regulating concrete quality ken day, consultant melbourne, australia
TRANSCRIPT
The Objectives
To achieve suitable regulation it is first necessary to:
A) Realise what you are trying to achieve
B) Realise what you are trying to prevent
Historically:
Specification was related to an individual batch of concrete
Batch quantities were the subject of the regulation
Full time inspection was affordable
Strength as a Criterion
Strength was then recognised as the only workable basis
An absolute minimum strength was specified
Inevitable Variability recognised
Strengths of successive deliveries of supposedly identical concrete were seen to vary by up to +/- 15MPa, rarely less than +/- 5MPa
Grouping Results
Small groups of 3, 4 or 6 results were tried by various countries
Even groups of 6 did not provide an accurate mean strength and variability
Even groups of 3 represented too much concrete to reject as a unit
“Percentage Defective” A “Normal Distribution” was found
to be applicable so that results could be analysed for mean strength, standard deviation, and % below any given strength
About 30 results were needed to give good accuracy
“Percentage Defective”
Percentage defectives of 1, 5 and 10% have been used, multiplying the SD by 2.33, 1.645 and 1.28 respectively
Decision based on “what is a reasonable margin”
I would suggest it should be based on the value placed on low variability
What are You Trying to Stop? A low mean strength?
A high variability?
Occasional gross errors?
ALL OF THE ABOVE!
Gross Errors Even testing alternate trucks (at
excessive expense) would give only a 50% chance of detection
You are reliant on the producer’s equipment and QC system so these need maximum encouragement/reward
Penalisation Marginal underperformance cannot
be fairly dealt with any other way than financial penalisation (marginal is grey, not black or white!)
Failure to penalise underperformers places good producers at a disadvantage
Downturn detection Even with appropriate financial
compensation, purchaser (and producer!) will be keen to avoid defective concrete. This raises two questions:
How to predict eventual strength from early result?
How to get enough results quickly at acceptable cost?
Speeding downturn detectionTwo techniques make a huge difference:
Base control on plant rather than project
Use multigrade basis, i.e. combine results from possibly hundreds of grades of concrete in an analysis of situation
Speeding downturn detectionThe combination of these techniques
can increase a hundredfold the number of results available and drastically reduce time to detection of a downturn
A downturn in a particular grade at a particular project may be detected before any results are available on that project, or even on that grade
Speeding downturn detectionFurther improvement in detection time
possible using advanced analysis system
Cusum analysis has been shown to be approximately three times as effective as Shewhart charting – which is still better than normal graphing
Speeding downturn detection
Better Prediction:Early results not usually % of later
results, adding average gain better Needs continuous feedback of true
gain which can change abruptly
Speeding downturn detection
Cusum graphs of many items – density, slump, temperature, cement tests, sand specific surface etc etc can give instant explanation of strength changes
Cusums are Cumulative Sums of difference between current value and previous mean – can include LW and dense on same density graph, high and low strength grades on strength graph
Multivariable Analysis
Speeding downturn detection
The purchaser is not in as good a position as the producer to detect downturns early
If a later penalty is inevitable, the producer will be just as keen as the purchaser to detect and rectify downturns early
Conclusion
What is needed is a type of regulation that will encourage producers to expend every effort to establish a system and physical facilities that will:
Produce low variability concrete Correctly target mean strength React quickly to any downturn
Regulation in UK and Europe Recent new standard EN206
Requirements rather than control system
QSRMC is real control system in UK
QSRMCQuality Scheme for Ready Mixed Concrete Established by the industry, big
advance on world scale
First to introduce Cusum (dev by RMC)
Multigrade technique uses transposition of results to a single grade for analysis
USA Strangely resistant to innovation Perhaps partly due to fragmented
industry but prime example of specification-driven barrier to progress
Prescription mixes still common Mix adjustment actually prohibited Producer designs abused if permitted
Australia (AS1379)
Regulations are by Aust. Standards Assn. Production mainly by few large producers Producers required to undertake own
testing and report monthly to purchasers Not perfect, but best example of suitable
regulation leading to good control – could be better early reporting, penalties
Draft of Desirable RegulationsThe concrete producer shall have in
operation an effective QC system with at least the following features:
1) Plant to produce, preserve, and link to QC system, complete record of actual and intended batch quantities of every batch
Draft of Desirable Regulations2) Batch records to be analysed to
show any systematic trend to error or any significant individual error and any such to be reported to purchasers
3) Mixes may be collected into multigrade groups and each such group shall have a minimum rate of testing each month
Draft of Desirable Regulations4) All data shall be entered in control
system within 24hrs of obtaining and analysed daily to detect change using graphical, multigrade, cusum analysis or proven equally effective alternative
5) All purchasers of concrete PREDICTED to be sub-standard shall be immediately informed
Draft of Desirable Regulations6) A monthly report detailing for each
mix in production, at least: number of results, early age and predicted and actual mean strength, standard deviationminimum strength, No & % of results below specified strength
Draft of Desirable Regulations Note emphasis on early detection
of any problem and ready availability of data to establish cause
A usually trivial cost penalty of twice the cost of the amount of cement that would have raised the month’s mean strength to the required would be sufficient to ensure fair competition
Quality Implications W/C ratio basic factor and directly
related to strength – at a given strength the mix with the LOWEST cement content is the best (lower water)
Pozzolanic materials reduce cost, improve durability and environment
More uniform concrete likely to be easier to place, better appearance
Quality Implications Important to understand that this
paper does not pass any judgement on desirable strength margins in structural design, or for durability considerations
Author believes extra cost of higher margin often worthwhile but should not be by requiring higher mean regardless
Cost Implications
Difficult to quantify savings by proposals
Avoiding costs of further testing, negotiations, rejections, due to poor control (or poor testing!)?
Better mix design, wider material choice?
Reduced expenditure on control testing?
Reduced mean strength due lower SD!
Conclusions
Paper is concerned with best way to ensure a selected strength obtained with max certainty and min cost
A key factor is that regulations must not inhibit progress and must provide a fair basis for competition
Conclusions
A comparison of practice in different countries illustrates that failure to apply these principles inhibits development of improved technology
Conclusions It may never be possible to
completely eliminate problems but if they can be largely foreseen and the rest detected and resolved in minutes or hours instead of days or weeks, the economic benefits could be substantial
The main losers are likely to be the legal profession and the physical investigators of defective concrete!