one section of the QSM, but deficiencies are noted in other sections during the QSM review and approval process. These issues can be understandably frustrating to the plant and have resulted from several causes.

These causes include:

1.     The current revision of QSM-1, Preparation Guidelines for a Quality System Manual of a PCI-certified Plant, was issued in April 2018 and a compliance deadline of 6/30/19 was established. In spite of the extended implementation period, well over half of the certified plants submitted their QSM for review within the next 2 months, causing a large backlog. Unfortunately, some of the reviews were apparently not as thorough as they could have been during this initial review period.

2.     As with any new task, repetition improves proficiency. While the QSM reviewers were trained in the new QSM requirements, they are now more proficient and detailed in their reviews than they were at the very beginning.

3.     No one review is exhaustive.  As a QSM is reviewed during audits and revision submissions, a subsequent reviewer may see something that previous reviewers missed.

We apologize for these situations and continue to work to improve the quality of all services, including the QSM reviews. Your feedback and understanding are both appreciated.

New Certificate Template for Certified Plants

There are some changes to the plant certificate for 2021. During PCI’s recent audit of the plant certification program by IAS, IAS required several changes to the template PCI uses for its certificate. The most recognizable change is the separate listing of dates for the Policy 20 certification, which is an annual certification, and the ISO 9001 certification, which is a three-year certification with an annual renewal. Reference was also added to the full description of the PCI certification categories on the PCI website. Please contact qualityprograms@pci.org if you have any questions about these changes.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Quality Talks – Series 3

The Quality Enhancement Committee has released the first three issues for the third series of Quality Talks. The series 3 Quality Talks can be accessed using this link (Series 3 Talks) and include: Prestressing Strand Traceability, Concrete Cover over Reinforcement, and Form Surface Defect Assessments.

The Series 1 talks are also available in Spanish. The translation of the series 2 Talks is in process and should be completed by summer.

These toolbox talks cover a wide range of topics and should be used at least once a month to discuss quality with the production teams. All available topics may not directly relate to every plant’s production practices. Plant personnel are not limited to the topics provided; plants are encouraged to use this format to generate toolbox talks that may relate more directly to their specific needs. 

Plant Certification Renewal for 2021-2022

All producers should have received an email with instructions on how to complete the online sales declaration and their plant certification agreement. Completed forms must be submitted by May 31. This email was sent to the company’s designated CFO/Financial contact. Please note that only the designated CFO/Financial contact has access to the online sales declaration and failure to complete this on time will result in a lapse in a plant’s certification status. For any questions regarding your plant’s certification status, please contact qualityprograms@pci.org.

Producers should have also received a separate email with instructions for completing the Producer Member renewal. This process is just like last year, and this email was sent to the company’s designated Company Administrator. For any questions regarding the designated CFO/Financial contact or Company Administrator, please contact membership@pci.org.

Erector Certification Renewal for 2021-2022

All certified erectors should have received an email from PCI with instructions for completing the online erector certification renewal form, erector certification agreement, and the online Certified Erector Member renewal form. Completed forms are to be submitted by May 31. This email was sent to the company’s designated Company Administrator. The renewal process will be just like last year for producer/erectors. Independent erectors not owned by a PCI producer member will only need to complete one combined form to renew membership and certification, in addition to the erector agreement.

Please note that failure to complete the online erector certification and membership renewals on time will result in a lapse in an erector’s certification status. For any questions regarding your erector’s certification status, please contact qualityprograms@pci.org. For any questions regarding the designated contact for your company, please contact membership@pci.org.

Personnel Certification Management System Update

Development of phase 2 of the Certification Management System (CMS) for personnel certification is nearing completion. Initial testing of the system in production has been completed and requested programming changes are in process. A second set of testing will be performed following these programming changes. The initial phase of the CMS was completed last November and included implementation of online, computer-based exams. This second phase includes online application, proctor selection and registration processes, convenient links to the exam, and for successful candidates, access to their certificates. 

Online, computer-based exams are now being used for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications. There is a new Proctored Online Exam Request Packet that must be used to register for these online exams, until such time as phase 2 of the CMS is implemented. The CFA and CCA certification exams are still in a paper format but will be converted to a multiple-choice, online format in coming months. For CFA and CCA proctored exam requests, please email qualityprograms@pci.org to receive this proctored exam request packet.

Exceptional Precast Practices Deadline is July 1

The deadline for submitting completed Exceptional Precast Practices (EPP) Program surveys is July 1, 2021. This is a voluntary program specifically designed for continuous quality improvement of precast plants.

Companies that have successfully adopted a path of continuous quality improvement typically exhibit a pattern of reduced costs, improved quality, and expanded capabilities. They show growing sales because they better serve the needs of their clients.

There are a variety of continuous quality improvement tools available, but the EPP program is a tool developed specifically for the precast concrete industry. The EPP program, developed by the Quality Enhancement Committee, offers both a roadmap for improvement efforts and milestones for measuring progress.

Here is how this voluntary program works: Your plant fills out the self-assessment survey for each of the seven sections/modules – Productivity, Personnel, Safety, Field operations, Sales and marketing, Sustainable plant, and Concrete. This process allows your plant to not only benchmark where you are today but also review programs of proven worth that other PCI plants find valuable.

That process allows plant personnel to decide on a roadmap for the future. If this process is managed well, that roadmap becomes the goals and programs for improvement, and it provides the basis for accountability for achievement. Your benchmark score allows your plant to actually measure progress from year to year. There is no minimum score required. This is not a contest. Scores will not be published. There is no overall winner. All participants in this voluntary program seriously win. All participating plants are provided with an annual certificate of participation and are recognized at the PCI Committee Days and Technical Conference.

To participate or to read more about the program, click here to access the Member Resources section of the PCI website. To receive recognition for 2021, completed forms must be returned to PCI by July 1.

PCI Company Audits

Company audits conducted to support PCI’s Erector Certification Program are conducted by a group of experienced Certified Company Auditors trained to conduct these types of audits. The qualifications necessary to perform these audits are outlined in the PCI Company Auditor FAQs. If you are interested in learning more about conducting these audits, please review the FAQ document and contact PCI at QualityPrograms@pci.org.

Coil Lifting Systems Webinar

A recording of the Coil Lifting Systems webinar is now available in PCI’s eLearning Center. This webinar discusses the potential safety issues when using coil inserts, coil nuts, coil rods, and coil bolts from different manufacturers. 

Since there is no national standard for the manufacturing of these coil products, there is no guarantee that parts from different manufacturers will work together as intended and designed. The presentation outlines factors that should be considered in the selection and proper use of coil lifting hardware, inserts, and bolts, as well as the items that should be inspected, the attributes that should be reviewed, and the associated inspection methods.

The webinar can be accessed through PCI’s eLearning Center via this link: Coil Lifting Systems Webinar

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Exceptional Precast Practices Deadline is July 1

Companies that have successfully adopted a path of continuous quality improvement typically exhibit a pattern of reduced costs, improved quality, and expanded capabilities. They show growing sales because they better serve the needs of their clients.

There are a variety of tools available, but are you looking for a continuous quality improvement tool developed specifically for the precast concrete industry? The Exceptional Precast Practices (EPP) program, developed by the Quality Enhancement Committee, offers both a roadmap for your efforts and milestones for measuring your progress.

Born out of the QA 2020 Vision Program, the key working committees at PCI have set forth a self-assessment and the process steps that provide both the roadmap and the milestones for continuous improvement.

Here is how it works: Your plant fills out the self-assessment survey for each of the seven sections/modules – Productivity, Personnel, Safety, Field operations, Sales and marketing, Sustainable plant, and Concrete. This process allows your plant to not only benchmark where you are today but also review programs of proven worth that other PCI plants find valuable.

That process allows plant personnel to decide on a roadmap for the future. If this process is managed well, that roadmap becomes the goals and programs for improvement, and it provides the basis for accountability for achievement. Your benchmark score allows your plant to actually measure progress from year to year. There is no minimum score required. This is not a contest. Scores will not be published. There is no overall winner. All participants in this voluntary program seriously win. All participating plants are provided with an annual certificate of participation and are recognized at the PCI Committee Days and Technical Conference.

To participate or to read more about the program, click here to access the Member Resources section of the PCI website. To receive recognition for 2021, completed forms must be returned to PCI by July 1.

Plant Certification Renewal for 2021-22

All producers should have received an email with instructions on how to complete the online sales declaration and their plant certification agreement. This email was sent to the company’s designated CFO/Financial contact. Please note that only the designated CFO/Financial contact has access to the online sales declaration and failure to complete this on time will result in a lapse in a plant’s certification status. For any questions regarding your plant’s certification status, please contact qualityprograms@pci.org.

Additionally, producers will receive a separate email with instructions for completing the Producer Member renewal. This process will be just like last year, and this email will be sent to the company’s designated Company Administrator. For any questions about the designated CFO/Financial contact or Company Administrator, please contact membership@pci.org.

Erector Certification Renewal for 2021-22

All certified erectors should have received an email from PCI with instructions for completing the online erector certification renewal form, erector certification agreement, and the online Certified Erector Member renewal form. This email was sent to the company’s designated Company Administrator. The renewal process will be just like last year for producer/erectors. Independent erectors not owned by a PCI producer member will only need to complete one combined form to renew membership and certification, in addition to the erector agreement.

Please note that failure to complete the online erector certification and membership renewals on time will result in a lapse in an erector’s certification status. For any questions regarding your erector’s certification status, please contact qualityprograms@pci.org. For any questions regarding the designated contact for your company, please contact membership@pci.org.

New Certificate Template for Certified Plants

During our recent audit of the plant certification program by IAS, IAS required several changes to the template PCI uses for its certificate. The most recognizable change is the separate listing of dates for the Policy 20 certification, which is an annual certification, and the ISO 9001 certification, which is a three-year certification with an annual renewal. Reference was also added to the full description of the PCI certification categories on the PCI website. Please contact qualityprograms@pci.org if you have any questions about these changes.

Architectural Certification Program Update

The change in implementation date for the new architectural certification program categories to October 1, 2021, from July 1, 2021, has resulted in several changes to the plant certification renewal process for the 2021-22 certification year. These involve when updated certificates will be issued and the architectural categories that will be reflected on those certificates.

PCI-certified plants should be aware of the following:

1. Renewal certificates issued effective July 1, 2021, will still reflect the current categories. The certificates for plants with architectural group certification will be effective for three months, through September 30, 2021. New certificates will be issued for the architectural plants reflecting their new categories achieved, effective October 1 through the balance of the certification year (June 30, 2022).
2. Plants that have not met the requirements for the new categories by October 1, 2021, will not have certification in the architectural group after that date. Therefore, it is important that plants have the mockup panels ready for the auditor’s review during their audits. As previously outlined, two of these panels can be constructed prior to the audit and one must be completed during the audit (pre-pour inspection, cast, cured, stripped and finished).
3. If an onsite audit and review of the panels in the producer’s facility is not feasible due to COVID-19 concerns, panels can be made available to the auditor at a mutually agreeable onsite or offsite location that is accessible to the producer and auditor, at the producer’s expense.  The producer will notify PCI and RBA in advance of the audit if they are not accepting visitors and need to coordinate an offsite review.

T. Henry Clark Award Nominations Due June 1

Nominations for the T. Henry Clark Award, to be presented during 2021 PCI Committee Days, should be submitted to qualityprograms@pci.org by June 1, 2021. The T. Henry Clark Award nomination form is available at www.pci.org/PCI/About/Awards/Clark.

The T. Henry Clark Award was established to recognize an individual, group of individuals, or firm that has delivered a resource that improves or enhances the quality of precast/prestressed concrete products or processes. T. Henry Clark believed in quality and quality processes, and this award is to recognize those who create or promote quality in a way that would have made him proud.

For more information, contact Gary Wildung, the Quality Activities Council chair, at gary.wildung@fdgcolorado.com or Mike Kesselmayer, PCI managing director of quality programs, at mkesselmayer@pci.org.

PCI Company Audits

Company audits conducted to support PCI’s Erector Certification Program are conducted by a group of experienced Certified Company Auditors trained to conduct these types of audits. The qualifications necessary to perform these audits are outlined in the PCI Company Auditor FAQs. If you are interested in learning more about conducting these audits, please review the FAQ document and contact PCI at QualityPrograms@pci.org.

Online Certification Exams

Online, computer-based exams are now being used for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications. There is a new Proctored Online Exam Request Packet that must be used to register for these online exams. The CFA and CCA certification exams are still in a paper format but will be converted to a multiple-choice, online format in coming months. For CFA and CCA proctored exam requests, please email qualityprograms@pci.org to receive this proctored exam request packet.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Architectural Certification Program Update

The change in implementation date for the new architectural certification program categories to October 1, 2021, from July 1, 2021, has resulted in several changes to the plant certification renewal process for the 2021-22 certification year. These involve when updated certificates will be issued and the architectural categories that will be reflected on those certificates.

PCI-certified plants should be aware of the following:

1. Renewal certificates issued effective July 1, 2021, will still reflect the current categories. The certificates for plants with architectural group certification will be effective for three months, through September 30, 2021. New certificates will be issued for the architectural plants reflecting their new categories achieved, effective October 1 through the balance of the certification year (June 30, 2022).
2. Plants that have not met the requirements for the new categories by October 1, 2021, will not have certification in the architectural group after that date. Therefore, it is important that plants have the mockup panels ready for the auditor’s review during their audits. As previously outlined, two of these panels can be constructed prior to the audit and one must be completed during the audit (pre-pour inspection, cast, cured, stripped and finished).
3. If an onsite audit and review of the panels in the producer’s facility is not feasible due to COVID-19 concerns, panels can be made available to the auditor at a mutually agreeable onsite or offsite location that is accessible to the producer and auditor, at the producer’s expense.  The producer will notify PCI and RBA in advance of the audit if they are not accepting visitors and need to coordinate an offsite review.

PCI Company Audits

Company audits conducted to support PCI’s Erector Certification Program are conducted by a group of experienced Certified Company Auditors trained to conduct these types of audits. The qualifications necessary to perform these audits are outlined in the PCI Company Auditor FAQs. If you are interested in learning more about conducting these audits, please review the FAQ document and contact PCI at QualityPrograms@pci.org.

T. Henry Clark Award Nominations Due June 1

Nominations for the T. Henry Clark Award, to be presented during 2021 PCI Committee Days, should be submitted to qualityprograms@pci.org by June 1, 2021. The T. Henry Clark Award nomination form is available at www.pci.org/PCI/About/Awards/Clark.

The T. Henry Clark Award was established to recognize an individual, group of individuals, or firm that has delivered a resource that improves or enhances the quality of precast/prestressed concrete products or processes. T. Henry Clark believed in quality and quality processes, and this award is to recognize those who create or promote quality in a way that would have made him proud.

For more information, contact Gary Wildung, the Quality Activities Council chair, at gary.wildung@fdgcolorado.com or Mike Kesselmayer, PCI managing director of quality programs, at mkesselmayer@pci.org.

Erector Field Quality Audits

PCI Policy 29, Erector Certification Program, requires that certified erectors submit a Field Quality Audit Report AND an Erectors Post-Audit Declaration for each primary erection crew once each half of the calendar year if that crew erected precast for more than 60 days during the period. Please note that the EPAD is required even if no nonconformances were noted in the FQAR, as the EPAD serves as confirmation that the erector has received and reviewed the FQAR. All FQARs and EPADs should be emailed to audit@pci.org.

Online Certification Exams

Online, computer-based exams are now being used for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications. There is a new Proctored Online Exam Request Packet that must be used to register for these online exams. The CFA and CCA certification exams are still in a paper format but will be converted to a multiple-choice, online format in coming months. For CFA and CCA proctored exam requests, please email qualityprograms@pci.org to receive this proctored exam request packet.

Requirement for Use of PCI-Certified Erectors

The use of PCI-certified Category A erectors will be required effective October 1, 2021 for projects in the new AA, AB and AC architectural categories, for plants certified in those categories. Producers are encouraged to work with their local erectors if they are not PCI-certified, informing them of the new requirements and the benefits of PCI certification.  Certified erectors that do not have certification in Category A should contact Qualityprograms@pci.org for information regarding adding this category.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

T. Henry Clark Award Nominations Due June 1 

Nominations for the T. Henry Clark Award, to be presented during 2021 PCI Committee Days, should be submitted to qualityprograms@pci.org by June 1, 2021. The T. Henry Clark Award nomination form is available at https://www.pci.org/PCI/About/Awards/T_Henry_Clark_Award.

The T. Henry Clark Award was established to recognize an individual, group of individuals, or firm that has delivered a resource that improves or enhances the quality of precast/prestressed concrete products or processes. T. Henry Clark believed in quality and quality processes, and this award is to recognize those who create or promote quality in a way that would have made him proud.

For more information, contact Gary Wildung, the Quality Activities Council chair, at gary.wildung@fdgcolorado.com or Mike Kesselmayer, PCI managing director of quality programs, at mkesselmayer@pci.org.

Erector Field Quality Audits

PCI Policy 29, Erector Certification Program, requires that certified erectors submit a Field Quality Audit Report AND an Erectors Post-Audit Declaration for each primary erection crew once each half of the calendar year if that crew erected precast for more than 60 days during the period. The EPAD is required even if no nonconformances were noted in the FQAR, as the EPAD serves as confirmation that the erector has received and reviewed the FQAR. Copies of the FQARs for the second half of 2020 were to have been submitted no later than January 15. In the event that the crew did not meet the 60-day threshold, a letter to that effect must be submitted. All FQARs, EPADs, and letters should be emailed to audit@pci.org.

Architectural Certification Program Update

The implementation date for the new architectural certification program categories has been changed to October 1, 2021, from the previously planned July 1, 2021. The Architectural Certification Subcommittee made this decision after careful consideration of the COVID-19 pandemic’s impact on plant operations in many regions and on our ability to perform onsite plant audits.  In addition to revising the implementation date, the subcommittee has outlined an alternative option for producers to have their completed mockup panels reviewed when access to a producer’s facility is not feasible.

Producers that are not able to allow visitors for an onsite audit due to COVID concerns may receive a remote audit. Documentation will be electronically shared, and the producer and auditor will use video conferencing to monitor production processes and observe the production of the mockup panel required to be cast in the presence of the auditor. The mockup panels must be reviewed by the auditor in person to appropriately perform visual inspection and verify tolerances. If review of the panels in the producer’s facility is not feasible, panels can be made available to the auditor at a mutually agreeable onsite or offsite location that is accessible to the producer and auditor, at the producer’s expense.  The producer will notify PCI and RBA in advance of the audit if they are not accepting visitors and need to coordinate an offsite review.

The subcommittee determined that delaying the effective date for the new categories by three months was the best course of action for plants experiencing COVID-19 related impact. This delay provides equity and additional time for mockup panel construction and audits for affected plants, allowing the plants additional opportunity to meet program requirements before implementation of the new categories.

Renewal certificates issued effective 7/1/21 will still reflect the current categories. The certificates for plants with architectural group certification will be effective for three months, through 9/30/21. New certificates will be issued for the architectural plants reflecting their new categories achieved, effective October 1^st through the balance of the certification year (6/30/22).

Online Certification Exams

Online, computer-based exams are now being used for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications. There is a new Proctored Online Exam Request Packet that must be used to register for these online exams. The CFA and CCA certification exams are still in a paper format but will be converted to a multiple-choice, online format in coming months. For CFA and CCA proctored exam requests, please email qualityprograms@pci.org to receive this proctored exam request packet.

Requirement for Use of PCI-Certified Erectors

The use of PCI-certified Category A erectors will be required effective 10/1/21 for projects in the new AA, AB and AC architectural categories, for plants certified in those categories. Producers are encouraged to work with their local erectors if they are not PCI-certified, informing them of the new requirements and the benefits of PCI certification.  Certified erectors that do not have certification in Category A should contact qualityprograms@pci.org for information regarding adding this category.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Erector Field Quality Audits

PCI Policy 29, Erector Certification Program, requires that certified erectors conduct a field quality audit for each primary erection crew once each half of the calendar year if that crew erected precast for more than 60 days during the period. Copies of the field quality audits for the second half of 2020 are to be submitted no later than January 15. In the event that the crew did not meet the 60-day threshold, a letter to that effect must be submitted. All field quality audits and letters should be emailed to audit@pci.org.

Architectural Certification Program Update

The implementation date for the new architectural certification program categories has been changed to October 1, 2021, from the previously planned July 1, 2021. The Architectural Certification Subcommittee made this decision after careful consideration of the COVID-19 pandemic’s impact on plant operations in many regions and on our ability to perform onsite plant audits.  In addition to revising the implementation date, the subcommittee has outlined an alternative option for producers to have their completed mockup panels reviewed when access to a producer’s facility is not feasible.

Producers that are not able to allow visitors for an onsite audit may receive a remote audit. Documentation will be electronically shared, and the producer and auditor will use video conferencing to monitor production processes and observe the production of the mockup panel intended to be cast in the presence of the auditor. The mockup panels must be reviewed by the auditor in person to appropriately perform visual inspection and verify tolerances. If review of the panels in the producer’s facility is not feasible, panels can be made available to the auditor at a mutually agreeable onsite or offsite location that is accessible to the producer and auditor, at the producer’s expense.  The producer will notify PCI and RBA in advance of the audit if they are not accepting visitors and need to coordinate an offsite review.

The subcommittee determined that delaying the effective date for the new categories by three months was the best course of action for plants experiencing COVID-19 related impact. This delay provides equity and additional time for mockup panel construction and audits for affected plants, allowing the plants additional opportunity to meet program requirements before implementation of the new categories.

Renewal certificates issued effective July 1, 2021, will still reflect the current categories. The certificates for plants with architectural group certification will be effective for three months, through September 30, 2021. New certificates will be issued for the architectural plants reflecting their new categories achieved, effective October 1 through the balance of the certification year (June 30, 2022).

Schedule for Architectural Certification Audits Released

The schedule for the next audit cycle (January to June) has been completed, and notification of assigned two-week audit windows has been provided to architectural program producers who have not successfully completed the assessment of their mockup panels to the new program requirements. Auditors continue to contact plant personnel approximately two to three weeks prior to the planned audit date to verify if the plant is currently producing product, if the plant is accepting outside visitors, whether there are any regulations that would preclude or impact an audit, and if the plant has implemented any specific safety protocols that would affect the auditor. If an onsite audit cannot be conducted, the auditor will discuss arrangements for performing a remote audit.

Architectural plants that do not yet have approved production drawings and mix designs for the mockup panels are receiving reminder emails. These production drawings and concrete mix designs are to be submitted 45 days in advance of the architectural program audits. These reviews are intended to help assure that the plans for the mockup panels comply with the requirements of the Architectural Certification Program Supplemental Requirements and are for the benefit of the plant. Please submit these, as required, to RBA at kmecheck@rossbryan.com and to PCI at audit@pci.org.

Online Certification Exams

PCI implemented the use of online, computer-based exams for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications in November, as part of the development of the new Personnel Certification Management System (CMS). The CFA and CCA certification exams are still in a paper format but will be converted to a multiple-choice, online format in coming months. Please note that there is a new Proctored Online Exam Request Packet that must be used to register for the online exams.

Registration for proctored exams continues to follow the current “paper” process, pending full deployment of the CMS. Upon successful registration, the certification candidate, selected proctor, and company administrator (in the case that the candidates did not self-register) will receive confirmation emails explaining the process. The PCI website is in the process of being updated to reflect these new procedures. Exams are administered through PCI’s new Learning Management System LMS), which is accessed through PCI’s eLearning Center on the PCI website.

Requirement for Use of PCI-Certified Erectors

The use of PCI-certified Category A erectors will be required effective October 1, 2021, for projects in the new AA, AB and AC architectural categories, for plants certified in those categories. Producers are encouraged to work with their local erectors if they are not PCI-certified, informing them of the new requirements and the benefits of PCI certification.  Certified erectors that do not have certification in Category A should contact Qualityprograms@pci.org for information regarding adding this category.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

New Architectural Certification Program Implementation Date

The implementation date for the new architectural certification program categories has been changed to October 1, 2021, from the previously planned July 1, 2021. The Architectural Certification Subcommittee made this decision after careful consideration of the COVID-19 pandemic’s impact on plant operations in many regions and on our ability to perform onsite plant audits.

Certification in a new architectural category requires the plant to demonstrate their capabilities for their desired category by constructing a series of three mockup panels. In many cases, the pandemic has caused manpower shortages and other related issues, interfering with the plant staff’s ability to complete the mockup panels in time for the audits.  Additionally, the mockup panels cannot be adequately assessed using video or cameras during a remote audit; they must be reviewed during an onsite audit. In many cases, local/regional travel restrictions, plant safety precautions, or COVID outbreaks at plants have precluded the performance of scheduled onsite audits.

To be equitable and provide an opportunity for plants experiencing COVID-related impact to be certified in time for implementation of the new categories, the subcommittee determined the best course of action was to delay the effective date by three months, to allow additional time for mockup panel construction and audits. Renewal certificates issued effective July 1, 2021, will still reflect the current categories. The certificates for plants with architectural group certification will be effective for three months, through September 30, 2021. New certificates will be issued for the architectural plants reflecting their new categories achieved, effective October 1 through the balance of the certification year (June 30, 2022).

Transition to Online Certification Exams

As part of the development of the new Personnel Certification Management System (CMS), PCI has implemented the use of online, computer-based exams for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications. The CFA and CCA certification exams are still in a paper format but will be converted to a multiple-choice, online format in coming months. Please note that there is a new Proctored Online Exam Request Packet that must be used for the online exams.

Registration for proctored exams continues to follow the current “paper” process, pending full deployment of the CMS. Upon successful registration, the certification candidate, selected proctor, and company administrator (in the case that the candidates did not self-register) will receive confirmation emails explaining the process. The PCI website is in the process of being updated to reflect these new procedures. Exams are administered through PCI’s new Learning Management System LMS), which is accessed through PCI’s eLearning Center on the PCI website.

When the CMS is complete, individuals seeking to achieve or renew PCI certification will be able to apply for certification, upload any relevant documents and pay their certification fees through the system. The online certification exam administration results in immediate scoring and test results for the candidates. Although the use of the external proctor system continues, the use of additional administration methods is also being explored.

Individuals will have 24/7 access to their certification records through their individual accounts available via the PCI website and the PCI Mobile APP. There will also be a certification verification feature available to the general public, which will be similar to the system used by ACI. Behind the scenes, all information relative to the certification process, records, and certification decisions will be stored electronically. The CMS implementation is expected to be completed in early 2021.

Copies of Plant and Erector Certificates

Copies of the certificates for PCI-certified plants and erectors are now available to authorized certification contacts through the PCI website. Instructions for accessing the certificates via computer/laptop and via mobile devices/tablets are available on the Plant Certification Policies, Procedures & Logo Usage and the Erector Certification Policies & Procedures pages.

Changes to Policy 28 (Quality Personnel Certification Program)

At its September meeting, the PCI Board of Directors approved a series of changes to PCI’s Quality Personnel Certification Program (Policy 28). These revisions fell generally into one of three categories:

1. Revisions to address cheating and fraudulent acts

2. General reorganization of the document

3. General maintenance, including items that needed clarification, updating or correction

Additional information is available on the Certification Program Changes page on the PCI website.

Plant Audit Update

Onsite audits will be conducted for about 75 percent of plants this audit cycle (July to December). Current plans are to continue performing onsite audits where possible, but we are monitoring the impact of the pandemic with a focus on safety for all involved and will make changes if appropriate. The schedule for the next audit cycle (January to June) is almost complete and those architectural plants that have not yet been approved for their new certification category will receive their two-week audit window in coming weeks. 

Auditors are contacting plant personnel approximately two to three weeks prior to the planned audit date to verify that the plant is currently producing product, if the plant is accepting outside visitors, whether there are any regulations that would preclude or impact an audit, and if the plant has implemented any specific safety protocols that would affect the auditor. If an onsite audit cannot be conducted, the auditor will discuss arrangements for performing a remote audit.

For plants seeking certification to the new architectural precast concrete categories and constructing mockup panels… The mockup panels cannot be adequately assessed using video or cameras during a remote audit. Consequently, these mockup panels need to be reviewed during an onsite audit. Also, the auditor will review any panels that are complete as well as the panel that is required to be cast and processed during an onsite audit. It is not necessary to have all three panels complete prior to the auditor’s review. Any remaining panels can be reviewed during the next audit, but all three must be approved prior to being certified in the new category.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Transition to Online Certification Exams

As part of the development of the new Personnel Certification Management System (CMS), transition to the use of online, computer-based exams will be implemented during the week of November 16. The online exam administration will provide an improved grading process (eliminating the need for faxing, mailing or emailing exams and answer sheets), provide immediate results to the examinee, and facilitate better oversight of the entire examination process. The exams for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications have been incorporated into the new system; the CFA and CCA certification exams will be converted to a multiple-choice format and will follow in coming months.

The new Certification Management System (CMS) will complement the recently deployed new Learning Management System (LMS). The LMS is accessed through PCI’s eLearning Center and is used to house and administer all education activities, including education courses, webinars, as well as individual training records. The goals of the new CMS are to provide easier access to all aspects of the certification system, streamline processes, and eliminate the need for paper, including paper-based, written exams.

When complete, individuals seeking to achieve or renew PCI certification will be able to apply for certification, upload any relevant documents and pay their certification fees through the system. Online certification exam administration will result in immediate scoring and test results for the candidates. The use of the external proctor system will continue, although the use of additional administration methods is also being explored.

Individuals will have 24/7 access to their certification records through their individual accounts available via the PCI website and the PCI Mobile APP. There will also be a certification verification feature available to the general public, which will be similar to the system used by ACI. Behind the scenes, all information relative to the certification process, records, and certification decisions will be stored electronically. The CMS implementation is expected to be completed by the end of the year.

Designer Resources – Architectural Certification Program

The Architectural Certification Subcommittee is developing various resources to assist the design community in understanding and implementing the new architectural certification program categories. These resources will be made available in the Designer Resources section of the Architectural Certification Program page on the PCI website. Producers may also find these useful as they explain the changes to their clients.

Several resources are currently available:

• The first of these resources, PCI Industry Frequently Asked Questions has been posted on the website.
• A presentation discussing the new categories has been presented on three separate occasions to the design industry. This webinar, How Precast Builds: PCI Architectural Certification Program is available for any producer member to view in the eLearning Center. The course can then be downloaded. For producers wishing to give the presentation, a direct link to a dropbox folder can be obtained by emailing a request to marketing@pci.org.
• The PCI Architectural Certification Program brochure has been completed and is available as a PDF download on the website.
• PCI’s Architectural Record Innovation Conference Architectural Precast Concrete education session is available to watch on the Architectural Record continuing education center. 

Additional resources are in development. Be sure to check the website frequently for additional resources.

Requirement for Use of PCI-Certified Erectors

Per the Architectural Certification Program Supplemental Requirements, the use of PCI-certified Category A erectors will be required effective July 1, 2021, for projects in the new AA, AB, and AC architectural categories, for plants certified in those categories. Producers are encouraged to work with their local erectors if they are not PCI-certified, informing them of the new requirements and the benefits of PCI certification.

Plant Audit Update

Onsite plants audits are currently being conducted for most plants. Auditors are contacting plant personnel approximately two to three weeks prior to the planned audit date, to verify that the plant is currently producing product, if the plant is accepting outside visitors, whether there are any regulations that would preclude or impact an audit, and if the plant has implemented any specific safety protocols that would affect the auditor. If an onsite audit cannot be conducted, the auditor will discuss arrangements for performing a remote audit.

For plants seeking certification to the new architectural precast concrete categories and constructing mockup panels… The mockup panels cannot be adequately assessed using video or cameras during a remote audit. Consequently, these mockup panels will need to be reviewed during an onsite audit, in the next audit cycle. Also, the auditor will review any panels that are complete or are cast during the audit. It is not necessary to have all three panels complete prior to the auditor’s review. Any remaining panels can be reviewed during the next audit.

Architectural Certification Program Notes

Be sure to use the most current revision of the Architectural Certification Program Supplemental Requirements document when developing production drawings and mix designs for construction of the mockup panels for the new certification categories. The current revision of this document is June 2020.

As a reminder to all architectural plants – Production drawings and concrete mix designs for the mockup panels are to be submitted at least 45 days in advance of the architectural program audits. Plants are encouraged to submit these as soon as possible to maximize the time for review of the documents, incorporation of any needed revisions, and fabrication of the panels. These reviews are intended to help assure that the plans for the mockup panels comply with the requirements of the Architectural Certification Program Supplemental Requirements and are for the benefit of the plant. Please submit these to RBA at kmecheck@rossbryan.com and to PCI at audit@pci.org.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Coil Lifting Systems Webinar

The Coil Lifting Systems webinar, which was presented live to over 500 attendees in July, was recorded and is now available in PCI’s eLearning Center. This webinar discusses the potential safety issues when using coil inserts, coil nuts, coil rods, and coil bolts from different manufacturers.

Since there is no national standard for the manufacturing of these coil products, there is no guarantee that parts from different manufacturers will work together as intended and designed. The presentation outlines factors that should be considered in the selection and proper use of coil lifting hardware, inserts, and bolts, as well as the items that should be inspected, the attributes that should be reviewed, and the associated inspection methods.

Access the webinar through PCI’s eLearning Center via this link: Coil Lifting Systems Webinar

New LMS Deployed, New CMS in Process

Development of a new Certification Management System (CMS) to complement the recently deployed new Learning Management System (LMS) is in process. The LMS is accessed through PCI’s eLearning Center and is used to house and administer all education activities, including education courses, Quality Control sessions, and webinars, as well as individual training records. The goals of the new CMS are to provide easier access to all aspects of the certification system, streamline processes, and eliminate the need for paper, including paper-based, written exams.

Transition to the use of online, computer-based exams for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications is expected to be implemented in early November. The online exam administration will provide an improved grading process (eliminating the need for faxing, mailing or emailing exams and answer sheets), provide immediate results to the examinee, and facilitate better oversight of the entire examination process. The CFA and CCA certification exams, which will be revised and converted to a multiple-choice format, will follow in coming months. The balance of the CMS is expected to be completed by the end of the year.

When complete, individuals seeking to achieve or renew PCI certification will be able to apply for certification, upload any relevant documents and pay their certification fees through the system. Certification exams will be converted to electronic format and will be administered online. This will result in immediate scoring and test results for the candidates. The use of the external proctor system will continue, although the use of additional administration methods is also being explored.

Individuals will have 24/7 access to their certification records through their individual accounts available via the PCI website. There will also be a certification verification feature available to the general public, which will be similar to the system used by ACI. Behind the scenes, all information relative to the certification process, records, and certification decisions will be stored electronically.

Requirement for Use of PCI-Certified Erectors

Per the Architectural Certification Program Supplemental Requirements, the use of PCI-certified Category A erectors will be required effective July 1, 2021, for projects in the new AA, AB, and AC architectural categories, for plants certified in those categories. Producers are encouraged to work with their local erectors if they are not PCI-certified, informing them of the new requirements and the benefits of PCI certification.

Plant Audit Update

Onsite plants audits are currently being conducted for most plants. Auditors are contacting plant personnel approximately two to three weeks prior to the planned audit date, to verify that the plant is currently producing product, if the plant is accepting outside visitors, whether there are any regulations that would preclude or impact an audit, and if the plant has implemented any specific safety protocols that would affect the auditor. If an onsite audit cannot be conducted, the auditor will discuss arrangements for performing a remote audit.

For plants seeking certification to the new architectural categories and constructing mockup panels… The mockup panels cannot be adequately assessed using video or cameras during a remote audit. Consequently, these mockup panels will need to be reviewed during an onsite audit, in the next audit cycle. Also, the auditor will review any panels that are complete or are cast during the audit. It is not necessary to have all three panels complete prior to the auditor’s review. Any remaining panels can be reviewed during the next audit.

Architectural Certification Program Notes

Be sure to use the most current revision of the Architectural Certification Program Supplemental Requirements document when developing production drawings and mix designs for construction of the mockup panels for the new certification categories. The current revision of this document is June 2020.

As a reminder to all architectural plants, production drawings and concrete mix designs for the mockup panels are to be submitted at least 45 days in advance of the architectural program audits. Plants are encouraged to submit these as soon as possible to maximize the time for review of the documents, incorporation of any needed revisions, and fabrication of the panels. These reviews are intended to help assure that the plans for the mockup panels comply with the requirements of the Architectural Certification Program Supplemental Requirements and are for the benefit of the plant. Please submit these, as required, to RBA at kmecheck@rossbryan.com and to PCI at audit@pci.org.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Changes to Policy 20 (PCI Plant Certification Program)

At its June meeting, the PCI Board of Directors approved a change to PCI’s Plant Certification Program, which involves the thresholds for determining the number of audit days a plant will receive each year.  

The number of audit days for each plant is based upon the annual sales volume for the plant’s prior fiscal year, as provided in their Sales Declaration. Previously, plants with annual sales of less than $3 million received two 1-day audits. Plants with annual sales of $3 million to $6 million received one 1-day audit and one 2-day audit. Plants with sales in excess of $6 million received two 2-day audits. Those thresholds have been revised to $6 million and $13 million, respectively. These changes were effective with the audit cycle that started July 1, 2020.

A full copy of the revised Policy 20 was emailed to all plants in late July.

Spanish Translation of PCI Quality Talks Now Available

Series 1 of the PCI Quality Toolbox Talks has been translated into Spanish and is now available in the Quality Assurance Resources section of the PCI website.

Modelled after the more familiar plant safety toolbox talks, these Quality Talks are intended to reinforce best quality practices in the plant. The talks are short and include a variety of relevant topics. There are currently two 12-topic series of talks, with a third series being developed. Series 1 has been translated into Spanish to reach a broader audience within PCI plants.

New LMS Deployed, New CMS in Process

PCI recently deployed a new Learning Management System (LMS) through PCI’s eLearning Center. The LMS will be used to house and administer all education activities, including many education courses, Quality Control sessions, webinars, and more. Individual training records will also accessible through this system. Access to the LMS is available through the eLearning Center link on PCI’s website: eLearning Center. PCI is also developing a new Certification Management System (CMS) that will complement the LMS.

The goals of the new CMS are to provide easier access to all aspects of the certification system, streamline processes, and eliminate the need for paper. When complete, individuals seeking to achieve or renew PCI certification will be able to apply for certification, upload any relevant documents and pay their certification fees through the system. Certification exams will be converted to electronic format and will be administered online. This will result in immediate scoring and test results for the candidates. The use of the external proctor system will continue, although the use of additional administration methods is also being explored.

Individuals will have 24/7 access to their certification records through their individual accounts available via the PCI website. There will also be a certification verification feature available to the general public, which will be similar to the system used by ACI. Behind the scenes, all information relative to the certification process, all records, and certification decisions will be stored electronically.

Administration of online exams for the Level 1, Level 2, Level 3, and GFRC QC Technician/Inspector certifications are expected to be implemented by the end of September. The CFA and CCA certification exams will follow in coming months. The balance of the system will be completed by the end of the year.

Architectural Certification Program Notes

Be sure to use the most current revision of the Architectural Certification Program Supplemental Requirements document when developing production drawings and mix designs for construction of the mockup panels for the new certification categories. The current revision of this document is June 2020.

As a reminder to all architectural plants – Production drawings and concrete mix designs for the mockup panels are to be submitted at least 45 days in advance of the architectural program audits. Plants are encouraged to submit these as soon as possible to maximize the time for review of the documents, incorporation of any needed revisions, and fabrication of the panels. These reviews are intended to help assure that the plans for the mockup panels comply with the requirements of the Architectural Certification Program Supplemental Requirements and are for the benefit of the plant. Please submit these, as required, to RBA at kmecheck@rossbryan.com and to PCI at audit@pci.org.

Policy 20 Clarification

The Plant Certification Committee recently reviewed the requirements of section 20.7.2 of Policy 20 (PCI Plant Certification Program), which reads: “A plant must be Certified in all Product Groups and in applicable Categories in which the plant intends to produce and for which the Plant Auditor(s) determines they are eligible.” The committee clarified that this provision would apply to a precast plant certified for conventional reinforcing only (categories B1 or C1) that starts producing prestressed product. In this case, the plant would need to be certified in category B2 to B4 or C2 to C4, as appropriate. Similarly, a plant that is producing products for a project that specifies architectural products would need architectural group certification.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

DEADLINE EXTENDED - Exceptional Precast Practices Deadline is July 30

The deadline for participating in the Exceptional Precast Practices (EPP) Program has been extended to July 30. If you planned on completing and submitting the EPP worksheets for your plant but have not yet done so, please submit them to qualityprograms@pci.org by the new deadline.

The EPP Program is a voluntary program for PCI producer member plants, developed by the Quality Enhancement Committee, intended to help improve the quality of their operations. Additional information concerning the program and the program materials are available on the Quality Assurance Resources page on PCI’s website by using this link: Quality Assurance Resources Page (You will need to log in to the Members Resources page to be able to access this page.)

Companies that have successfully adopted a path of continuous quality improvement typically exhibit a pattern of reduced costs, improved quality, and expanded capabilities. They show growing sales because they better serve the needs of their clients.

There are a variety of tools available, but are you looking for a continuous quality improvement tool developed specifically for the precast concrete industry? The Exceptional Precast Practices (EPP) program, developed by the Quality Enhancement Committee, offers both a roadmap for your efforts and milestones for measuring your progress.

Here is how it works: Your plant fills out the self-assessment survey for each of the seven sections/modules – Productivity, Personnel, Safety, Field operations, Sales and Marketing, Sustainable Plant, and Concrete. This process allows your plant to not only benchmark where you are today but also review programs of proven worth that other PCI plants find valuable.

That process allows plant personnel to decide on a roadmap for the future. If this process is managed well, that roadmap becomes the goals and programs for improvement, and it provides the basis for accountability for achievement. Your benchmark score allows your plant to actually measure progress from year to year. There is no minimum score required. This is not a contest. Scores will not be published. There is no overall winner. All participants in this voluntary program seriously win. All participating plants are provided with an annual certificate of participation and are recognized at the PCI Committee Days and Technical Conference.

To participate or to read more about the program, click here to access the Member Resources section of the PCI website. To receive recognition for 2020, returned completed forms to PCI by July 30.

Updated Plant and Erector Certificates

The 2020-21 certificates for PCI-certified plants and erectors are available online at the PCI website. There are two ways the renewed certificates can be accessed - either by using a desktop computer or by downloading the PCI mobile app, available in your App Store. Once logged into the PCI website, a blue “Certificate” button should be visible on your profile page. If you have trouble accessing your certificate(s), please email QualityPrograms@pci.org for assistance.

Erector Field Quality Audits

PCI Policy 29, Erector Certification Program, requires that certified erectors conduct a field quality audit for each primary erection crew once each half of the calendar year if that crew erected precast for more than 60 days during the period. Copies of the field quality audits for the first half of 2020 were to be submitted no later than July 15. In the event that the crew did not meet the 60-day threshold, a letter to that effect must be submitted. Email all field quality audits and letters to Qualityprograms@pci.org.

Update on Status of Plant Audits

Onsite plants audits resumed effective July 1, with the goal of performing as many audits as possible in the plants during the July to December cycle. Of course, the scheduling and planning for these audits is sensitive to local travel restrictions and other mandated safety precautions, for the protection of both the plant and audit staff. We also recognize that some plants are not allowing outside personnel into their facilities or have implemented other plant-specific precautions. These safety concerns have resulted in several changes to our processes.

PCI’s plant certification audits are almost always unannounced. During this audit cycle, however, auditors will be contacting all plants several weeks in advance of their audits. The purpose of these calls is to determine if the plant is open to non-plant employees and to ascertain if there are any state or local safety mandates or plant-specific protocols that must be followed. All plant staff are requested to please provide full information to the auditors when they are contacted. This is important to the safety of all involved and to the success of the audit program. Additionally, architectural plants that will not have their mockup panels constructed for review during this cycle should convey that information to the auditor. In some cases, that may change the planned duration of the audit.   

If it is not feasible to perform an on-site audit at the plant, the auditor will discuss arrangements for a remote audit. The scope of this audit will depend upon whether the plant’s most recent audit was remote or was onsite. If the prior audit was a remote audit, the auditor will discuss options for allowing review of production processes and product in storage.

Update on Status of Erector Audits

Implementation of the remote audit process for certified erectors was initiated in June. Certified erectors should expect to be contacted by their assigned company auditors in the coming weeks. It is expected that this will be our primary process for completing these company audits for the near future, while we are affected by the COVID-19 pandemic. While not the preferred format, these audits are very document review-centric and this format lends us the flexibility to get these accomplished during the travel restrictions.

Architectural Certification Program Notes

There have been several inquiries about the review of the formwork for the mockup panels to be constructed for the new Architectural Certification Program audits. Two of the panels are to be constructed in advance of the audit. The forms for these two panels do NOT need to be retained for review by the auditor during the audit. The third mockup panel will be cast, cured, stripped and finished during the audit, so the forms for this panel will necessarily be reviewed during the audit.

As a reminder to all architectural plants, production drawings and concrete mix designs for the mockup panels are to be submitted at least 45 days in advance of the architectural program audits. Plants are encouraged to submit these as soon as possible to maximize the time for review of the documents, incorporation of any needed revisions, and fabrication of the panels. These reviews are intended to help assure that the plans for the mockup panels comply with the requirements of the Architectural Certification Program Supplemental Requirements and are for the benefit of the plant. Please submit these, as required, to RBA at kmecheck@rossbryan.com and to PCI at audit@pci.org.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

FINAL REMINDER!! - Certified Plant and Certified Erector Renewals

All PCI plant and erector certifications will expire June 30, 2020. The deadline for all PCI-certified plants and certified erectors to return their annual renewal documentation was May 31, 2020. For certified plants, this includes the signed contracts and sales declarations. Certified erectors need to submit their signed contracts and Certification Renewal forms. Reminders have been emailed to the designated contacts for the plants and erectors who have not yet submitted the required documentation. Please do not ignore these reminders. Questions about renewal status should be directed to qualityprograms@pci.org.

Mockup Panel FAQs

As production drawings are being developed for the mockup panels, various questions have been submitted seeking clarification on the mockup panel details and the requirements of the new categories, as outlined in the Architectural Certification Program Supplemental Requirements. These questions and their associated answers have been published as a series of PCI Producer Frequently Asked Questions, which has been posted on the architectural program page of PCI’s website. Plant staff are encouraged to review this resource if they have questions associated with the construction of the mockup panels.   

Precast Concrete Mix Design Training Course

The PCI Concrete Mix Design Training Program will be offered online in a series of modules on July 8, 9 and 10, 2020. This course is intended to assist plants in meeting the QC personnel requirements for categories AA and AB in the revised Architectural Certification Program, if they do not have a PCI Level 3 QC Technician on staff. More information about the course and a link to register for the course is available at the following link: PCI Concrete Mix Design Training Course.

Update on Status of Plant and Erector Audits

The remote audit process continues to be the primary means of conducting plant audits while we are impacted by COVID-19. Similarly, a remote audit process has been developed and implemented for company audits of certified erectors. Initial feedback has been that the remote audit process is working to bridge the gap until we can fully resume onsite audits. Thank you for your cooperation. We realize that these audits are not the norm and appreciate your understanding and assistance, especially when you are dealing with your own COVID-19 issues at your businesses.

We have initiated a very limited resumption of in-plant audits. This is a very “soft” opening with audits of some plants within driving distance of Nashville. Scheduling and planning for these audits is sensitive to local travel restrictions and other mandated safety precautions, for the protection of both the plant and audit staff. The Architectural Certification Subcommittee will be considering options for performing architectural program audits and implementation of the new certification categories, in the event that a full schedule or audits cannot be implemented for all plants on July 1 as planned.

Implementation of the remote audit process for certified erectors was initiated last week. Certified erectors should expect to be contacted by their assigned company auditors in the coming weeks. It is expected that this will be our primary process for completing these company audits for the near future, while we are affected by the COVID-19 pandemic. While not the preferred format, these audits are very document review-centric and this format lends us the flexibility to get these accomplished during the travel restrictions.

Architectural Certification Program Updates

There are three important updates for the architectural program. First, the audit schedule for the new architectural program has been completed and notifications of the two-week audit windows have been distributed to those plants that submitted applications to the new program categories. These audits are currently scheduled to begin July 1^st. Obviously, adjustments will be made as circumstances dictate. Producers are asked to confirm receipt of the schedule notification, if they have not already done so.

Second – As plant staff continue review the mockup panel drawings and submit requests for information on the details, the necessity for several clarifications to the details has become evident. These updated details are contained in Revision 2 (dated June 2020) of the Architectural Certification Program Supplemental Requirements. The Revision Log describing the changes is on page vii.

Finally, as a reminder to all architectural plants – Production drawings and concrete mix designs for the mockup panels are to be submitted 45 days in advance of the architectural program audits. Plants are encouraged to submit these as soon as possible to maximize the time for review of the documents, incorporation of any needed revisions, and fabrication of the panels. These reviews are intended to help assure that the plans for the mockup panels comply with the requirements of the Architectural Certification Program Supplemental Requirements and are for the benefit of the plant. Please submit these, as required, to RBA at kmecheck@rossbryan.com and to PCI at audit@pci.org.

FINAL REMINDER: Exceptional Precast Practices Deadline is July 1

Companies that have successfully adopted a path of continuous quality improvement typically exhibit a pattern of reduced costs, improved quality, and expanded capabilities. They show growing sales because they better serve the needs of their clients.

There are a variety of tools available, but are you looking for a continuous quality improvement tool developed specifically for the precast concrete industry? The Exceptional Precast Practices (EPP) program, developed by the Quality Enhancement Committee, offers both a roadmap for your efforts and milestones for measuring your progress.

Born out of the QA 2020 Vision Program, the key working committees at PCI have set forth a self-assessment and the process steps that provide both the roadmap and the milestones for continuous improvement.

Here is how it works: Your plant fills out the self-assessment survey for each of the seven sections/modules – Productivity, Personnel, Safety, Field operations, Sales and marketing, Sustainable plant, and Concrete. This process allows your plant to not only benchmark where you are today but also review programs of proven worth that other PCI plants find valuable.

That process allows plant personnel to decide on a roadmap for the future. If this process is managed well, that roadmap becomes the goals and programs for improvement, and it provides the basis for accountability for achievement. Your benchmark score allows your plant to actually measure progress from year to year. There is no minimum score required. This is not a contest. Scores will not be published. There is no overall winner. All participants who participate in this voluntary program seriously win. All participating plants are provided with an annual certificate of participation and are recognized at the PCI Committee Days and Technical Conference.

To participate or to read more about the program, access PCI Member Resources. To receive recognition for 2020, completed forms must be returned to PCI by July 1.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.

Plant Certification Audit Update

As previously announced, all in-plant audits of PCI-certified plants were suspended until May 18.  After reviewing the current situation regarding the COVID-19 pandemic, we have decided to begin a very limited resumption of in-plant audits. This will be a very “soft” opening with audits of some plants within driving distance of Nashville. These will be sensitive to local travel restrictions and other mandated safety precautions, for the protection of both the plant and audit staff.

In the meantime, we have implemented our process for performing remote audits in lieu of in-plant audits, while we are impacted by COVID-19. As of May 15, almost 50 remote audits had been scheduled for May and June. Thank you for your cooperation. We realize that these audits are not the norm and appreciate your understanding and assistance, especially when you are dealing with your own COVID-19 issues at your plants. We anticipate the great majority of the remaining audits through the end of June will be conducted remotely.

Erector Certification Audit Update

All company audits of certified erectors were suspended in mid-March. A procedure for conducting remote audits while companies are impacted by the COVID-19 pandemic is being developed and is expected to be implemented within the next few weeks. 

Schedule for Architectural Certification Audits Released

The audit schedule for the new architectural program has been completed and notifications of the two- week audit windows will be distributed to those plants that submitted applications to the new program categories, beginning the week of May 18. These audits are currently scheduled to begin July 1st. Obviously, adjustments will be made as circumstances dictate.

As a reminder to all architectural plants, production drawings and concrete mix designs for the mockup panels are to be submitted 45 days in advance of the architectural program audits. We realize that this will be a very tight time frame for those plants scheduled for July but encourage plants to submit these as soon as possible. These reviews are intended to help assure that the plans for the mockup panels comply with the requirements of the Architectural Certification Program Supplemental Requirements and are for the benefit of the plant. Please submit these, as required, to RBA at kmecheck@rossbryan.com and to PCI at audit@pci.org.

Request for Architectural Precast Concrete Photos

PCI needs your help to make the rollout of the new PCI Architectural Certification Program a big success. This is also great opportunity to have your precast concrete projects and companies be featured in publicity and resources which thousands of people will see the next several months.

PCI is looking for producers to provide images of representative architectural precast concrete that can be used in a series of presentations, publications, marketing collateral, and much more for the new architectural categories. These images can be of various types and complexities of architectural panels. While we appreciate photos of completed projects, we especially desire orthogonal views of individual panels.

We are seeking photos demonstrating facets of each of the new categories:

• AA: Architectural products with multiple concrete mixtures and textures in extremely unique projects. Extremely unique projects that include complex geometry and surface profiles  Projects that may require extremely tight tolerances for material interfaces
• AB: Projects that have three-dimensional surface profiles such as bullnoses, cornices, radii, and integral returns. Projects that have multiple concrete mixes and/or surface finishes,  stone, ceramic, tile, or terra cotta veneers
• AC: Plants producing products with architectural finishes such as cladding and wall panels with plant-applied finishes, including brick veneers and formliners.
• AD: Plants producing structural products with an architectural finish such as wall panels with plant-applied finishes, including structural products with brick veneers and formliners or extruded profiles.  
• AT: Plants producing architectural trim products such as copings and lintels with plant-applied finishes. 

Please complete the image license request form for any images provided. For more information, email Becky King at bking@pci.org.

Plant and Erector Certification Renewals Due May 31

REMINDER - The deadline for all PCI-certified plants and certified erectors to return their annual renewal documentation is May 31, 2020.  For certified plants, this includes submitting signed contracts and completing he online sales declaration process. For certified erectors, this includes submitting signed contracts and completing the online certification renewal form. The designated contact for all certified plants and erectors should have received an email with instructions on how to complete these processes. Please note that failure to complete these renewals on time will result in a lapse in certification. For any questions regarding certification status, please contact qualityprograms@pci.org. For any questions regarding the designated contact, please contact membership@pci.org.

Exceptional Precast Practices Deadline is July 1

Companies that have successfully adopted a path of continuous quality improvement typically exhibit a pattern of reduced costs, improved quality, and expanded capabilities. They show growing sales because they better serve the needs of their clients.

There are a variety of tools available, but are you looking for a continuous quality improvement tool developed specifically for the precast concrete industry? The Exceptional Precast Practices (EPP) program, developed by the Quality Enhancement Committee, offers both a roadmap for your efforts and milestones for measuring your progress.

Born out of the QA 2020 Vision Program, the key working committees at PCI have set forth a self-assessment and the process steps that provide both the roadmap and the milestones for continuous improvement.

Here is how it works: Your plant fills out the self-assessment survey for each of the seven sections/modules – Productivity, Personnel, Safety, Field operations, Sales and marketing, Sustainable plant, and Concrete. This process allows your plant to not only benchmark where you are today but also review programs of proven worth that other PCI plants find valuable.

That process allows plant personnel to decide on a roadmap for the future. If this process is managed well, that roadmap becomes the goals and programs for improvement, and it provides the basis for accountability for achievement. Your benchmark score allows your plant to actually measure progress from year to year. There is no minimum score required. This is not a contest. Scores will not be published. There is no overall winner. All participants who participate in this voluntary program seriously win. All participating plants are provided with an annual certificate of participation and are recognized at the PCI Committee Days and Technical Conference.

To participate or to read more about the program, access PCI Member Resources. To receive recognition for 2020, completed forms must be returned to PCI by July 1.

T. Henry Clark Award Nominations Due June 1

Nominations for the T. Henry Clark Award, to be presented during the 2020 PCI Committee Days, September 22–25, 2020, should be submitted to qualityprograms@pci.org by June 1, 2020. View the T. Henry Clark Award Nomination Form.

The T. Henry Clark Award was established to recognize an individual, group of individuals, or firm that has delivered a resource that improves or enhances the quality of precast/prestressed concrete products or processes. T. Henry Clark believed in quality and quality processes, and this award is to recognize those who create or promote quality in a way that would have made him proud.

For more information, contact Gary Wildung, the Quality Activities Council chair, at gary.wildung@fdgcolorado.com or Mike Kesselmayer, PCI managing director of quality programs, at mkesselmayer@pci.org.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Mike Kesselmayer at mkesselmayer@pci.org.