915 PRODUCTION PLANTS

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915.01 GENERAL
These specifications are applicable to all batching and proportioning plants.
915.01.01 Approval. The plant from which the Contractor proposes to obtain material shall be approved by the Office of Materials Technology (OMT) before starting deliveries.
915.01.02 Lead Time. Notify OMT at least two working days prior to the start of operations. OMT shall be kept informed of plant operational procedures and be notified when a change is planned. Inspectors shall have safe access to all areas of the plant for the performance of their duties. All equipment, tools, machinery, and parts of the plant shall be maintained in a satisfactory working condition at all times.
915.01.03 Storage. The storage and handling of aggregates in stockpiles and bins shall be done in a manner that will prevent segregation, intermingling, and contamination by foreign material or equipment. Bins discharging to feeder systems shall be equipped with accessible calibrated devices to vary the quantity of material being fed.
915.01.04 Measuring Devices. Measuring devices shall meet the current edition of the National Institute of Standards and Technology Handbook 44, except as modified by Table 915. The producer shall provide all personnel and equipment for calibrating measuring devices.
Before the plant starts any proportioning operation, and at least once each year thereafter, all measuring devices, meters, dispensers, test weights, and other measuring devices shall be inspected, tested, and certified to be in proper operating condition by an approved testing agency. During the period of operation, all measuring devices, meters, dispensers, and other measuring devices shall be tested monthly and certified for accuracy and operating condition by the producer or an approved testing agency. Any weighing device by which materials are sold by weight as a basis of payment shall be tested monthly and certified by an approved testing agency. The Engineer shall be notified at least two working days in advance of monthly scale inspections. The certifications shall state capacities, minimum graduations, loads applied, degree of accuracy, and magnitude.
Balance and zero conditions of scales shall be checked daily, and at any other time requested by OMT. The Engineer may, at any time, direct that any measuring device be tested by the producer or an outside agency if there is any doubt about the accuracy of the measuring device. Certificates of inspection shall be posted in a prominent place in the plant, and a copy shall be promptly submitted to the Engineer.
Production plant tolerances shall meet the following table:
TABLE 915
MATERIAL *MAINTENANCE TOLERANCE UNIT OF MEASURE
Aggregate 0.2% Weight
Portland Cement or Blended Hydraulic Cement of Ground Iron Blast Furnace Slag or Fly Ash 0.2% Weight
Asphalt 0.2% Weight or Volume
Water 1.5% Weight or Volume
Additives 0.5% Weight or Volume
∗Maintenance tolerance shall be the specified percent of the total capacity of the scale or the smallest scale graduation, whichever is greater.
If during the monthly check, the measuring devices are found to deviate from the allowable tolerance, they will be suspended from use until recalibrated to the Specification requirements. A price adjustment will apply to materials sold and accepted by weight that are supplied during the measuring device malfunction period when the malfunction resulted in an overpayment. The measuring device malfunction period is defined as the elapsed time between the two successive monthly checks.
915.01.05 Sampling Equipment. The producer shall provide all personnel and equipment for obtaining samples.
(a) Refer to M 156 and D140. Sample liquid binder from a tap located at the last practical and safe point between the binder control unit and the plant.
(b) Sample and split asphalt mixes per R 47.
(c) Sample and process aggregate per T 2.
915.01.06 Quality Control Laboratory. The producer shall provide an Administration-approved laboratory at proportioning or batching plants suitable for conducting the various tests required. An off-site laboratory may be used with Administration approval. Approval of the QC laboratory and testing personnel will be subject to periodic inspection. Correct any deficiencies to the satisfaction of the Administration or approval will be withdrawn.
915.02 ASPHALT PLANTS
M156. Asphalt plants shall be equipped with Automatic Batching and Recording of Batching except as modified in 915.01 and the following:
(a) Dryer. Dry the aggregates per the plant manufacturer’s recommendations.
(b) Hot Aggregate Bins. M 156.
(c) Mixer Unit for Batch Method. Minimum dry and wet mixing times shall be 5 and 15 seconds, respectively.
(d) Truck Scales. Per the National Institute for Standards and Technology (NIST).
(e) Delivery Records and Tickets.
(1) Maintain a delivery record showing the Contract number, truck identification (ID) number, identification of the type of mix being produced, number of truck loads, and total tons of mix.
(2) Use an approved plant automatic weighing and printing system. Provide a printed delivery ticket for each load with the cumulative total weight of mix in each truck.
Delivery tickets for each load shall also contain the truck ID number, Contract number, identification of the type of mix, date, time loaded, gross and tare weights, and net weight of the mix.
(3) Record the temperature of the mix on the delivery ticket when requested. The temperature may be handwritten.
(f) Hauling Units.
(1) Transport the mix to the work site in units cleaned of all foreign material. Treat the inside surface of all hauling units with an approved asphalt release agent that will not contaminate the mix nor alter its characteristics. The use of petroleum derivatives is prohibited.
(2) Cover the contents of each load with suitable material of sufficient size to completely protect it from the weather.
(g) Drum Mixer Plants.
(1) Refer to MSMT 453 for calibration approval.
(2) Provide a monitoring station for the purpose of controlling the entire operation. If any part of the control system fails, an alternative control system may be used for a maximum of two working days.
(3) Determine the moisture content of all aggregates per MSMT 251.
915.02.01 Certified Asphalt Plant. The producer is responsible for quality control of plant operations to ensure that the material meets specifications. The quality control process will be subject to unannounced periodic inspection when project production is in progress. The plant’s certified technician shall fully participate in the inspections.
Initial Inspection. Plants initially setting up and starting production will be subject to a comprehensive inspection to determine whether the plant equipment and personnel meet all applicable specifications. Certification by a professional engineer registered in the State of Maryland that the plant facilities meet as specified will be accepted. Final acceptance will be as determined.
915.02.02 Responsibilities of the Asphalt Producer.
Notification. Notify the Engineer one working day prior to producing materials for Administration projects. Report total tons shipped one business day after completed daily shipments. Send report to superpave@mdot.maryland.gov.
Quality Control (QC). Refer to 504.03. Perform additional sampling and testing when directed. Provide the Engineer with the opportunity to witness all sampling and testing. Report QC test results within 24 hours of production.
Reports. Furnish test results on Administration-approved documents. Retain all original QC source documents for five years.
915.02.03 Responsibilities of the Administration.
Technician Certification. Conducted per the Mid-Atlantic Region Technician Certification Program (MARTCP) and the Maryland Technician Certification Program.
Independent Assurance Audits (IAA). The Administration will evaluate the equipment and the proficiency of QC technicians through audits performed on a random basis. The QC technician shall cooperate with the IAA technician in the evaluations.
Split Samples to Evaluate the Effectiveness of the Plant Quality Control Operation. Take a mix sample at the plant or project and split per R47. Sample a minimum of once per ten days of production and when daily production exceeds 200 tons. Provide one of the split samples to the Administration for testing. Test the other split sample per MSMT 735 and submit the results within 72 hours. Approval may be withdrawn if split sample data is not submitted as specified.
(a) Effective Plant Quality Control Operations. Plant QC operations will be evaluated as effective when both split sample results compare within AASHTO Acceptable Range of Two Test Results, Multi-Laboratory Precision parameters for binder content, percent passing the 4.75mm, 2.36 mm, 0.075mm gradation sieves, and maximum specific gravity (Gmm).
After three consecutive split samples compare within the AASHTO parameters and have been evaluated, the split sample frequency may be decreased to a minimum of once every 15 days of production.
(b) Ineffective Plant Quality Control Operations. When two consecutive QC and Administration split samples do not compare, a three-way split will be taken and evaluated. If the results of the three-way split compare, the QC Lab will be considered effective and monitored. If the three-way split evaluation does not compare for all the indicated tests, the QC operation will be evaluated by the Administration and approval may be withdrawn if equipment or procedural deficiencies are determined to exist.
Recertification of Plant QC Laboratory. Documentation of corrective action shall be submitted by the QC Plan Administrator. A comprehensive inspection will be conducted to recertify the plant once the documentation is approved.
Dispute Resolution. Following is the procedure to resolve conflicts resulting from discrepancies between test results from the Office of Materials Technology’s (OMT) Asphalt Technology Division or their designated AASHTO accredited third-party testing laboratory and the producer.
Verification. The producer and/or Project Engineer will provide a written dispute to OMT’S ATD Chief describing the nature of the dispute along with any pertinent information. Also provide OMT’s Deputy Director for Material Quality with a copy of the written dispute.
The written dispute must be filed within five business days after receiving QA data from OMT. If the dispute was filed by the producer only, then OMT will inform the Project Engineer. The dispute will only be considered for review if test results are outside the multi-lab or operating tolerance limits for any particular test of concern.
ATD’s Assistant Division Chiefs will review the pertinent information and report to the Chief. The Chief will report the findings of their review to the producer. This process will take three business days from the day written notification was received. This level will identify if further investigation or retesting is required.
Check Testing. Check testing will be performed on a split sample from the next day’s production by the producer and OMT’s Central Laboratory to determine any sampling/testing errors. The Producer and/or OMT can witness the testing performed by each laboratory if requested.
Verification and Check Testing will be completed within three to five business days from the day of the agreement and will focus on the questionable test results. If the issue is still not resolved, refer to Third-party Testing.
Third-party Testing. The producer and OMT will employ an AASHTO accredited laboratory to perform testing using split of the original sample. The lab whose test results vary the most from the test performed by the third-party lab will pay for the testing. The new test results will replace the original test results in the pay factor calculations. Third-party results will be considered binding unless the dispute is resolved without third-party testing, then mutually agreed upon test results will be considered binding. Testing shall be completed by the third-party testing laboratory within 10 business days of sample receipt.
Dispute Resolution Process for Discrepancies Related to Non-Test Results. The resolution process for non-test related disputes (pay factor calculations, turnaround times or mix design approvals) of sufficient magnitude to impact payment is as follows:


(a) When a non-test related dispute arises, the producer or Project Engineer will file a written dispute with the ATD Chief describing the nature of the dispute along with the pertinent information. The OMT Deputy Director of Material Quality will be copied on all written disputes. The written dispute must be filed within five business days from when the issue arises.
(b) The ATD Chief or Deputy Director of Material Quality will appoint a panel of three members to provide recommendations to resolve the dispute. The panel will include a member selected by the asphalt industry.
(c) The panel will make recommendations to the ATD Chief within five business days from the appointment.
(d) The ATD Chief or Deputy Director of Material Quality will decide the disposition of the dispute based on the panel’s recommendations.
(e) A written report from the panel describing all subsequent actions and final disposition of the dispute shall be included in the project records.
(f) The process will be completed within ten business days from the date of notification.If subsequent disputes arise on the same issue, the written report will be included as a resource during the resolution process.
915.03 PORTLAND CEMENT CONCRETE PLANTS
M 157, except as modified herein, including the applicable requirements of 915.01.
915.03.01 Aggregate Storage . All aggregate used in Portland cement concrete shall be maintained at a uniform moisture content in excess of its saturated surface dry condition. Water used shall meet 921.01.
915.03.02 Moisture Probes. Moisture probes may be used in place of actual daily moisture testing of fine aggregate. Calibrate and maintain moisture probes per the manufacturer’s recommendations.
(a) Perform actual moisture tests for fine aggregate weekly and as directed. When the actual tests of the fine aggregate indicate a difference of greater than 0.5 percent free moisture than the moisture probe readings, immediately perform a second actual test.
(b) If the second test indicates a moisture difference of greater than 0.5 percent, recalibrate the moisture probe and verify. Records of all calibrations and weekly tests shall be maintained and made available.
915.03.03 Mixing Temperatures. The plant shall be equipped with approved methods of heating and cooling the mix. The temperature of the plastic concrete shall meet 902.10.03. The temperature of the cementitious materials and water during mixing shall not exceed 170 F.
915.03.04 Load Tickets. M 157. Provide approved computer generated batch ticket indicating the pertinent information for each load in duplicate. The ticket shall indicate maximum allowable water, and maximum water allowed for jobsite slump adjustment.
Distribute load tickets as specified in 915.03.06(c)(2). The producer’s copy shall be readily available for inspection upon request. Issue a Form 116 for each load in the event a computer generated batch ticket cannot be provided.
915.03.05 Mixers and Agitators. M 157 except as follows:
(a) Operate drums during transit, at agitating speed only. Mixing during transit is prohibited.
(b) Add at least 85 percent of design water requirement at the plant through the certified plant water meter.
(c) Water for slump adjustment may be added at the plant through truck water system under the supervision of the certified concrete technician, provided the maximum specified water/cement ratio is not exceeded.
(d) A maximum of 3 gal of water per cubic yard of concrete may be added at the point of discharge provided it does not exceed the maximum specified water/cement ratio.
(e) No water be added after partial discharge of the load.
(f) Loading of mixers or agitators that contain wash water in the drum is prohibited.
(g) When the concrete is specified or permitted to be made by volumetric batching and continuous mixing, the batching and mixing unit shall meet C 685. Calibration shall meet MSMT 558.
(h) The minimum mixing time is 75 seconds for stationary mixers not subject to mixer performance tests.
915.03.06 Certified Concrete Plant.The producer shall be responsible for quality control of plant operations to ensure that the material meets as specified. The quality control process will be subject to unannounced periodic inspection by representatives of the Concrete Technology Division (CTD). Full participation in the inspection by the plant’s certified technician is required.
Initial and Annual Inspection. Any plant initially setting up and annually thereafter will be subject to a comprehensive inspection to determine whether the plant equipment and personnel meet all applicable requirements. The Administration will accept certification that the plant facilities meet all applicable requirements from either of the following:
(a) National Ready Mixed Concrete Association (NRMCA) Plant Certification Program. The Administration will review NRMCA Plant Certification Data and annually issue a written Plant Certification Approval. The Administration will perform QA visits as needed to validate the plant certification.
(b) A Professional Engineer registered in the State of Maryland with at least 5 years operational or technical experience in concrete production. The Administration will review the Engineer’s inspection report and issue a written Plant Certification Approval.
(c) The Administration will conduct the inspections only if (a) and (b) are not feasible or applicable. The cost for inspection will be charged to a current Contract if applicable or to the ready mix producer if a current Contract is unavailable.
Responsibilities of the Concrete Producer.
(a) Notification. Notify CTD one working day prior to producing materials for Administration projects. Notify CTD at least five working days in advance of scheduling the comprehensive inspection.
(b) Quality Control. Have the certified concrete plant technician present while concrete is being batched and delivered to Administration projects. This technician shall supervise concrete production.
(1) Develop and use an acceptable Quality Control Plan (QCP) that addresses all elements necessary for plant quality control. Submit the QCP for review and approval at the time of the annual comprehensive inspection. The QCP shall include the names, qualifications and responsibilities of a Quality Control Manager and Quality Control Technicians.
(2) Control tests shall be performed by or under the direct supervision of the certified concrete plant technician. The technician shall perform moisture tests, adjust proportions of aggregate for free moisture, complete and sign batch or approved delivery tickets, and ensure quality control of the batching operations.
(3) Concrete Plant Technician certification will be awarded upon satisfactory completion of examinations administered by the Administration.
(4) Supply all necessary test equipment.
(5) Sampling and testing shall meet the procedures and frequencies outlined in the Material Quality Assurances Processes, Details and Frequencies manual.
(c) Reports. The following reports shall be processed by the producer:
(1) Administration Form 113, daily. Provide a copy for the producer’s plant file for review.
(2) Load Tickets for each load. Provide a copy for the project and producer’s file.
(3) Administration forms for all concrete materials sampled at the plant.
(4) Test Worksheets for all tests performed daily at the plant.
(5) Provide a Monthly Production Report to CTD via e-mail to concrete@mdot.maryland.gov by the 10th of each month. Report the total cubic yards and the total weight of each type of supplementary cementitious material used in concrete production for Administration projects for the previous calendar month.
(d) Inspectors Office. The producer shall provide an onsite office meeting the basic

requirements of Section 103 Type A - Engineers Office for the exclusive use of SHA Engineers and Inspectors, as approved by the Engineer. The requirement for a mobile office trailer is waived.

Responsibilities of the Administration.
(a) Comprehensive Inspection and Acceptance Inspection and Testing.
(1) The Quality Control Manager will be notified immediately to correct any deficiencies found during an Administration inspection to the satisfaction of the Engineer. Production will be suspended for deficiencies where the quality of the product is affected, as determined by the Administration.
(2) If critical deficiencies are found or consecutive inspections reveal identical or additional deficiencies, a Non-Compliance Report (NCR) will be issued to the Quality Control Manager detailing the findings and actions to be taken by the producer.
(3) The Administration reserves the right to assign an Inspector to monitor operations for a maximum of five Administration production days. If at the end of this period the quality control process is not satisfactory, a NCR will be issued and plant approval will be rescinded. The plant shall be recertified before Administration production can continue.
(b)Recertification of Concrete Plant. Documentation of corrective action shall be submitted to the CTD by a professional engineer registered in the State of Maryland. A comprehensive inspection will be conducted by the Administration to recertify the concrete plant once the documentation is approved.
(c) Independent Assurance Audits (IAA). The Administration will evaluate the equipment and the proficiency of QC technicians through audits performed on a random basis. The QC technician shall cooperate with the IAA technician in the evaluations.
(d)Technician Certification Conducted per the Mid-Atlantic Region Certification Program (MARTCP) and the Maryland Technician Certification Program.
915.04 BASE COURSE PLANTS
915.04.01 Non-Stabilized. Base course plants producing graded aggregate base material without a stabilizing agent shall meet 915.01 and the following:
(a) Produce the material in a processing plant using qualified aggregate sources and approved job mix formula.
(b) Submit the Quality Control Plan to the Soils and Aggregate Technology Division (SATD) of OMT for approval prior to production.
(c) The production shall meet the gradation requirements of the approved job mix formula.
(d) Maintain the required moisture content according to the approved job mix formula prior to shipment.
(e) Maintain stockpiles to prevent segregation.
(f) Frozen aggregates shall not be used.
(g) Mixed material shall be handled and transported in a manner that will minimize segregation and the loss of moisture. All loads shall be covered with suitable material of sufficient size to completely protect it from the weather and in accordance with State laws.
915.04.02 Stabilized.
(a) Mechanical mixers shall be used, as approved. All plants shall be equipped with automatic cutoff devices interlocked so the plant will stop operating if delivery of any component of the mix fails.
(b) The amount of stabilization shall be measured according to MSMT 254.
(c) The charge in a batch mixer or rate of feed to a continuous mixer shall not exceed the capacity that will permit complete mixing of all materials.
(d) Mixed material shall be handled and transported in a manner that will minimize segregation and the loss of moisture. All loads shall be covered with suitable material of sufficient size to completely protect it from the weather and in accordance with State laws.
(e) The required moisture content shall be maintained according to the approved job mix formula prior to shipment.
(f) When emulsified asphalt is used as a stabilizing agent, all aggregate shall contain moisture in excess of the saturated surface dry condition at time of mixing.
915.04.03 Certification of Base Course Plants. The quality control and condition of all materials used in base courses, as well as all necessary adjustments required in using the materials, is the responsibility of the base course producer. The quality assurance process will be subject to unannounced periodic inspection by representatives of the SATD when Administration projects are in progress. The plant’s certified technician shall participate in the inspection.
915.04.03.01 Initial and Annual Inspections. Any plant initially setting up and annually thereafter will be subject to a comprehensive inspection to determine whether the plant equipment and personnel meet all applicable requirements. After the initial inspection, the plant shall meet 915.01.04.
(a) The Administration can conduct the initial or annual inspection. The cost for inspection will be charged to a current Contract if applicable or to the base course producer if a current Contract is unavailable.
(b) The Administration will accept certification by a professional engineer registered in the State of Maryland with at least five years operational or technical experience in base course production. The Administration will review the Engineer’s inspection report and issue a written Plant Certification Approval. Final acceptance will be determined by the Administration.
915.04.03.02 Responsibilities of the Base Course Producer.
(a) Notification. Notify SATD one day prior to producing materials for Administration projects. Report total tons shipped one business day after completed daily shipments. Send report to gab@mdot.maryland.gov.
(b) Quality Control. The producer is responsible for quality control of plant operations to ensure that the material meets specification requirements. All producers supplying base courses shall have a certified base course Plant Technician present while base course material is being plant mixed and delivered to the project. The Plant Technician shall perform quality control sampling, testing, and documentation as specified.
(1) Control tests shall be performed by a certified base course plant technician. This technician shall obtain samples and test according to the current version of the Material Quality Assurance Process Manual for Soils and Aggregate Technology Division, Aggregate Materials, Controlled Mixtures.
(2) Technician certification will be awarded upon satisfactory completion of a written and practical examination given by the Administration.
(3) Supply all necessary test equipment and provide on-site facilities suitable for conducting the required tests.
(c) Reports.
(1) Prepare and submit the following reports to SATD at gab@mdot.maryland.gov:
i. MDOT SHA Form 43, daily, stating that the material was sampled and tested using the Administration’s sampling and testing guidelines and meets the applicable specifications.
ii. MDOT SHA Form 88, for all additives introduced at the plant.
(2) Producer shall keep a record of the following forms at the Plant:
i. Daily Plant Certification Form (MDOT SHA Form GA-1) showing that a technician was on duty at the plant.
ii. The Producer’s Daily Quality Control test worksheet, for all tests performed at the plant.
iii. Base Course Plant Daily Production log sheet posted on the GAB Bulletin Board.
915.04.03.03 Responsibilities of the Administration.
(a) Comprehensive Inspection. – SATD/OMT will perform the Initial or Annual inspection.– SATD/OMT will perform the Initial or Annual inspection.
(b) Quality Assurance Inspection and Testing. – Will be performed according to the current version of the Material Quality Assurance Process Manual for SATD, Aggregate Materials, Controlled Mixtures.
(1) If deficiencies are found, as defined in the base course plant checklist during a quality assurance inspection, the producer will be notified immediately, and operations will be suspended if corrections are not made to the satisfaction of the Engineer.
(2) If consecutive inspections reveal identical or additional deficiencies, a Non-Compliance Report (NCR) will be issued to the Quality Control Manager detailing the findings and actions to be taken by the producer.
(3) A reinspection will be held in two Administration production days. All deficiencies shall be corrected by the reinspection date. OMT will determine whether plant certification will be revoked.
(c) Independent Assurance Audits (IAA). The Administration will evaluate the equipment and the proficiency of QC technicians through audits performed on a random basis. The QC technician shall cooperate with the IAA technician in the evaluations.
(d) Recertification of Aggregate Base Course Plant. Documentation of corrective action shall be submitted by a Professional Engineer registered in the State of Maryland with at least five years operational or technical experience in base course production. When this documentation is approved, a comprehensive inspection will be conducted to recertify the base course plant.
(e) Technician Certification. Conducted according to the Mid-Atlantic Region Technician Certification Program (MARTCP) and the Maryland Technician Certification Program.
915.05 CERTIFIED PRECAST CONCRETE PLANTS
Shall meet the applicable requirements of 915.01, 915.03 and the following.
Certified Precast Concrete Plant. The producer shall be responsible for quality control of plant operations to ensure that the material meets specification requirements. The quality control process will be subject to unannounced periodic inspection by representatives of the Concrete Technology Division (CTD). Full participation in the inspection by the plant’s certified technician will be required.
All plants producing precast concrete items of any description for Administration contracts shall be certified as appropriate by one or more of the following at the time of their Annual Inspection:
(a) The American Concrete Pipe Association (ACPA)
(b) The National Precast Concrete Association (NPCA)
(c) The Precast/Prestressed Concrete Institute (PCI).
Plants may be required to hold multiple certifications in order to produce a variety of products.
Initial and Annual Inspection. The Administration will perform comprehensive initial and annual inspections on all plants to ensure that the plant equipment and personnel meets all applicable specification requirements. The Administration will accept certification that the plant facilities meet all applicable requirements from a professional engineer registered in the State of Maryland with at least five years operational or technical experience in concrete production. Final acceptance and approval will be as determined by the Administration.
The cost for inspection will be charged to a current Contract if applicable or to the precast producer if a current Contract is unavailable.
915.05.01 Responsibilities of the Precast Concrete Producer.
(a) Notification. Notify CTD 14 days prior to producing any precast items for each Administration project. Notify CTD at least 5 working days in advance of scheduling the comprehensive inspection.
(b) Quality Control. Have the certified quality control technician present while concrete is being batched and cast. The technician shall supervise all aspects of precast concrete production.
(c) Quality Control Procedures. Quality control procedures shall be detailed in the Quality Control Plan and include the following:
(1) The method of inspecting reinforcement steel placement and forms prior to pouring concrete.
(2) The method of curing the concrete.
(3) The method of maintaining accurate quality control records.
(4) Samples of documents approved by the Engineer.
(5) Patching procedures.
(6) Methods of preparing the concrete units for shipment.
(7) A method of identifying each piece as tested and approved by quality control.
(d) When required, the producer shall submit a repair procedure for the precast product for approval that conforms to PCI Manual 137 and all other applicable specifications. All materials used for repairs shall be supplied from approved sources.
(e) Develop and use an acceptable Quality Control Plan (QCP) that addresses all elements necessary for plant quality control. Submit the QCP for review and approval at the time of the annual comprehensive inspection. The QCP shall include the names, qualifications and responsibilities of a Quality Control Manager and Quality Control Technicians.
(1) All precast concrete products shall meet the Standards or approved working drawings. All materials shall be from an Administration approved source and meet all applicable specifications.
(2) The plan shall indicate how the producer intends to handle all of its materials.
(3) Sample and testing frequency and certification of materials shall meet the Material Quality Assurances Processes, Details and Frequencies manual.
(4) The producer shall submit a repair procedure for approval conforming to PCI Manual 137 and all other applicable specifications. All materials used for repairs shall be supplied from approved sources.
(f) Quality Control Technician. Certified Quality Control Technicians shall hold the following certifications:
(1) Maryland Department of Transportation State Highway Administration – Office of Materials Technology Certified Concrete Plant Technician (Certified Plant Technician)
(2) American Concrete Institute (ACI) Level I
Technicians shall also hold one of the following certifications as required:
(1) PCI Level I,
(2) NPCA Production & Quality School (PQS) Level I,
(3) ACPA Q-Cast Certified Technician.
(g) Test Equipment and Facilities. Supply all necessary test equipment and provide Administration-approved facilities suitable for conducting the various tests required. Off-site test facilities shall be approved by the Engineer.
(h) Reports. The following reports shall be processed by the producer:
(1) Load Tickets for each load. Provide a copy for producer’s file for review.
(2) Administration Forms for all concrete materials sampled at the plant.
(3) Test Worksheets for all tests performed daily at the plant.
(4) Provide a Monthly Production Report to CTD via e-mail to concrete@mdot.maryland.gov by the 10th of each month. Report the total cubic yards and the total weight of each type of supplementary cementitious material used in concrete production and the total number of precast items shipped to Administration projects for the previous calendar month.
(i) Inspectors Office. The producer shall provide an onsite office meeting the basic requirements of Section 103 Type A - Engineers Office for the exclusive use of SHA Engineers and Inspectors, as approved by the Engineer. The requirement for a mobile office trailer is waived.
915.05.02 Responsibilities of the Administration
(a) Comprehensive Inspection.
(b) Verification Testing.
(1) Verification of certification will be performed a minimum of once per year at the discretion of the Administration.
(2) The Administration reserves the right to discontinue acceptance of precast units if verification indicates that materials or test procedures do not meet the Contract Documents.
(c) Acceptance Inspection and Testing.
(1) If deficiencies are found during an Administration inspection, the Quality Control Manager will be notified immediately to correct the deficiencies to the satisfaction of the Engineer. Production will be suspended for critical deficiencies where the quality of the product is affected as determined by the Administration.
(2) If critical deficiencies are found or consecutive inspections reveal identical or additional deficiencies, the Engineer will issue a Non-Compliance Report (NCR) to the Quality Control Manager detailing the findings and actions to be taken by the producer.
(3) The Administration reserves the right to assign an Inspector to monitor plant operations for a maximum of five Administration production days. If at the end of this period the quality control process is not satisfactory, a NCR will be issued and plant approval will be rescinded. The plant shall be recertified before Administration production can continue.
(d) Recertification of Precast Concrete Plant. Documentation of corrective action shall be submitted to the CTD by a Professional Engineer registered in the State of Maryland. After approval of the corrective action documentation, a comprehensive inspection will be conducted to recertify the concrete plant.
(e) Independent Assurance Audits (IAA). The Administration will evaluate the equipment and the QC technicians’ proficiency through audits performed on a random basis. The QC technician shall cooperate with the IAA technician in the evaluations.
(f) Technician Certification. Conducted per the Mid-Atlantic Region Technician Certification Program (MARTCP) and the Maryland Technician Certification Program.