DEE CONCRETE, INC. QUALITY SYSTEM PROCEDURE Doc No: QC-asP.o1 Page : 10f13 QUALITY CONTROL REVISION HISTORY CHANGE DESCRIPTION EFF, DATE a Initial Release ORIGINATOR APPROVAL _ a John Dee amr DISTRIBUTION (Pasig Off (Ober (tees Pasig Pant (others (Otters PROPRIETARY NOTICE. TMPORTANT THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY-MIXINC. ANY | Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | wih stamps are ‘PREMIER READY.MIX INC, conscered ofaDEE CONCRETE, INC. Doc No: QC-QSP-01 QUALITY SYSTEM PROCEDURE QUALITY CONTROL 1. OBJECTIVE Page : 20f13 1.1 This procedure defines the systematic inspection of all materials used in the production of concrete. All procedures meet the ASTM, AASHTO, ACI, BS and DPWH requirements and specifications to ensure that Premier Ready-mix, Inc. produces high quality produets, 2. SCOPE, 2.1 This procedure applies to all the testing requirements needed in the production and verification of concrete provided by Premier Ready-mix Inc. and its satellite plants. 3. DEFINITION 3.1 ASTM - American Society for Testing and Materials 3.2 AASHTO - American Association State Highway and Transportation Officials 3.3 ACI - American Concrete Institute 3.4. BS - British Standard 3.5 DPWH - Department of Public Works and Highways. 4. REFERENCE DOCUMENT 4.1 Materials Warehousing Procedure 5, RESPONSIBILITY 5.1 Quality Control Materials Engineer and the Quality Control Laboratory ‘Technician are responsible for the inspection and testing of incoming raw materials to be used in the production of high quality ready-mix concrete. 5.2 Quality Control Supervisor is responsible for ensuring that the quality of conerete leaving the plant is correct and is up to customer's specifications. ‘PROPRIETARY NOTICE. IMPORTANT THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY.MIX INC. ANY | Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | wih stamps are PREMIER READY-MIX INC. considered oftDEE CONCRETE, INC. Doc No: QC-aSP-01 QUALITY SYSTEM PROCEDURE QUALITY CONTROL 6. PROCEDURE DETAILS Page : 30f 13, 6.1 Incoming Inspection 6.1.1 The materials checker informs the Quality Control Laboratory Technician that a delivery of raw materials has arrived by giving him a copy of the delivery receipt 6.1.2 The Quality Control Laboratory Technician checks the delivery receipt to identify what test is required to be done, The material shall be inspected based on specific inspection criteria as defined in the Acceptance of Raw Materials Delivered (sec. 6.2) 6.2 Acceptance of Raw Materials Delivered; 6.2.1 Cement 6.2.1.1 The Quality Control Laboratory Technician gets the mill certificate attached to the Delivery Receipt. 6.2.1.2 Take 5 kg sample for testing from bulk carrier per day of delivery per plant cement silo of origin. 6.2.1.3 Test for time setting according to AASHTO T 162-82 6214 Initial Setting | Final Setting | Time Time |" Minimum | Two (6) Hours | Three (7) | Hours 62.1.5If cement meets all of our requirements the Laboratory Technician stamps “PASSED” on the Delivery Receipt, otherwise it shall be stamped with “REJECT.” 6.2.1.6 If the cement passes the test for time setting, the laboratory technician files the mill certificate in the Cement Mill/Test Certificate Binder. Mill certificates of rejected deliveries are returned to the driver of the truck. 6.2.1.7 Time setting test results are filed in the Cement Testing Binder and grouped according to the respective makes. ‘PROPRIETARY NOTICE IMPORTANT THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY.MIXINC. ANY | Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY] _ wit stamps are PREMIER READY-MIX INC. considered ofaDEE CONCRETE, INC. Doc No: c-aSP-01 QUALITY SYSTEM PROCEDURE QUALITY CONTROL Page : 40f13 622 Fly Ash 6.2.2.1 The Quality Control Laboratory Technician gets the mill certificate attached to the Delivery Receipt. 6222 If fly ash meets ASTM C 618-98 specifications the Laboratory Technician stamps “PASSED” on the Delivery Receipt, otherwise it shall be stamped with “REJECT.” 6.2.23 A monthly independent laboratory testing is required from the fly ash suppliers for verification purposes. This is then filed in the Cement Quality Test Binder. 62.24 The mill certificate is then filed in the Cement Mill/Test Certificate Binder. 6.23 Coarse Aggregates 6.2.3.1 The Quality Control Laboratory Technician gets the production certificate attached to the Delivery Receipt and check if it meets the requirements of ASTM C 33-02a, 6.2.3.2 The Laboratory Technician visually inspects the delivery, if coarse aggregates pass visual inspection, the Laboratory Technician moves on to next step (6.2.3.3). If size of the coarse aggregates is doubtful, he will take samples and perform tests according to ASTM C 136-96a. 6.23.31 coarse aggregates meet the ASTM C 33-02a specifications the Laboratory Technician stamps “PASSED” on the Delivery Receipt, otherwise it shall be stamped with “REJECT.” 6.2.3.4 If the laboratory technician approves the delivery of coarse aggregates, he will file the Production Certificate in the Coarse Aggregates Production Certificate Folder. Production Certificates of rejected deliveries are returned to the driver of the truck. 6.2.3.5 Sieve analysis results are then filed in the Coarse Aggregates Sieve Analysis folders respective to the size of coarse aggregates delivered PROPRIETARY NOTICE IMPORTANT THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY-MIX NC. ANY | Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | _ wit stamps are PREMIER READY-MIX INC. considered oficialDEE CONCRETE, INC. QUALITY SYSTEM PROCEDURE QUALITY CONTROL Doc No: QC-QSP-01 Page : 50f13 6.24 Fine Aggregates 6.24.1 The Quality Control Laboratory Technician tests fine aggregates according to ASTM C 136-01 6.2.4.2 If fine aggregates meet the ASTM C 33-02a specifications the Laboratory Technician stamps “PASSED” on the Delivery Receipt, otherwise it shall be stamped with “REJECT.” 6.2.4.3 If the laboratory technician approves the delivery of the fine aggregates, the sieve analysis result is then filed in the Fine Aggregates Sieve Analysis Binder. 62.5 Admixture 6.2.5.1 Specific gravity of admixture is checked by the Laboratory Technician per delivery. 6.2.5.1.1 PSP-PS, specific gravity 1.03 + 0.01 6.2.5.1.2 PSP-PX, specific gravity 1.04 +0.01 6.2.5.1.3 DCI-C3, specific gravity 1.05 + 1.07 6.2.5.2 If the admixture meets the required specific gravity the Laboratory Technician stamps “PASSED” on the Delivery Receipt, otherwise it shall be stamped with “REJECT.” 6.2.5.3 If admixture passes the specific gravity test, the Production Certificate is filed by the Laboratory technician in the Admixture Production Certificate Folder. If the admixture fails the test the Production Certificate is returned to the driver of the truck. 6.2.5.4 Specific gravity test results are filed in the Admixtures Specific Gravity Binder. ‘PROPRIETARY NOTICE IMPORTANT ‘THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY-MIX INC. ANY | Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | wih stamps are ‘PREMIER READY-MIX INC, considered oficialDEE CONCRETE, INC. QUALITY SYSTEM PROCEDURE QUALITY CONTROL Doc No: QC-aSP-01 Page : 60f13 6.3 Frequency of Inspection and Testing of Raw Materials; 6.3.1 Cement [Test | Frequency Time Setting (Vieat | One test per day of Method) ASTM C191- | delivery per silo Ola ‘Complete Physical & | Monthly Chemical Tests ASTM | C 150-02 Mill Certificate PNS | One test per day of 07-1992 delivery per silo 63.2 Coarse Aggregates Test ___|__Frequeney Production Certificate | One test per day of | delivery per plant ASTM C_ 136-01 | Monthly Standard test_method for particles size of coarse aggregates ASTM C__ 117-95 | Monthly Standard test method for materials finer than #200 : ASTM C 127-01 | Monthly Standard test_method for specific gravity coarse aggregates ‘ASTM C 29/C 29 M- | Monthly: 97 Standard test method for unit weight | and voids of, | | aggregates ASTM CG 142-97 | As per client request Standard test method for clay lumps of friable particles in aggregates | ‘PROPRIETARY NOTICE. IMPORTANT THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY-MIXINC. ANY | Oniy documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | wih stamps are ‘PREMIER READY-MIX INC. considered ofea633 DEE CONCRETE, INC. QUALITY SYSTEM PROCEDURE QUALITY CONTROL ‘ASTM C 131-01 & | Monthly 535-01 Standard. test | method — for — Los | Angeles abrasion test. Doc No: QC-QSP-01 Page : 7 of 13, Standard test method for percentage of fractures in aggregates | ASTM D_ 5821-01 | As per client request BS 812 PT 105.1:1990 Standard test method | for flakiness index of | coarse aggregates, As per client request Standard test method | for soundness of | coarse aggregates ASTM C_— 88-99a | As per client request ASTM C_117-95 | Monthly standard test method for materials finer than #200 Fine Aggregates Test Frequency _] Grading ‘One test per day of delivery per quarry ASTM C_—128-01 | Monthly standard test_method for specific gravity Fine aggregates ASTM C 29/C 29 M- 97 standard test method for unit weight and voids aggregates SEE ASTM C 136-01 | Monthly standard test method for particles size of fine aggregates PROPRIETARY NOTICE IMPORTANT ‘Tuls DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY.MIXING. ANY] Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | _ wit stampe are PREMIER READY-MIX INC. considered ofcDEE CONCRETE, INC. Doe No : QC-QS-01 QUALITY SYSTEM PROCEDURE QUALITY CONTROL Pee [ASTM C 88-99 | As per client request | standard test_method for soundness of fine aggregates ASTM D_ 2419-95 | As per client request standard test method | for sand equivalent of aggregates ASTM C 40-99 | As per client request standard test method for organic impurities of aggregates 6.3.4 Admixture |__Test__ Frequency ___ Specific Gravity ‘One test per day of delivery Complete — Chemical | Monthly Tests ASTM C 494- {98a 63.5 Water [ Test Frequency [Complete Chemical [Annually | Tests AASHTO T 26- | J 79 636 Fly Ash Test Frequency [Mill Certificate ASTM | One test per day of | |.C618-01 delivery per source [Complete Chemical | Annually | Tests ASTM C 618-01 PROPRIETARY NOTICE TMPORTANT ‘THis DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY.MIXINC ANY | Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | wit stamps are PREMIER READY-MIX INC. considered oflDEE CONCRETE, INC. Doc No: QC-asP-01 QUALITY SYSTEM PROCEDURE QUALITY CONTROL pet 6.4 Inspection of Conerete Production 64.1 The plant operator monitors the slump of concrete through slump meter found on the control panel. If slump reading is low, additional water is introduced to the mix to achieve the required slump. 64.2 After the concrete has been loaded into the transit mixer, the transit mixer moves to the side for a final inspection, A Quality Control Technician-Slumper visually inspects the slump of the concrete and verifies if itis the required slump. The Q.C. Technician will take concrete from the truck and will test the flow, L-box, temperature, and Filter press as required by the client. 6.4.3 Concrete products that passed the inspection of the Quality Control Technician-Slumper and the Client Representative, are allowed for delivery. 6.4.4 Its the responsibility of the Quality Control Supervisor to make sure that the quality of the concrete is correct and what is required. 6.5 Delivery of Concrete 6.5.1 Once conerete is passes the Quality Control inspection, it is then dispatched to the site. 65.2. Drivers are given instructions on the location of the unloading point and a sketch shown and/or given to the driver. 6.5.3 Location and travel time are monitored by GPS and relayed to the coordinator at the site. 6.6 Acceptance of Concrete at Site 6.6.1 Upon instruction of the customer/site engineer, the Quality Control Technician performs a slump/flow test and checks the temperature of the concrete upon arrival at the site based on ASTM C 94/C 94 M-98C. 6.6.2 If slump obtained is lower than the required slump, admixture is added to the concrete inside the transit mixer. Once the admixture has been thoroughly mixed with the concrete, a retest is done to see whether the adjustments made have corrected the slump. ‘PROPRIETARY NOTICE IMPORTANT ‘THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY.MIXINC. ANY | Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | _ wit stamps are PREMIER READY-MIX INC. considered oficialDEE CONCRETE, INC. Doc No: QC-aSP-01 QUALITY SYSTEM PROCEDURE QUALITY CONTROL Page : 100f13 Additional admixture introduced to the conerete mix is always within the recommended dosage of the admixture supplier. 66.3 Once the delivery has been approved by the customer/site engineer the transit mixer queues for unloading at the designated queuing area. 6.6.4 The Delivery Receipt of the said transit mixer is then signed by the customer/site engineer as a sign of acceptance and approval 6.1 Verification of product Delivered 6.7.1 The Quality Control Technician takes 6-8 samples of the concrete in transit mixer based on ASTM C 143/C 143M-98. These samples, represent the strength of conerete delivered. One set of samples will be taken for every 75 cubic meters of concrete poured as per DPWH specifications. 6.7.2 Samples taken are then placed inside a cage to ensure that samples will not be disturbed in its curing stage. In case no more cages are available for use, the Quality Control Technician makes sure that the samples are left in a secure location. 6.7.3. After the pouring is done for a specific project the Quality Control Technician creates a Concrete Samples Report. In the report the quantity, design, and location are indicated to make sure that collection of the samples could be done efficiently 6.74 After 24 hours (+ 8 hours) the Quality Control Collectors gathers all samples done by QL. technician per site. The samples are demoulded and submerged under water in the site-curing tank for 28 days curing as per ASTM C 31/C31M-98 6.7.5 Samples due for testing on 7, 14 and 28 days are then collected by Quality Control Coordinators. ‘These samples will be brought to an independent laboratory for breaking which is to be witnessed by a consultant of the contractor and its representative 67.6 Acceptance of concrete tested is based on design strength requirement. PROPRIETARY NOTICE, IMPORTANT ‘THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY.MIXINC. ANY. | Oniy documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | wih stamps are PREMIER READY-MIX INC. considered oficialDEE CONCRETE, INC. Doc No: @0-asP-01 QUALITY SYSTEM PROCEDURE QUALITY CONTROL fe 6.7.7 Official test results of the cylinder breaking are submitted by the independent laboratory to the Quality Control Department and are filed in folders corresponding to the project the cylinder was made for. 6.7.8 In cases where the samples fail to meet the required strength, other forms of testing are conducted; which are rebound hammer and coring, 6.7.9 Ifall tests fail, Premier Ready mix is responsible for removing and replacing the conerete which has failed. 7. CONTROL OF NON CONFORMING PRODUCTS 7.1 Disposition 7.1.1 All raw materials delivered which do not pass our incoming inspections are not allowed to be unloaded and are automatically sent back to the supplier. 7.1.2. Rejected concrete are sent back to the plant as soon as possible for immediate decision on its fate by the Quality Control Supervisor and Dispatcher. 7.2 Recording 7.2.1 All rejected raw materials are recorded in the Non-Conforming Raw Materials Log Sheet. 7.2.2 All rejected concrete are recorded in the Rejected Concrete Log Sheet. This is also noted in the Pouring report of the SE/Coordinator on site and on the Dispatcher’s Report. 7.3 Issuance of Corrective and Preventive Action Report Form 7.3.1 Rejected Raw Materials 7.3.1.1 The Materials engineer shall fill up the Corrective and Preventive Action Report Form and submit it to the QMR and the Quality Control Manager for approval. PROPRIETARY NOTICE IMPORTANT ‘THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY-MIX INC. ANY | Oniy documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | wit stamps are PREMIER READY.MIXINC, considered ofaDEE CONCRETE, INC. Doc No: @¢-2SP-01 QUALITY SYSTEM PROCEDURE Page : 120f13 QUALITY CONTROL 7.3.1.2 Once the CPAR form has been approved by the QMR and the Quality Control Manager, it is photocopied. One copy is kept in the CPAR Binder while the other is to be forwarded to the supplier whom the CPAR is directed to. 7.3.1.3 Once the CPAR is returned by the supplier, evaluation of the corrective and preventive action is done by the Quality Control Manager. This is also to be approved by the QMR. Once the CPAR has been approved by both the Quality Control Manager and the QMR, it is to be attached to the original CPAR and filed in the CPAR Binder. 7.3.1.4 Verification of the corrective/preventive action shall be done by visiting the supplier every eighth non conformance of each supplier. 7.3.2 Rejected Conerete 7.3.2.1 The Operations Manager/Chief Operations Officer shall register the incident on the Rejected Concrete Log Sheet. Based on the reason for rejection, an investigation is conducted to confirm its validity, If it is found that the concrete was rejected due to reasons beyond the control of PRL, it is marked as invalid on the Rejected Conerete Log Sheet. If the rejection is valid, the Operations Manager/Chief Operations Officer fills up the Corrective and Preventive Action Report Form and submits it to the QMR for approval 7.3.2.2 Once the CPAR is approved by the QMR, it is given to the person responsible for the rejection. 7.3.2.3 The CPAR is to be returned to the QMR after one (1) day with the corresponding corrective and preventive action. Evaluation and verification of the actions are to be done by the Operations Manager/Chief Operations Officer and the QMR. 7.3.2.4 Once the evaluation and verification has been complete, the CPAR form is to be filed in the CPAR Binder, PROPRIETARY NOTICE. IMPORTANT THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY-MIXINC. ANY | Oniy documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY | wa stamps are ‘PREMIER READY.MIXINC, considered oficialDEE CONCRETE, INC. Doc No: QC-aSP-.01 QUALITY SYSTEM PROCEDURE QUALITY CONTROL Page : 130f13 8. ATTACHMENTS 9.1 Specific Gravity & Absomption (F.A.) 9.2 Specific Gravity & Absorption (C.A.) 9.3 Unit Weight of Aggregates 9.4 Mechanical Analysis 9.5 Test Report on Quality Test of Aggregates 9.6 Admixture Specific Gravity Table 9.7 Rejected Concrete Log Sheet 9.8 Rejected Raw Materials Log Sheet 9.9 Corrective and Preventive Action Report Form PROPRIETARY NOTICE IMPORTANT, THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO PREMIER READY-MIXINC. ANY | Only documents DISCLOSURE OR USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSIONBY | wit stamps are PREMIER READY-MIX INC. considered oficial