CPCQA Certification Program

Presented By: Bill LeBlanc, P. Eng.

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Specifying Manufacturers that meet a certification program built on superior quality assurance processes, which go above and beyond the minimum building code standards, is a wise and value-added step to protect your investment, manage risk and enhance the quality and safety attributes of your projects. It also provides these benefits to your partners, end users, tax payers, and the general public.

Why a New Program in 2017? • CPCI and CCPPA agreed to merge their

existing certification programs.

• To create a more independently administered third party audited certification program for precast concrete manufacturing in Canada.

• Combines the strengths of the two programs into one stronger program.

• Eliminated some overlap and redundancies between the two programs

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• CPCI: Canadian Precast / Prestressed Concrete Institute.

• CCPPA: Canadian Concrete Pipe and Precast Association.

• They represent the “Body of Knowledge (BOK*)” of the industry in Canada.

• *BOK: Is the collective knowledge of an industry that is relied upon to design and build with specific systems. This knowledge helps form the building codes, design guides, education programs, certification programs, and other inputs to health of the industry and other stakeholders.

Who Are CPCI and CCPPA and What do they Do?

History of CPCI

• Established in 1961.

• Published first design manual in North America – prior to the PCI Design Manual in the USA.

• Currently has 63 producing member Plants – 61 in Canada and 2 in the USA. The vast majority of it’s members are also “CPCQA Certified.”

• CPCI continues to publish updated Design Manuals other technical publications based on CSA Standards and best practices from Canada and other jurisdictions, as well as funding various research projects at Canadian universities

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History of CCPPA• Established in 2013.

• Currently has 18 members – some with multiple plant locations. 10 members are located in Ontario: The remainder from Quebec, Manitoba, Saskatchewan, Alberta, and British Columbia.

• Members of CCPPA are not required to be CPCQA certified.

• CCPPA is staffed with Professional Engineers who form the backbone of the organization’s expertise.

• Key activities of CCPPA involve specification and standard development, education of design professionals, developing research programs, and promotion of the associations members products and services.

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History of Precast Concrete Certification in Canada

• The Precast Concrete Bureau was created in 1967

• 1970: CSA International began certifying precast concrete plants. The program was initially managed, and plants audited, by people well experienced in the industry.

• Mid 1990s – CSA moved away from plant certification: “Process certification” to “Product Certification” This became more of a documentation review based system.

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Precast ConcreteBureau

History of Precast Concrete Structural / Architectural Certification in Canada

• 2005: CPCI manufacturing members voted to investigate an improved certification program that would move the industry forward.

• 2007 – CPCI reintroduced an updated Plant audit-based process certification program – CPCI Certification Program. – Based on conformance to CSA A23.4, MNL-116 &

117 (from PCI in the USA) and related standards. – By 2017 – Approximately 80% of the precast

volume in Canada was produced in manufacturing locations that were “CPCI Certified.”

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History of Precast Pipe Plant Prequalification Program in Canada

• The Ontario Water Resources Commission (OWRC) and the Ontario Concrete Pipe Manufacturers (OCPA) established the Plant Prequalification Program in 1965

• 1990 - the Plant Prequalification Advisory Committee assumed overall responsibility for the program

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History of Precast Pipe Plant Prequalification Program in Canada

2017 Plant Prequalification Program Advisory Committee:• Ministry of Transportation of Ontario (MTO)• Municipal Engineers Association (MEA)• Ontario Provincial Standards (OPS)• Concrete Precasters Association of Ontario

(CPA)• Ontario Concrete Pipe Association (OCPA)

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Why a New Program in 2017? • CPCI and CCPPA agreed to merge their

existing certification programs.

• To create a more independently administered third party audited certification program for precast concrete manufacturing in Canada.

• Combines the strengths of the two programs into one stronger program.

• Eliminated some overlap and redundancies between the two programs

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A well run plant certification Program considers the following:

• Verifies that essential components of a QC system are:o Present o Functioning properly at time of audit.o Documentation is being maintained properly.

• Increases probability of a successful project

• Reduces Risk

• Indicates the manufacturer is capable of meeting the criteria required by the certification program

General QA Program Definitions

CPCQA Program Description

• The CPCQA Certification Program is a corporation under the Canada Not-for-profit Corporation Act

• Governed by its own Board of Directors and advised by a Quality Assurance Council (QAC) composed of a broad cross section of industry professionals.

• Plant auditors work for an independent and third-party Auditing Firm -Canadian Certification Services Inc. (CCS)

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CPCQA Program: Eligibility• Any qualified manufacturer located in North America

who produces structural precast concrete products, architectural precast concrete products, or concrete pipe, maintenance hole sections and precast concrete drainage products and complies with the requirements of the CPCQA Certification Program is eligible for participation in the program

• The manufacturer must establish, document and apply an internal Quality System in conformance with CPCQA Certification Program Requirements.

• For Manufacturers of CSA A23.4 products: The Manufacturer must employ or engage the services of a registered professional engineer to regularly review the plants application of the manufacturing and quality control aspects of the CPCQA program requirements.

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CPCQA Organizational ChartBoard of Directors

Quality Assurance Council(QAC)

Auditing FirmCanadian Certification

Services

Kassian Dyck & Associates

PROCHK Engineering Inspections

Bill LeBlanc(Managing Director)

Governance - Who Runs The Program?

Quality Assurance Council (QAC)

A multi-disciplinary independent body with representation by:• Independent Architects, • Independent Consulting Engineers, • Municipal building officials, • Ministry of Transport representatives• General Interest representatives• Precast manufacturers

Meets 2-3 times per year

CPCQA Quality Assurance Council: Governing Body

The Corporation shall have a special advisory council (“Quality Assurance Council”). The Quality Assurance Council’s role shall be to:

1) Establish auditing criteria and grading standards for the Program;2) Provide administrative review to ensure that Program requirements are administered uniformly and are followed by all manufacturers;3) Develop, review and approve all literature related to the Program;4) Make recommendations to the Board on the qualification standards and requirements for plant prequalification and certification applications;. 5) Make recommendations to the Board on the qualification standards and requirements for the Auditing firms. The QAC resolves some of the “Grey Areas” in the various standards as they affect the audit process and grades

CPCQA QUALITY ASSURANCE COUNCILFirst Name Last Name Company Prov

Quality Assurance Council

CURRENT

Muhamed Arapovic Lafarge Precast Producer MB

Bill * LeBlanc Bill LeBlanc Consulting CPCQA AB

Brian * Clarke ProChk Engineering CCS ON

Nick Colarusso Municipal Engineers Assoc Municipal ON

Dean * Frank Dean Frank Associates LLC Vice Chair US

Chris Yurchesyn Strescon Producer NS

Allan Hegedus Saskatchewan Ministry of Highways MOT SK

Malcolm Hachborn M.E. Hachborn Engineering Engineer ON

Bo Ni Ministry of Transportation Ontario MOT ON

Wayne * Kassian Kassian Dyck Associates CCS AB

Edwin Kling Forterra Pipe and Precast Producer ON

Clayton Matwychuk AB Transportation MOT AB

Bernard Pilon MTQ MOT QC

Peter Quail Precon / OSCO Chair ON

Saidur Rahman City of Oakville Municipal ON

David Rhead Retired - Ex of Ontario MTO Gen interest ON

Scott Kirby MCON - Ayr Ontario Producer ON

Savio DeSouza Bridge Check Canada General Int ON

Danielle -Magda Salem MB Infrastructure MOT MB

Ian Graham AE Concrete Producer BC

Matt MacArthur NB DOTI MOT NB

Gerrie Doyle RAIC Architect ON

Mark Sokolowski Knelsen - Precast Div Producer AB

Anil Mehta PSI Producer ON

Paul Imm Forterra – Cambridge, Ont Producer

* Members in shaded cells are non-voting

CPCQA Program: Audits

• Quality Audits are the heart of the program

• Ensure manufacturers have a quality system in place and are capable of producing to necessary standards

• Evaluate and identify areas requiring upgrading or corrective action

• Continual improvement - along with reinforcing appropriate follow-through

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1st, 2nd & 3rd PARTY AUDITINGFirst Party (Supplier):• Responsible manufacturers have an internal quality

program to ensure their products meet all requirements.• But…definition of “good quality” can be subjective.

Second Party (Purchaser):• Audit performed by a stakeholder such as the designer,

contract administrator, contractor, or owner.• But…some cannot properly assess both the specialized

precast production process & the finished products of the industry.

Third Party (Independent Auditors):• Unbiased, independent auditors who are qualified to

assess both the product and the production process.

Good

Best

Better

Auditing FirmAuditor for the former CPCI Certification Program:

Wayne Kassian, P.Eng.Kassian Dyck & Associates

Auditor for the former PPP Certification Program :

Brian Clarke, P.Eng.PROCHK Engineering Inspections Inc.

New Combined Auditing Firm for the CPCQA ProgramCanadian Certification Services

Auditing Firm appointed Directors to the CPCQA QAC:• Wayne Kassian, P. Eng.

• Brian Clarke, P. Eng.

CPCQA Program: Audits

For structural and architectural precast concrete facilities

• Minimum of two regular audits in each full calendar year• Audits are two days in duration unless otherwise designated

by the auditing firm.

For precast concrete drainage products

• Facilities are inspected at least once a year - considered an intermediate inspection

• 6 months after each plant must submit an Interim Report to the auditor to provide details of any quality control testing and verify that all record keeping has been maintained during this period.

• Every third year, the auditor undertakes a detailed inspection and testing of each plant

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Precast Concrete Plant Quality Assurance Program: Audits

Grading Requirements for CSA 23.4 Products

• The Auditing firm performs a detailed audit, and determines a grade for each Division, Product Group and the Overall Plant Quality

• A passing grade for Certification in each Product Group is a minimum total grade of 80 for the Group and a minimum grade of 70 for any one Division of that Group.

• For example: the Bridge “Group” as a whole has 7 component “Divisions” – each with its own weighting. The individual “Division “ grades are added to determine the overall Bridge “Group” Grade.

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CPCQA Program Auditors

• The key to any successful auditing Program is the quality of the individual auditors monitoring the program – no matter how well written the Certification Program Documents may be.

• All auditors of the CPCQA program (with one current exception) are Professional Engineers - with a great deal of experience in design, production and inspection of precast concrete.

• CPCQA auditors spend significant amounts of time on the plant floor during audits to verify products and procedures.

• In depth follow ups are conducted with the individual plants to assist in their efforts to improve.

Program RequirementsAll Manufacturers are required to:

• Establish and maintain the highest standards of integrity, skill and practice in the design and fabrication of their products and systems.

• Undertake the performance of only those services and produce only those products for which they are certified.

• Be in Compliance with all current applicable regulations and standards

• All Manufacturers are required to develop, submit, maintain and utilize a plant-specific Quality System Manual (QSM) for approval, by the Auditing firm.

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Program RequirementsAll Manufacturers are required to:

• Follow the relevant Quality Assurance Council Documents:– CPCQA Certification Program

Requirements – Current Edition– CPCQA Quality Assurance Council –

“Binder of Advisories and Non-Conformances.”

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Program Standard Requirements

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For Structural and Architectural Precast Manufacturers - CSA Standards :

• A23.1/2 – Concrete materials and methods of concrete construction/A23.2 – Methods of test and standard practices for concrete

• A23.4 – Precast concrete — Materials and Construction

• A257 – Concrete pipe and manhole sections• B66 – Design, material and manufacturing

requirements for prefabricated septic tanks and sewage holding tanks

Program Standard Requirements

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For Structural and Architectural Precast Manufacturers

Precast/Prestressed Concrete Institute (US)• PCI Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete Products – MNL-116• PCI Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products – MNL-117•PCI Level I and II Certification: Required for the plant’s QC individual (level I for reinforced only products – Level I & II for prestressed products.

Program Standard RequirementsFor Precast Concrete Drainage Product

Manufacturers:

QC Personnel are required to have ACI Concrete Field Testing Technician Grade 1.

All plant QC personnel and a minimum of one person from Production must pass the PPP Examto prove their knowledge of the program requirements.

PASS = 90% mark Valid for 5 years

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Program Standard Requirements

For Precast Concrete Drainage Product Manufacturers:

Visual inspection of all finished products.

Check dimensions to CSA, ASTM or AWWA 302 tolerances.

Measure or test fit pipe joints.

Test finished products: Three-Edge Bearing (3EB) Test Hydrostatic Testing

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What’s the Basic Difference between products in the Structural / Architectural side of the program versus the

Drainage Side of the Program?

• Structural and Architectural Products are generally designed and manufactured using the CSA Design and manufacturing Codes: CSA A23.3, CSA S6, CSA A23.4: Precast Concrete- Materials and Construction.

• Most Drainage Products are manufactured based on standard designs. Most circular products are confirmed by way product testing.

• Some Drainage products in Category D1 are manufactured in accordance with the CSA A23.4 standard and designed with the relevant CSA design codes.

How are Product Certified Categories Determined for each individual plant?

• A plant initially applies for certification in a particular category(s)

• The audit process may confirm or modify the plant’s certified categories based on the results of the initial audits.

• A plant may apply for a category upgrade or downgrade as changes to their business may dictate. For an upgraded category special audits may be required to verify the plant’s ability to produce the new products.

• Some CSA Categories are very broad (Bridge Category B3 for example). In these cases the plant or the auditor may want to restrict the plant’s certification to a segment of the larger category (for example: Category B3 – bridge deck slabs only).

DRAFT - FLNR Precast Fabricator Qualification Tables(March 8, 2021 Draft - See Ministry Standards for Current Qualification

Requirements)

Category /Group ID

Category /Group Name

Sub-cat-

egory ID

Sub-category Name Example FLNR Components

B* BridgesB1 Precast bridge

productsReinforced non-prestressed components:- for bridges (e.g. slab girders, compo-girders, deck panels, ballast walls, cap beams, footings, retaining walls, etc.)- other (e.g. retaining walls, cattleguard abutments/sills, etc.)

B2** Prestressed miscellaneous bridge products

No FLNR standard or typical components

B3*** Prestressed straight strand bridge members

Prestressed (with straight strands) superstructure components (e.g. prestressed box girders or prestressed slab girders)

B4**** Prestressed deflected strand bridge members

No FLNR standard or typical components

Table 1- DRAFT Acceptable Fabricator Prequalification Categories for FLNR “Bridges” (Structural Bridge Components) fabricated in accordance with CSA A23.4-16 “Precast Concrete- Materials and Construction”(note: Fabricators are limited within each category in accordance with any limitations (if any) specified by the prequalifying agency)

Footnotes:* If a fabricator is prequalified to a category that has an A behind the B (e.g. BA1) it indicates the fabricator is qualified for architectural as well as non-architectural products in the same category without the A (e.g. B1)** also includes prequalification for products in category B1*** also includes prequalification for products in categories B1 and B2**** also includes prequalification for products in categories B1, B2 and B3

DRAFT - FLNR Precast Fabricator Qualification Tables(March 8, 2021 Draft - See Ministry Standards for Current Qualification

Requirements)

Category /Group ID

Category /Group Name

Sub-category ID

Sub-category Name

Example FLNR Components

B Bridges (all- see Table 1)

(all- see Table 1) Reinforced non-prestressed culverts or culvert components, e.g.: - Box culverts, arch culverts;- Footings, pile caps, headwalls, etc.

D Drainage Products

D1 Standard precast concrete drainage products

Reinforced non-prestressed culverts or culvert components, e.g.: - Box culverts, arch culverts;- Footings, pile caps, headwalls, etc.

Table 2- DRAFT Acceptable Fabricator Prequalification Categories for FLNR “Drainage Products” (Culvert) Precast Components fabricated in accordance with CSA A23.4-16 “Precast Concrete- Materials and Construction”

(note: fabricators are limited within each category in accordance with any limitations (if any) specified by the prequalifying agency)

DRAFT - FLNR Precast Fabricator Qualification Tables(March 8, 2021 Draft - See Ministry Standards for Current Qualification

Requirements)

Table 3- DRAFT Acceptable Fabricator Qualification Requirements for FLNR Precast Concrete Bridge Components not required to be fabricated in accordance with CSA A23.4-16 “Precast Concrete- Materials and Construction”

Example FLNR Component Applicable Ministry Standard

Fabricator Qualification Requirements

Interlocking Concrete Blocks(typ. 1500x750x750 mm)

FLNR Bridge Component Concrete Standard

Fabricator prequalified to category B or D (see Tables 1 & 2)

OR

Fabricators shall have their operations and products inspected and approved by a Ministry Engineer.

Concrete Roadside Barriers/ Bridge Approach Barriers

FLNR Bridge Component Concrete Standard (which refers to the BC MoTI Standard Specifications Section 941)

Fabricator prequalified to category B or D (see Tables 1 & 2)

OR

Fabricator shall provide proof (if requested by the ministry) of recent satisfactory fabrication of barriers in accordance with BC MoTI Standard Specifications Section 941.

Can the CPCQA program certify a “Temporary Plant” that may be set up for a large “One-of” Project?

• Some large projects or remote site locations may make it not physically or economically feasible bring in precast from an existing certified precast plant. These temporary plants are typically managed by large General Contractors or P3 partnerships (such projects as LRT guideways, Segmental precast bridge elements, precast tunnel segments etc).

• In order that owners and other stakeholders can have the same level confidence in these temporary plants as they do in established, certified precast plants CPCQA felt it necessary to develop specific procedures to deal with these situations.

• So: The answer is Yes - CPCQA can certify a temporary plant that conforms to specific CPCQA requirements.

Do the CPCQA Audits take into account every Project’s Particular Specification?

• No – The audits are based on the standards in our Program Requirements (CSA, PCI, ASTM, some Ontario Standard Specifications (OPSS) for drainage products, and AWWA 302).

• There will be cases where the particular provincial standards or the project specifications are either more stringent, more lenient, or “just different” than the standards our auditors use to conduct their audits.

• In these cases the owner or the owner’s inspection agency may override a “non-conformance” noted by a CPCQA audit if it finds that the item in question is in conformance with the project specific specification.

• These issues are discussed and resolved between the plant and the CPCQA auditors in their required “post Audit follow up meeting”.

Would CPCQA “Retroactively” certify a plant’s products before they have achieved CPCQA certified status?

• No – Only those products in the appropriate categories produced after the plant has obtained certification are considered to have been produced by a CPCQA certified plant.

• Owners and specifiers can check the CPCQA website to see an up to date listing of CPCQA certified plants - along with a listing of the product categories for which they have qualified.

• There is no listing on the CPCQA website for plants that may be in the process of obtaining CPCQA certification (ie. no classifications such as “Certification Pending” or “Certification in Progress”).

How long does it take for a plant to become CPCQA certified?

• The time lines vary greatly – from a couple months to a specified time limit of 12 months. The 12 month limit may be extended in rare cases if CPCQA and the auditors agree the plant is making reasonable efforts, but there are extenuating circumstances delaying the process.

• The timeline is mostly dependent on the effort the plant devotes to the process – ie. writing and submitting a QSM, obtaining proper certifications for plant QC personnel (PCI / ACI), responding to auditor comments from the “Pre-Certification Evaluation etc.

• The quicker timelines generally come from non-CPCQA plants that have been in operation for several years, and are only now applying for CPCQA certification. The longer timelines would generally come from plants that are new to the business.

How did / is CPCQA Handling COVID 19?

• Unlike some other certification programs which decided to cancel on location audits and just extend certificates, CPCQA decided it was important to ourselves and our stakeholders to maintain our program throughout the crisis.

• Our auditing firm developed a “virtual audit” program. This program considered documentation reviews as well as real time video and photographic audit methods where appropriate.

• All audits for 2020 were completed: either virtually where in person audits were not possible due to government or corporate travel and safety restrictions, or in-person where audits could be conducted safely for our auditors and the plant personnel at the facility to be audited.

• We continue to monitor the ongoing effects of COVID 19 this year

Summary of Attributes: CPCQA Certification Program(Not all Programs are created equal !)

• Focus on certification of Plant, Process, And People (“the Three P’s).• Focuses on much more than documentation.• Committed to continuous improvement of products and systems. • Certified to CSA, ASTM, PCI MNL 116 and 117, AWWA 302, and some Ontario OPSS

drainage specification requirements, whichever is the more stringent.• Includes provisions for certification of Ultra-High Performance concrete according to

CSA.• Includes provisions for certification of environmentally sustainable precast operations.• Designed to be harmonized with PCI Certification (USA requirements).• Mandated minimum annual audits: 2 – 2 day audits for Architectural and Structural

Plants, 1 - 2 day audit (plus additional days for testing as required) for Precast Pipe, Maintenance hole, and Precast Concrete drainage products.

• Program governed by an independent multi-disciplinary, Canada wide Quality Assurance Council (QAC) that oversees the program (over 20 members).

• Includes mandatory special advisories that address quality issues and best practice guidelines – these go well beyond the codes and standards.

• Audits evaluate all aspects of a plants operation: drawings, procedures and products in accordance with detailed checklists – to Canadian and USA standards. Defined pass / fail criteria are used.

What are important benefits to the AEC Community

• Easy identification of plants committed to maintaining the highest level of certification available in North America.

• Assurance that bidders have demonstrated their ability to manufacture quality products.

• Certified manufacturers with a confirmed capability to produce superior products and systems.

• Minimization of Risk – Resulting in project savings of time, money and potential headaches.

• No additional costs - Members pay all costs related to the CPCQA audit program and the required audits.

What are important benefits to the Precast Concrete Manufacturers

• 3rd-party validation of capability to produce to recognized standards and specifications.

• Aligned audit program and approach across various types of precast concrete products

• 3rd-party audit process contributes to the business’ commitment to quality production and continuous improvement.

• Provides opportunities to learn from other industry experts – producers, specifiers and users.

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CPCQA Certification Plant Status(Website Updated in Real Time )

www.precastcertification.ca

For more Information: Canadian Precast Concrete Quality Assurance Certification programwww.precastcertification.ca

Canadian Concrete Pipe & Precast Association (CCPPA)www.ccppa.ca

Canadian Precast / Prestressed Concrete Institute (CPCI)www.cpci.ca

Contact Information

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