Plant Certification

PCI’s Plant Certification Program ensures that each plant has developed and documented an in-depth, in-house quality system based on time-tested, national industry standards. Each plant undergoes two thorough, unannounced audits each year. They are conducted by third-party engineers who inspect the plant according to requirements specifically targeted to the products being manufactured at that location.

Precasting plants can be certified in as many as four product groups:
Group A—Architectural Products;
Group B and BA—Bridge Products;
Group C and CA—Commercial (Structural) Products; and
Group G—Glass-Fiber-Reinforced Concrete (GFRC) Products.

PCI Certified plants are audited in accordance with standards published in three PCI quality-control manuals (MNL-116, MNL-117, and MNL-130).

PCI's plant certification program as compared to those offered by the National Precast Concrete Association (NPCA) and the Architectural Precast Association (APA):
 
Criterion PCI NPCA APA This criterion is important because:

Structural products (prestressed)—established 5 years or more
√
  
  • Established, proven experience demanded by the construction industry.
  • High structural capacity, long-term durability, and serviceability of both conventionally reinforced and prestressed concrete products, all of which are directly influenced by the manufacturer’s quality and production operations.
  • Prestressing operations are performed by properly trained plant personnel supervised by certified quality-control personnel.

Precast concrete product
(conventional reinforcement)
√
√
  • High-quality manufacturing of conventionally reinforced products, which are often nonstructural and nonarchitectural in nature.
  • Avoidance of high repair and/or replacement costs for products that are placed underground.

Architectural precast concrete
√
√
  • More stringent tolerance and appearance requirements for architectural precast concrete products than for conventional or structural precast concrete products.
  • Architectural precast concrete products that not only look good, but are manufactured to maximize long-term durability and desired function.

P.E. inspection/oversight
√
√
√
  • Verifiable proof, provided by professional engineering registration, of a minimum level of competence, experience, and education.

All inspections unannounced
√
√
  • A more accurate measure of a plant’s routine compliance with required quality operations and manufacturing practices, leading plants to maintain constant vigilance and a strong focus on quality.

Minimum 2 inspections per year
√
√
  • Ongoing compliance with quality and manufacturing requirements.
  • A plant quality system that incorporates the latest techniques and is operating properly on a regular basis.

Clearly defined product certification categories
√
√
  • Clear identification of plants that are equipped and prepared to fulfill project product requirements.
  • Increased assurance that you will receive products ideally suited to your project.
  • Recognition of each producer’s specific strengths.

Approval of plant QC manual
√
√
  • Review and approval of a plant’s internal quality manual prior to conducting an audit to verify that a plant has addressed all of the critical factors throughout the quality system.
  • A quality manual that clearly addresses each product group and category that the plant manufactures.

Mandatory for PCI
Producer Members
√
  • Mandatory participation for members, which indicates that an organization truly believes in and supports quality in the industry.
  • All members’ plants are operated with established processes and professionalism because their organization requires certification as a prerequisite for membership.

Personnel certification
√
  • Properly trained plant personnel, who are critical to ensuring production of high-quality precast concrete products.
  • Verifiable proof of proper personnel training, which creates a positive credential that can be used in job advancement.
  • Expiration dates for personnel training and certification, requiring periodic recertification with verification of qualifications and competence assessments.

Field certification
√
  • Extension of the demanding quality standards required with plant certification to the process of erecting the finished precast concrete components at the site.
  • Erection to nationally recognized standards.
  • Assurance that the structure will be built as designed.

Technical manuals
√
  • A continuing foundation of technical knowledge for both manufacturing and designing with precast/prestressed concrete components, provided by technical manuals developed by professional members and supplemented by research and development projects.
  • Substantial advancements in casting, design, and erection techniques that aid everyone on the construction team.

Quality-control (QC) manuals
√
√
√
  • Exposure to detailed and comprehensive quality-control manuals that provide the basis for proper personnel training and each plant’s manufacturing and quality operations, with specific information to ensure uniform interpretation of both requirements and supplemental commentary.
         

© 2008 Precast/Prestressed Concrete Institute