REMINDER - Erector Field Quality Audits Due July 15

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. Copies of the FQARs for the first half of 2023 are due July 15. If 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.  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.

New Field Quality Audit Report Form Issued

The Field Quality Audit Report (FQAR) and Erectors Post-Audit Declaration (EPAD) forms have been updated and are to be used for all erector field audits. 

The new FQAR and EPAD forms are now available on the PCI website and their use is to be implemented immediately. Additionally, copies will be emailed to all CFAs and certified erectors, notifying them of the change.

Although the use of the new forms is effective immediately, it is understood that there are some field audits currently in process and it will also take some time for everyone to become aware of the change. Please note that as of May 1, 2024, full implementation of the new forms was complete, and prior revisions of the forms will no longer be accepted.  

As a reminder, FQARs and EPADs should be emailed to audit@pci.org. Hard copies are not required. Please direct any questions to Qualityprograms@pci.org.

Accessing Plant and Erector Certificates

We have completed the renewals for plant and erector certificates for 2024-25. Thank you to everyone for completing the renewal process and we look forward to working with you in 2024-25 and beyond. Updated plant and erector certificates are available on the PCI website. If additional staff need access to your certificates, please email the request to audit@pci.org.

Instructions for accessing Certification Certificates on Computers/Laptops

  1. To access your certificate, log into your profile at www.pci.org.
  2. Your Username is your work email address. If you do not know your password, click on the Forgot Password? link.
  3. After you sign in, click on My Account at the top of the page on the Right. Take a moment to review your account page to be sure your contact information is current.
  4. Next, click the blue Producer Certification Certificate or Erector Certification Certificate button. This will open a second window in your browser where you can scroll through the certificates or download and open them in Adobe to print. Note: Click the blue arrow to see all the certificates. The blue arrow is clickable as long as it is Blue, even if the box says only “1 of 1”. Click the Adobe icon and open the file. Scroll through the certificates, which is easier if there are more than a few. Save the Certificate you wish to send to other parties.

Instructions for accessing Certification Certificates on Mobile Devices/Tablets

  1. To access your certificate, log into the PCI Mobile App (you can find it in your app store by searching for PCI Mobile App, Make sure the app you are about to download has the PCI logo).
  2. Open the PCI Mobile App.
  3. If you have not signed in, click the ≡ symbol in the top left corner. Your username and password is the same one you use to log into www.pci.org Your User id will always be your work email.
  4. Once you are logged in, again select the ≡ symbol. Your name will be listed under the Home button. Click on Home to be taken to your profile. Take a moment to review your profile to be sure your contact information is current.
  5. On your profile, you will see a Certificates blue button. Click this button to be taken to a new screen that will list up to two certificates per plant/plant you are attached to.
  6. From the App, you can view the certificate(s), text it, e-mail it, and save it to your phone.

For any questions regarding your plant’s certification status, please contact qualityprograms@pci.org.

Key Feature Points for Architectural 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. This will be administered using a rolling two-year period, based upon the last four regular audit cycles (semi-annual), after the initial two-year certification period.

Points are tracked on a rolling basis rather than for a fixed, defined period, after the initial two-year certification period. This ensures that plants will have four opportunities to demonstrate the required points, as the regular audits are conducted at approximately six-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 an eligible product was observed during one of these special audits.

Depending upon the timing of their audits and when the initial certification was issued, a plant may not have their fourth audit until after the two-year anniversary of their initial certification date. It is also possible that a plant may have four or even five audits, depending upon the timing. In any case, the certification will continue through the four regular audits or two years from the date of initial certification, whichever occurs later.

The key features to be demonstrated for each category are listed in the respective chapters of the Architectural Certification Program Supplemental Requirements. Of course, the preferred way to get the points is to be able to show products in production or storage that have the required features. Plants that are short of points as their two-year mark is approaching and do not expect to have production that will provide the required points can construct one or more mockup panels. There are two options for mockup panels:

  1. Construct one or more of the mockup panels fabricated for initial certification, as shown in the Architectural Certification Program Supplemental Requirements, for the plant’s certification category.
  2. Construct a mockup panel of the plant’s own design with appropriate key features to demonstrate their continued capabilities and earn the necessary points.

In either case, the drawings and mix designs for the mockup panel must be submitted for review well in advance of when the panel will be constructed, just as was required with initial category certification. This will allow time for review, to ensure the panel meets the eligibility criteria and would provide the necessary points.

ACRB Meeting Recap

The Architectural Certification Review Board (ACRB) held its first meeting on April 25, 2024, and reviewed most plant's Group A certification status during its meeting. They are holding subsequent monthly meetings and are providing recommendations to each plant, per the procedures outlined in the Supplemental Requirements.

The ACRB’s review is described in the ACRB findings letter which most Group A plants will receive about a month after receiving their audit report from PCI. Typically, in the ACRB findings letter you will notice three types of recommendations being made. The letter further asks the plant to declare which path it will take from the three recommendations being offered by the ACRB, within 14 days of receiving the ACRB findings letter. The three typical recommendations the ACRB will provide are listed below.

  • Commit to making mockup panels to achieve the minimum key features to maintain your current Group A category. This action will require you to submit new mockup drawings, new mix designs and schedule and pay for a special evaluation.
  • Declare a new category and provide written strategy to achieving the minimum key feature points for the new category.
  • Renounce your current Group A category and be recertified in a different category or group.

The first recommendation, “Commit to making mockup panels to achieve the minimum key features to maintain your current Group A category. This action will require you to submit new mockup drawings, new mix designs and schedule and pay for a special audit” has entertained many discussions. Hopefully the following statements answer most of your questions.

The mockup must be audited prior to the regular plant audit and must be conducted as a Special Evaluation. This recommendation follows the Supplemental Requirements. Group A plants that receive an ACRB findings letter may include the submittal of the Mockup Drawings and Mix Designs with the plant’s formal response to the ACRB findings within 14 days of receipt of the letter.

Once the mockup drawings and mix designs have been reviewed and approved, we will begin making arrangements for the Special Evaluation. The cost of the Special Evaluation will be determined by the additional travel costs associated, but will not exceed $6,000. PCI will notify the auditors and request scheduling of your Special Evaluation. Then the Special Evaluation must be conducted within 15 - 45 days from the approval of the mockup drawings and mix designs. 

Scheduled Plant Closings

PCI-certified plants generally observe the six major national holidays, and no audits are scheduled on these dates or, as with Christmas and New Years, the few days around those holidays. Observance of the other federal holidays varies widely. Obviously, we do not want to schedule a plant audit for days when the plant is closed. Plants are requested to let us know if there are other federal or state holidays that are observed by the plant, so that we can avoid these. This also includes other periods of plant closure.

Suggestions

Please forward suggestions for future quality-related articles for this newsletter to Bartlomiej Krol at bkrol@pci.org.