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Quality Assurance Quality Control Plan
Rev: 2 10/21/15 2 of 93
Dome Technology Quality Assurance Quality Control Plan
Table of Contents
List of Forms ................................................................................................................................................. 5
QAQC Quality Assurance / Quality Control Overview .................................................................................. 7
Purpose ......................................................................................................................................................... 7
Scope ............................................................................................................................................................ 7
Referenced Documents ................................................................................................................................ 7
Responsibilities ............................................................................................................................................. 7
Organizational Chart (Project Specific) ......................................................................................................... 8
QAQC 1.0: Civil/Foundation Work ................................................................................................................ 9
QAQC 1.1: Earth Work .................................................................................................................................. 9
QAQC 1.1.1: Excavation ............................................................................................................................... 9
QAQC 1.1.2: Backfill ..................................................................................................................................... 9
QAQC 1.2: Piles/Piers ................................................................................................................................. 10
QAQC 1.2.1: Precast Piles.......................................................................................................................... 10
QAQC 1.2.2: Aggregate Piles ..................................................................................................................... 11
QAQC 2.0: Materials & Equipment QC ....................................................................................................... 13
QAQC 2.1: Materials QC ............................................................................................................................. 13
QAQC 2.1.1: Concrete ................................................................................................................................ 13
QAQC 2.1.2: Steel Reinforcement .............................................................................................................. 14
QAQC 2.2: Equipment QC .......................................................................................................................... 15
QAQC 2.2.1: Formwork ............................................................................................................................... 15
QAQC 3.0: Dome Construction ................................................................................................................... 16
QAQC 3.1: Ringbeam ................................................................................................................................ 16
QAQC 3.1.1: Ringbeam - Lean Fill ............................................................................................................ 16
QAQC 3.1.2: Ringbeam - Rebar ................................................................................................................ 17
QAQC 3.1.3: Ringbeam - Forms ................................................................................................................. 17
QAQC 3.1.4: Ringbeam - Concrete ............................................................................................................ 17
QAQC 3.2: Airform ...................................................................................................................................... 19
QAQC 3.2.1: Dome Layout ......................................................................................................................... 19
QAQC 3.2.2: Airform Inflation - Air Form Fabric Quality ............................................................................. 20
Rev: 2 10/21/15 3 of 93
Dome Technology Quality Assurance Quality Control Plan
QAQC 3.2.3: Airform Inflation - Pressure .................................................................................................... 20
QAQC 3.3: Polyurethane Foam Process .................................................................................................... 22
QAQC 3.3.1: Polyurethane Foam Process - Primer Application ................................................................ 22
QAQC 3.3.2: Polyurethane Foam Process - Application ............................................................................ 24
QAQC 3.4: Pre-Mat Steel ............................................................................................................................ 26
QAQC 3.4.1: Pre-Mat Steel - Sticker Placement ........................................................................................ 26
QAQC 3.4.2: Pre-Mat Rebar Placement .................................................................................................... 27
QAQC 3.4.3: Depth Gauge Installation ...................................................................................................... 28
QAQC 3.4.4: Mounter Wire Placement ....................................................................................................... 29
QAQC 3.5: Dome Shell ............................................................................................................................... 30
QAQC 3.5.1: Shotcrete - Materials ............................................................................................................. 30
QAQC 3.5.2: Shotcrete Placement ............................................................................................................ 31
QAQC 3.5.3: Embedment of Pre-Mat Steel with Shotcrete ....................................................................... 32
QAQC 3.5.4: Shotcrete Surface Preparation .............................................................................................. 33
QAQC 3.5.5: Structural Rebar Placement .................................................................................................. 34
QAQC 3.5.6: Shotcrete Placement and Structural Steel Embedment ........................................................ 35
QAQC 3.5.7: Final Shell Completion ......................................................................................................... 36
QAQC 4.0: Tunnel Construction ................................................................................................................. 38
QAQC 4.1: Precast Sections....................................................................................................................... 38
QAQC 4.1.1: Precast Forms ....................................................................................................................... 38
QAQC 4.1.2: Precast Sections - Rebar & Embed Placement .................................................................... 39
QAQC 4.1.3: Precast Sections - Concrete Placement and Curing ............................................................. 40
QAQC 4.2: Invert ......................................................................................................................................... 41
QAQC 4.2.1: Invert Steel ............................................................................................................................ 41
QAQC 4.2.2: Invert Concrete ...................................................................................................................... 42
QAQC 4.3: Tunnel Placement & Finishing .................................................................................................. 43
QAQC 4.3.1: Placing Precast Sections ....................................................................................................... 43
QAQC 4.3.2: Closure Pour.......................................................................................................................... 44
QAQC 4.3.3: Hopper Concrete Walls ......................................................................................................... 45
QAQC 4.3.4: Waterproofing ........................................................................................................................ 46
Rev: 2 10/21/15 4 of 93
Dome Technology Quality Assurance Quality Control Plan
QAQC 5.0: Additional Dome Elements ...................................................................................................... 47
QAQC 5.1: Curbs & Piers .......................................................................................................................... 47
QAQC 5.1.1: Curbs & Piers - Rebar .......................................................................................................... 47
QAQC 5.1.2: Curbs & Piers - Forms .......................................................................................................... 48
QAQC 5.1.3: Curbs & Piers - Concrete ..................................................................................................... 49
QAQC 5.2: Entryway .................................................................................................................................. 50
QAQC 5.2.1: Entryway - Rebar .................................................................................................................. 50
QAQC 5.2.2: Entryway - Forms ................................................................................................................. 50
QAQC 5.2.3: Entryway - Concrete ............................................................................................................. 51
QAQC 5.3: Floor Construction ................................................................................................................... 52
QAQC 5.3.1: Floor Construction - Rebar ................................................................................................... 52
QAQC 5.3.2: Floor Construction - Concrete .............................................................................................. 53
QAQC 5.4: Post Tensioning ....................................................................................................................... 50
QAQC 5.4.1: PT Ducts ............................................................................................................................... 50
QAQC 5.4.2: PT Anchorage....................................................................................................................... 50
QAQC 6.0: Steel ......................................................................................................................................... 52
QAQC 6.1: Bulkhead Doors ....................................................................................................................... 57
QAQC 6.1.1: Door Fabrication/Installation ................................................................................................. 57
Sample Forms ............................................................................................................................................. 57
Revisions ..................................................................................................................................................... 92
Rev: 2 10/21/15 5 of 93
Dome Technology Quality Assurance Quality Control Plan
List of Forms
Number Title Rev. Date
F-0SR1 Shipment Receiving Log 09/30/15
F-1E1 Earthwork - Excavation 09/30/15
F-1E2 Earthwork - Backfill 09/30/15
F-1E3 Earthwork - Compaction 09/30/15
F-1P1 Precast Pile Placement 09/30/15
F-1P2 Aggregate Pier Placement 10/21/15
F-2C1 Concrete Pour Card 10/12/15
F-2C2 Concrete Pour Inspection 10/12/15
F-2CW1 Cold Weather Log 09/30/15
F-2F1 Forms Checklist 10/12/15
F-2R1 Rebar Checklist-Concrete 10/12/15
F-3AI1 Airform Inflation Checklist 09/30/15
F-3DG1 Depth Gauge Installation QC Log 10/12/15
F-3DP1 Dome Profile 10/14/15
F-3P1 Primer Placement 10/12/15
F-3P2 Primer Application Checklist 10/14/15
F-3P3 Primer Adhesion Testing Log 09/30/15
F-3PF1 Polyurethane Foam Placement 10/12/15
F-3PF2 Polyurethane Foam Application Checklist 10/12/15
F-3PF3 Polyurethane Foam Log & Inspection 09/30/15
F-3PF4 Polyurethane Foam Adhesion Testing Log 09/30/15
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Dome Technology Quality Assurance Quality Control Plan
F-3R1 Rebar Placement-Dome 10/12/15
F-3R2 Rebar Checklist-Dome 10/19/15
F-3S1 Shotcrete Placement 10/12/15
F-3S2 Shotcrete Pour Card 10/12/15
F-3ST1 Sticker Placement 10/15/15
F-3ST2 Sticker Pull Test 09/30/15
F-3T1 Temperature, Relative Humidity & Dew Point Log 09/30/15
F-4PC1 Precast Tunnel QAQC 10/12/15
F-4PC2 Precast Placement Checklist 10/12/15
F-4W1 Waterproofing Checklist 10/12/15
F-5PT1 PT Duct Checklist 10/19/15
F-5PT2 PT Anchorage Checklist 10/19/15
F-6D1 Door Installation Checklist 10/19/15
Rev: 2 10/21/15 7 of 93
Dome Technology Quality Assurance Quality Control Plan
QAQC Quality Assurance / Quality Control Overview
Purpose
Dome Technology recognizes the importance of documenting its methods for ensuring quality dome
construction. Therefore, Dome Technology provides the following Plan as an overview of its Quality
Assurance/Quality Control (QAQC) policy. This Plan is instituted throughout our company.
The intent of the QAQC Plan is to ensure the quality of Dome Technology’s construction not only meets all
contract specifications but also allows its employees to walk away from a completed job feeling proud of
their work and leaves the client with the assurance that the work performed is something of which they can
also be proud. Ensuring quality by following this Plan also enhances employee safety by reducing the risks
associated with construction errors.
Construction of each project is based on the contract documents approved for that project. The Project
Manager is responsible to establish, with the Project Construction Superintendent, site specific
requirements for critical construction points such as construction air pressure, air pressure variances, phase
adjustments, scope of work, construction schedules, etc. Modification of these requirements must be
cleared through the Project Manager and the Project Construction Superintendent.
Construction activities associated with this Project are to be completed under this quality program. Only
controlled products & materials are accepted when delivered to Dome Technology. All construction phases
are to be built with skilled craftsmen following approved drawings using proper tools, materials and
equipment. Inspections, reports and tests are to be completed as outlined in this Plan to document the
construction is proper and meets Project requirements. Periodically, the processes are refined based on
identified quality problems, test data, inspection results, audits, and Dome Technology’s general
satisfaction with the quality of the Project.
Scope
This Plan applies to all Work performed by Dome Technology on the Project.
Referenced Documents
• Contract Documents
• Applicable Standards, Codes & Specifications
• QAQC Forms
Responsibilities
Quality Assurance & Quality Control on construction sites remain the responsibility of the Project
Construction Superintendent with the oversight of a Project Manager. On an as needed basis, projects may
also have the assistance of an onsite QAQC Manager. When an onsite QAQC Manager is assigned, the
Rev: 2 10/21/15 8 of 93
Dome Technology Quality Assurance Quality Control Plan
QAQC Manager is responsible for verifying compliance with this QAQC Plan and signing the required
QAQC reports. Where a QAQC Manager is not assigned, the Project Construction Superintendent is
responsible for performing all QAQC responsibilities.
Organizational Chart (Project Specific)
Dome Technology
Shotcrete Foreman
Dome Technology
Project Manager
(not on site full time)
__________________
Dome Technology
Project Superintendent
(on site full time)
__________________
General Contractor/
Onsite Representative
Owner/Customer
or Client
Dome Technology
QAQC Manager
(If assigned)
Dome Technology
Rebar Foreman
Dome Technology
Dome Building Team
Rev: 2 10/21/15 9 of 93
Dome Technology Quality Assurance Quality Control Plan
QAQC 1.0: Civil/Foundation Work
QAQC 1.1: Earth Work
QAQC 1.1.1: Excavation
Potential Quality Concern: Removal of hazardous materials; Hidden works & utilities; Over
excavation
Quality Control Measure: Excavated soil is to either be placed in an onsite temporary
staging area or loaded directly into trucks and transported to the
disposal facility. Prior to commencing the excavation, the owner
is responsible for identifying and confirming the location of buried
utilities and indicating the presence of hazardous materials on
site.
Quality Assurance Procedure: Confirmation from the owner is to be obtained for locating the
staging area and/or disposal locations for all excavated soils. The
locations of all underground utilities are to be marked and areas
of conflict or hazard are to be addressed with owner. All
excavated material is to be logged; an excavation form is filled out
daily and is to include planning information, truck numbers, ticket
numbers, load sizes and disposal and/or staging locations.
Acceptable Tolerance: The excavation is to be kept to a minimum while meeting the
dimensions & specifications of the construction documents and
adhering to required safety protocols.
Related Documents: F-1E1 (Earthwork-Excavation)
QAQC 1.1.2: Backfill
Potential Quality Concern: Backfill that does not meet the engineering specifications; poor
compaction.
Quality Control Measure: All backfill is to meet the required material specifications. The fill
is placed in lifts as specified in the approved plans. Soil is to be
compacted to meet the criteria of the construction documents.
Rev: 2 10/21/15 10 of 93
Dome Technology Quality Assurance Quality Control Plan
Compaction is to be completed with equipment suitable for the
soil type.
Quality Assurance Procedure: Test data & relevant documentation is to be obtained to
demonstrate that the fill material meets the design criteria.
Density testing is to be administered per the project general
structural notes and is to be in accordance with ASTM D1556.
Records are kept for all fill brought on site and each compaction
test performed.
Acceptable Tolerance: Backfill is to be placed and compacted to meet the project
specifications as given in the construction documents and as
noted in the project general structural notes.
Related Documents: F-1E2 (Earthwork-Backfill)
F-1E3 (Earthwork-Compaction)
QAQC 1.2: Piles/Piers
QAQC 1.2.1: Precast Piles
Potential Quality Concern: Incorrect strength, size or position, improper hammer; damaged
piles; piles placed out of plumb.
Quality Control Measure: Piles are to be transported and lifted with an appropriate bridle or
sling attached at pick points. Piles are to be rejected if they are
damaged and removed & replaced. A proper hammer is to be
used and in good working condition. Pile heads must be properly
protected and the pile should be held in vertical and horizontal
alignment when driving. Correct pile placement must be verified
with the approved design documents. Starter holes are not to be
drilled unless otherwise specified in the contract documents. All
pile splices are to be inspected and meet the requirements of the
contract documents. Adjacent piles must be measured for heave
and meet the design criteria. All damaged piles, or piles that do
not meet the quality control or tolerance criteria must be replaced
or corrected in accordance with the design professional
recommendations.
Rev: 2 10/21/15 11 of 93
Dome Technology Quality Assurance Quality Control Plan
Quality Assurance Procedure: The placement of all piles is to be documented. Piles are to be
given an identification # and a daily checklist (F-1P1) is to be
completed to verify the quality control procedures are followed.
The locations of all underground utilities are to be marked and
areas of conflict are to be addressed with owner. Pile design
strength and dimensions along with the transport method and
time of placement are to be included in the placement checklist.
Location and plumb for each pile placed are to be verified and
approved.
Acceptable Tolerance: Piles less than 60’-0” long are not to be splice unless noted
otherwise. Piles are to be cut to +/-1” of the design elevation and
cut level without damage. Adjacent Piles must be measured for
heave and re-driven if heaving is > 0.5” unless otherwise specified
in the contract documents. Driving stresses are not to exceed
85% of the pile design compressive strength.
Related Documents: F-1P1 (Precast Pile Placement)
QAQC 1.2.2: Aggregate Piers
Potential Quality Concern: Incorrect strength, size or position, damaged piers or cave-ins;
improperly protected piers
Quality Control Measure: The owner should be contacted to identify the locations of any
obstructions and utilities that is to be removed or relocated as
required before drilling the aggregate piers. A modulus test is to
be performed and the adequacy of the bearing strength of the
piers confirmed on a sample pier before placing the piers
generally. The location of each pile is to be surveyed and marked
and the center of each pier should meet the placement tolerance
defined in this plan. Drill depths are to be measured and must
meet the design specifications. Lift thicknesses are not to exceed
24” and the tamping of the aggregate should be done in using the
same method as the successful test pier. Relative density of the
aggregate piers is to be measured periodically and meet the
design specifications. Piers are to be rejected if they are
damaged, if soil caves into the drilled hole or if the piers are
otherwise not meeting the quality control criteria or tolerances
while being placed. The aggregate is to be removed & replaced
in piers that are rejected. Completed piers are to be properly
Rev: 2 10/21/15 12 of 93
Dome Technology Quality Assurance Quality Control Plan
protected, a drainage plan is to be put in place to prevent water
from ponding over the piers.
Quality Assurance Procedure: Verification of the modulus test pier must be recorded. The
placement of all piers is to be documented. Aggregate Piers
placed are to be recorded and a daily checklist (F-1P2) is to be
completed to verify the quality control inspection has been
completed and the correct procedures are followed. The
locations of all underground utilities are to be marked and areas
of conflict are to be addressed with owner. Pier design bearing
strengths, depths and diameters along with the time of placement
are to be included in the placement checklist.
Acceptable Tolerance: Aggregate lifts are not to exceed 24” unless otherwise specified
in the contract documents. Drill depths are to be within 3” (75mm)
or deeper than the specified design depths. The center of the
drilled piles must be placed within 4” of the designated position.
Unless otherwise specified, the relative density of the aggregate
lifts must test to be 15 blows minimum per 1.75” of penetration
using a Dynamic Cone Penetrometer in accordance with the
procedures of ASTM STP-399.
Related Documents: F-1P2 (Aggregate Pier Placement)
Rev: 2 10/21/15 13 of 93
Dome Technology Quality Assurance Quality Control Plan
QAQC 2.0: Materials & Equipment QC
QAQC 2.1: Materials QC
QAQC 2.1.1: Concrete
Potential Quality Concern: Mix, temperature, slump, air content or w/c ratio that do not meet
the design specifications; Old concrete; Insufficient compressive
strength
Quality Control Measure: The Construction Superintendent or QAQC Manager reviews
the batch information for each load. Concrete that does not meet
the design criteria or is not applied within the specified time
frame is to be turned away. If a truck is rejected, the reason for
refusing the truck is to be documented. Concrete is to be tested
using standard cylinders or as specified in the contract
documents. A test sample is to be obtained the greater of once
a day or every 150 yards (110 m3) per ACI 301 section 1.6.3.2d.
The compressive strength is accepted based on the criteria of
ACI 301 section 1.6.6.1. The Engineer of Record is to be
notified of the placement of any concrete that does not meet the
compressive strength requirements. Recommendations
provided by the Engineer are to be followed and all required
corrective actions must be taken.
Quality Assurance Procedure: Temperature, slump and air content are to be verified and
documented for each truck tested. Water may be added at the
site; however, the water to cement ratio and slump must fall
within the design parameters. A pour card is to be filled out each
day prior to placing concrete and an inspection report is to be
filled out to document the pour. Test reports are to be reviewed
by the Construction Superintendent or the QAQC Manager who
verifies that the design strength is reached. Concrete test data
is to be recorded and saved. Cylinder break inconsistencies are
to be examined by the Project Manager and corroborated by the
testing agency.
Acceptable Tolerance: Concrete must meet the mix design requirements for slump,
temperature & air content. Concrete must be poured within 90
Rev: 2 10/21/15 14 of 93
Dome Technology Quality Assurance Quality Control Plan
minutes of leaving the batch plant unless specified otherwise in
the contract documents. If the truck time extends beyond 90
minutes the slump & temperature may be retested per ACI 301
section 4.3.2.2 to ensure the concrete meets the design
requirements; otherwise, the truck is to be sent away. Concrete
is to meet the design strength in 28 days.
Related Documents: F-2C1 (Concrete Pour Card)
F-2C2 (Concrete Pour Inspection)
F-2CW1 (Cold Weather Log)
Concrete Testing Log
Concrete Batch Tickets
QAQC 2.1.2: Steel Reinforcement
Potential Quality Concern: Proper steel amounts, sizes, types & grades; Delivery of
damaged reinforcement
Quality Control Measure: The project Construction Superintendent or QAQC Manager
receive the steel reinforcement and embeds on site
accompanied by a mill certification. The mill cert is to be
reviewed to ensure the steel meets the specifications for quality,
type, size and grade. All steel reinforcement is to be deformed
and plain carbon steel bar in accordance with ASTM A615
unless otherwise specified in the contract documents. The steel
is to be physically assessed and inspected for rust, flaking,
excess bend damage or deleterious materials such as dirt or
grease. Steel reinforcement delivered to the site that is
damaged or does not meet the design specifications and is not
of high quality is to be rejected.
Quality Assurance Procedure: The mill certifications and delivery tickets for the reinforcing
steel are saved on site. A report detailing the size, condition
and quantity is to be completed. Details for what caused the
materials to be rejected are to be recorded for any steel
reinforcement which is deemed to be unacceptable. A rebar
checklist is to be completed each day rebar is placed and is to
verify that the bar has been inspected and meets the criteria of
this QAQC Plan.
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Dome Technology Quality Assurance Quality Control Plan
Acceptable Tolerance: Steel reinforcement must meet the design specifications. The
Project Superintendent or QAQC Manager reviews the mill
certificates and rejects any bar that does not meet the approved
specifications.
Related Documents: F-2R1 (Rebar Checklist-Concrete)
QAQC 2.2: Equipment QC
QAQC 2.2.1: Formwork
Potential Quality Concern: Incorrectly placed or out of tolerance; damaged or missing
bracing; bonding to concrete
Quality Control Measure: Forms are to be fully assembled. They are measured for
correct tolerances and inspected for any structural damage. A
form-release agent that does not bond or effect concrete
surfaces is to be used. Bracing and fasteners are to be
inspected by the Construction Superintendent or QAQC
Manager and verified to meet the loading criteria of ACI 347
section 2.2.
Quality Assurance Procedure: The project Construction Superintendent or QAQC manager
verifies the dimensions of the fully assembled forms prior to
concrete being delivered. A report is to be completed each
day formwork is placed and is to verify that the QAQC Plan is
being followed and document the type of forms and form-
release agent being used.
Acceptable Tolerance:
Related Documents:
Formwork is to meet the tolerance requirements for finished concrete of ACI 117 unless otherwise specified in the contract documents.
F-2F1 (Forms Checklist)
Rev: 2 10/21/15 16 of 93
Dome Technology Quality Assurance Quality Control Plan
QAQC 3.0: Dome Construction
QAQC 3.1: Ringbeam
QAQC 3.1.1: Ringbeam - Lean Fill
Potential Quality Concern: Poor concrete quality, Improper curing techniques,
Unacceptable subgrade preparation; Cold joints
Quality Control Measure: Before placing lean fill, the subgrade is verified to have met the
design specifications. The lean fill concrete is placed by or under
the direction of a qualified concrete foreman. Prior to pouring
concrete, excavations are to be cleaned from all loose material
and standing water is to be removed. Although lean fill is
generally specified with a low compressive strength, the design
strength is to be verified with the contract documents. The
acceptance of the concrete loads at the job site is to follow the
requirements of section 2.1.1 of this Plan. The rate of concrete
delivered to the site must be adequate to prevent cold joints
from forming; all construction joints must be as detailed or
approved by the Engineer of Record. Curing materials are to be
staged on hand. Cold or hot weather plans for concrete
placement must be followed as required.
Quality Assurance Procedure: Concrete quality is to be assured per the requirements of
section 2.1.1 of this Plan. The Project Construction
Superintendent or QAQC Manager inspects and documents
lean fill placement. A concrete pour card is to be filled out each
day prior to pouring concrete. An inspection report is filled out
to document the pour and ensure the quality control measures
are being implemented.
Acceptable Tolerance: Concrete quality tolerances are to be in accordance with section
2.1.1 of this Plan. Acceptable curing is to meet the criteria given
in ACI 308.
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Dome Technology Quality Assurance Quality Control Plan
Related Documents: F-2C1 (Concrete Pour Card)
QAQC 3.1.2: Ringbeam - Rebar
Potential Quality Concern: Incorrect size or quantity of rebar; Incorrect rebar placement;
missing dowels, anchors or ties
Quality Control Measure: The placement of the ringbeam steel reinforcement is
designated by the structural engineer and is to be placed as
specified on the approved construction drawings. The
placement of the steel in the ringbeam is done under the
direction of the project Construction Superintendent. Proper
placement of dowels, anchors and ties are verified and
documented as the steel is placed.
Quality Assurance Procedure: The steel is inspected and documented in accordance with the
requirements of section 2.1.2 of this Plan. A quality control
checklist is completed for the rebar placed within the ringbeam
formwork. This QAQC report is to note the required rebar
spacing, splice lengths and coverage. The form also includes
a record of the dowels and anchors placed.
Acceptable Tolerance: Rebar quality tolerances are to be in accordance with section
2.1.2 of this Plan. Rebar placement within the ringbeam is to
meet the coverage & spacing tolerances specified in ACI 117
section 2.2 unless otherwise specified in the contract
documents.
Related Documents: F-2R1 (Rebar Checklist-Concrete)
QAQC 3.1.3: Ringbeam - Forms
Potential Quality Concern: Forms located incorrectly, Damaged or warped materials;
inadequate or missing bracing
Quality Control Measure: The form quality control measures of section 2.2.1 of this Plan
are to be followed. The coordinates for the center of the dome is
to be clearly marked. The forms are assembled and then
Rev: 2 10/21/15 18 of 93
Dome Technology Quality Assurance Quality Control Plan
measured from dome center to verify correct dimensions &
placement. Forms are to be inspected for damage and must be
clean from deleterious materials. Bracing, clamps & fasteners
are to be inspected by the Construction Superintendent or
QAQC Manager. ¾” chamfer strip is to be used on exposed
corners unless otherwise specified in the contract documents.
Quality Assurance Procedure: The project Construction Superintendent or QAQC manager
inspects the fully assembled formwork prior to delivery of
concrete. A checklist is to be completed to document that the
quality control measures for the erection and securing of the
ringbeam forms are being followed.
Acceptable Tolerance: Formwork tolerances are to be in accordance with section 2.2.1
of this Plan. The drop lip of the Ringbeam may vary by +/- ½”
(13 mm) from the radius of the dome. The top of the Ringbeam
may vary +/- ½” (13 mm) from the design elevation.
Related Documents: F-2F1 (Forms Checklist)
QAQC 3.1.4: Ringbeam - Concrete
Potential Quality Concern: Poor concrete quality; Unacceptable subgrade preparation;
improper curing techniques or consolidation, Cold joints;
Inadequate finishing
Quality Control Measure: The acceptance of the concrete loads at the job site is to follow
the requirements of section 2.1.1 of this Plan. The concrete is
to be placed under the direction of an experienced foreman.
Consolidation equipment is to be in good working condition and
is to be staged on hand prior to pouring concrete. The concrete
is to be vibrated to ensure proper consolidation around
reinforcement and embeds and prevent honeycombing in
corners or against forms. The rate of concrete delivered to the
site must be adequate to prevent cold joints from forming; all
construction joints must be as detailed or approved by the
Engineer of Record. Curing materials are also to be staged.
Cold or hot weather plans for concrete placement must be
followed as required.
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Dome Technology Quality Assurance Quality Control Plan
Quality Assurance Procedure: Concrete quality is to be assured following the requirements of
section 2.1.1 of this Plan. The Project Construction
Superintendent or QAQC Manager inspects and documents the
ringbeam concrete placement. A concrete pour card is to be
filled out each day prior to pouring concrete. An inspection
report is filled out to document the pour and ensure the quality
control measures are being implemented. Concrete placement
is also recorded and the location of each load is documented.
Acceptable Tolerance: Concrete quality tolerances are to be in accordance with section
2.1.1 of this Plan. Acceptable curing is to meet the criteria given
in ACI 308. Acceptable finish is as required by the contract
documents.
Related Documents: F-2C1 (Concrete Pour Card)
F-2C2 (Concrete Pour Inspection)
QAQC 3.2: Airform
QAQC 3.2.1: Dome Layout
Dome Technology utilizes a specific dome layout comprised of zones and quadrants which are used in our
QAQC documentation. This layout helps to organize our communication when reporting on placement of
materials during the construction of each dome.
Each dome plan is separated into four quadrants: A, B, C, & D. QUAD A is the first quadrant to the left of
the air lock entry on each dome. The other quadrants are designated clockwise from the air lock; B, C, &
D respectively.
QUAD A
QUAD B QUAD C
QUAD D
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Dome Technology Quality Assurance Quality Control Plan
The vertical profile of the dome is divided into zones. The distance of each zone is approximately 20’-0” (6
meters). As the dome shell is constructed, the zone heights are based on the vertical lengths of the steel
reinforcement placed along the arc. The zone designation is not a vertical elevation notation; the zone
heights vary depending on the lap splices that are required for the vertical bars. Please refer to the figures
above for clarification on the dome layout.
QAQC 3.2.2: Airform Inflation – Airform Fabric Quality
Potential Quality Concern: Unacceptable air form fabric quality & safety margin; Ensure
proper airform fabric specifications for each project
Quality Control Measure: The airform manufacturer evaluates the anticipated dome
airform stresses and submits a request to order the proper
airform fabric based on the contract document specifications.
Quality Assurance Procedure: Dome Technology’s Project Manager reviews the fabric
request. Upon approval, the Project Manager orders the correct
airform for the Project.
Acceptable Tolerance: Dome Technology does not accept undersized, light weight or
poorly constructed airforms. Proper airforms are to be made of
high quality fabrics which are verified by testing to meet the
project specifications.
Related Documents: Air Form Engineering Report (provided by others)
QAQC 3.2.3: Airform Inflation - Pressure
Potential Quality Concern: Proper shape and volume of dome
Quality Control Measure: Airform construction pressure is critical for each dome. Dome
Technology determines the proper air pressure for each dome
and document the approved working pressure.
In determining airform pressures, Dome Technology takes into
account the dome size, the radius of curvature, the expected
temperatures during construction, the strength of the fabric, and
the thicknesses and locations of shotcrete placement. Dome
Technology balances the air pressure tension with the fabric
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strength. Air support of materials and the air pressure are also
balanced to keep both within an acceptable safety margin.
Dome Technology installs a continuous pressure reading device
at the air lock location on the dome. Each dome built has a
construction pressure level specified. It is the Project
Construction Superintendent’s responsibility to calibrate the
pressure gauge and set the pressure of the dome at the
appropriate construction pressure. The Project Superintendent
is responsible for daily maintenance of the inflators, motors,
engines, fans, pressure control box, etc. The pressure reading
is taken and is documented daily during each work period or
shift.
Quality Assurance Procedure: The dome air pressure is reported by the Construction
Superintendent or QAQC Manager each day. The dome air
pressure is tracked by the Project Manager from the daily
project reports and evaluated along with the temperature and
relative humidity for each job. This information is tabulated at
Dome Technology’s corporate office and is available for review
by management.
Acceptable Tolerance: Pressure readings are to be documented daily. The construction
air pressure must be maintained within a 1/4" (6 mm) tolerance
to specified pressures.
A monolithic dome air form cannot be fabricated to duplicate
exact design, shape, or size specifications. Some of the air form
fabrication variables that control actual shape and size are:
fabric stretch, inconsistencies in raw material characteristics,
slight differences in fabrication, temperature variations after
inflation, and slight distortions from the weight of the initial thin
layers of sprayed shotcrete, etc.
The height of the fabric form is to be within 3% of the total design
height measured at the center of the building, per ACI 334.3R-
05. This same percentage difference in the radius of curvature,
perpendicular to the design profile, may occur anywhere in the
dome.
When the inflated airform does not meet the 3% tolerance, the
shape must be reviewed by the structural engineer for possible
design changes. The project design engineers and architects
must allow for these tolerances by including flexibility in the
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design of the interior and exterior connections. These space
allowances must be made so the airform tolerances do not
become critical construction problems. Final connection designs
required for attachment to the dome, interior or exterior, are to
utilize actual measurement from the inflated dome after the pre-
mat steel is embedded. This stage of the dome construction
process provides a relatively stable dome with dimensions that
remain fairly consistent through final dome completion.
When specific or tight tolerances are required in the size and
shape of the dome, they must be specified by the customer and
agreed upon by Dome Technology prior to construction. The
tolerances are to be verified and approved by the customer
when the airform is inflated.
Related Documents: F-3DP1 (Dome Profile)
3.3: Polyurethane Foam Process
QAQC 3.3.1: Polyurethane Foam Process - Primer Application
Quality Control Measure: Proper adhesion, thickness, quality and finish
Potential Quality Concern:
1. Primer Adhesion:
Ensure the air form is clean and dry prior to spraying primer.
Ensure the paint pump is in good working condition. Ensure
proper curing conditions exist; note that as the temperature
cools, the primer may take longer to cure.
2. Primer Thickness: The primer should be sprayed on the air form at the rates
specified by the manufacturer.
3. Primer Quality: The primer must be stored properly and mixed thoroughly to
ensure the chemicals are the correct ratio throughout the barrel.
Primer must be applied under the direction of an experienced
technician.
4. Primer Finish: The primer surface should be uniform with minimal runs.
Quality Assurance Procedure:
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1. Primer Adhesion: The temperature, humidity and dew point are to be recorded
daily on form F-3T1. The airform is to be cleaned and inspected
to ensure it is free from dirt and is dry prior to applying primer.
After the primer has been applied and has cured, the adhesion
is to be tested prior to applying foam throughout the dome.
Every 10,000 ft2 (929 m2), four locations minimum, a ¼” (6 mm)
thick layer of foam is sprayed over a minimum area of 2’-0”
square (0.2 square meters). The adhesion is then tested and
verified following Dome Technology’s current means and
methods for primer adhesion testing. The results of the primer
adhesion test are to be recorded on form F-3P3.
2. Primer Thickness: A dye is added to the primer to improve the visibility which
allows the technicians to better observe the cured primer on the
air form. Total primer application rates may be verified by taking
the overall surface area of the air form and dividing by the
volume of primer used. Spot checks are to be performed by an
experienced technician to verify that the primer thickness meets
the design specifications. Daily logs are to be kept to record the
location and amount of primer sprayed and the design
application rates and thicknesses.
3. Primer Quality: The primer is mixed for at least ten minutes prior to use. Primer
is to be remixed if allowed to settle, such as overnight. The
primer is stored above 45° Fahrenheit (7.2° Celsius) per the
manufacturer’s recommendations. The primer application is
inspected by the Project Superintendent, QAQC Manager or
Foam Supervisor and a daily quality checklist is to be
completed.
4. Primer Finish: The primer is to be inspected after it is applied. Cured primer
should be tacky to the touch and running should be minimized.
Acceptable Tolerance:
1. Primer Adhesion:
The minimum adhesive strength of the primer must be 2.8 psi
(0.020 MPa). The results of site testing must confirm that the
adhesive strength meets the design requirements. Additional
primer is to be applied and retested in areas that do not meet
this minimum criteria.
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2. Primer Thickness:
At least 90% of spot checks must meet the minimum plan
thickness. Application rates must be within 10% of the design
rates.
3. Primer Quality: Dome Technology does not accept placement of poor quality
primer on the dome. If a section of primer does not meet the
design specifications, it is to be removed and reapplied.
4. Primer Finish: Primer is to be covered with polyurethane foam; therefore, the
surface texture is not an issue if other primer criteria are met.
Related Documents: F-3P1 (Primer Placement)
F-3P2 (Primer Application Checklist)
F-3P3 (Primer Adhesion)
F-3T1 (Temp, Relative Humidity & Dew Point Log)
QAQC 3.3.2: Polyurethane Foam Process - Application
Quality Control Measure: Proper adhesion, thickness, quality and texture
Potential Quality Concern:
1. Foam Adhesion:
The air form must be clean, dry and the primer properly cured
prior to spraying foam. Ensure the foam gun is in good working
condition. Temperatures and dew points inside the dome must
meet the quality control specifications.
2. Foam Thickness: The foam must be sprayed in uniform layers at specified
thicknesses. Uneven or irregular application of foam is to be
avoided.
3. Foam Quality: The foam equipment and foam machines must be in good working
condition to ensure the foam chemicals are delivered to the spray
tip at the correct ratio, pressure and temperature. Foam must be
applied under the direction of qualified technicians.
4. Foam Finish: Foam overspray must be cleaned between each layer applied.
Foam texture is to be inspected for proper adhesion between
layers; a smooth to orange peel texture is verified.
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Quality Assurance Procedure:
1. Foam Adhesion:
Temperature, Relative Humidity and Dew Points are to be
recorded daily on form F-3T1. The first layer of foam is to be quite
thin, especially if the skin temperature is low. After the first layer
is applied it should be allowed to set, cure and bond to the
skin/primer before additional layers are sprayed. This takes
longer in cold weather. Once all the foam has been applied and
has cured, the foam adhesion is to be tested prior to hanging
premat throughout the dome. Every 10,000 ft2 (929 m2), four
locations minimum, a sticker is to be cored and tension tested to
verify the adhesion between the foam layers. Dome Technology’s
current means and methods for foam adhesion testing is to be
used. The results of the foam adhesion test results are to be
recorded on form F-3PF4.
2. Foam Thickness: Foam placement and thicknesses are recorded daily. Foam
thickness is to be measured with a depth probe. The probe is
pushed into the foam on the air form and the depth is measured.
Care must be taken not to penetrate the air form when using the
probe.
3. Foam Quality: Foam barrels are stored at the manufacturers recommended
temperatures and are mixed prior to use. A sample of foam is to
be sprayed each day and inspected for quality in structure and
mix ratio prior to applying foam on the substrate. A daily log is
kept and foam chemical ratios, amounts, pressures and
temperatures are recorded. The foam application is inspected by
the project Construction Superintendent, QAQC Manager or
Foam Supervisor and a daily application checklist is completed.
Any foam placed that shows the characteristics of an off-ratio mix
is to be examined in detail. Wherever off-ratio foam is determined
to have been applied, it is removed and replaced.
4. Foam Finish: The Construction Superintendent or QAQC Manager ensures that
foam overspray is cleaned prior to applying an additional layer.
When properly prepared, the surface texture of the foam is
beneficial to adhesion when applying a subsequent layer of foam
or shotcrete.
Acceptable Tolerance:
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1. Foam Adhesion: Foam is only be applied when the Dew Point is measured to be
5° F (2.8° C) above the ambient temperature recorded inside of
the dome. The minimum adhesive strength of the foam core must
be 2.8 psi (0.020 MPa). The results of site testing must confirm
that the adhesive strength meets this design requirement. Foam
is to be repaired and retested in areas that do not meet this
minimum criteria.
2. Foam Thickness: The minimum total thickness of foam on an air form is 1¼” (32
mm). The tolerance for foam thickness is ±½" (13 mm). There is
to be at least ¾” (19 mm) in place prior to placing the stickers.
Sufficient foam must cover the stickers to lock them in place;
approximately ½” (13 mm). When thicker insulation is specified,
the additional foam should be applied prior to placing the stickers.
3. Foam Quality: Dome Technology does not accept placement of off-ratio foam on
the dome; off-ratio foam is to be removed and replaced.
4. Foam finish: All foam is to be covered with shotcrete; therefore, the surface
texture is not an issue if all foam QAQC criteria are met. The final
foam surface should be smooth enough both horizontally and
vertically to ensure the pre-mat rebar can be placed next to the
surface of the foam without being held away by undulating foam.
Related documents: F-3PF1 (Polyurethane Foam Placement)
F-3PF2 (Polyurethane Foam Application Checklist)
F-3PF3 (Poly Foam Log & Inspection)
F-3PF4 (Polyurethane Foam Adhesion)
F-3T1 (Temp, Relative Humidity & Dew Point Log)
QAQC 3.4: Pre-Mat Steel
QAQC 3.4.1: Pre-Mat Steel - Sticker Placement
Potential quality concern:
Incorrect sticker spacing; Improper leveling & spacing;
Inadequate tensile strength
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Dome Technology Quality Assurance Quality Control Plan
Quality Control Measure: The specifications for sticker placement are generated by the
Project Manager and Construction Superintendent. Sticker pull
testing is to be performed and documented to verify that the
design strength is achieved prior to hanging premat steel. When
performing the test, a sticker should be pulled to 50 lb (23 kg)
and held for 2 seconds. The sticker test should be performed
every 900 ft2 (81 m2) or every 30’-0” (9 meters) in each direction.
Quality Assurance Procedure: Sticker placement is recorded daily on form F-ST1. The sticker
placement is to be inspected by the Project Construction
Superintendent or the QAQC Manager. If a sticker fails the pull
test, an adjacent sticker is to be pulled and must pass or the
area is deemed deficient. Areas that are found to be deficient
in tensile strength are marked and additional foam is to be
applied. The area is retested until the strength requirements
have been satisfied.
Acceptable tolerance: Although it is essential that the correct number of sticker rows
be placed and that rows are placed level horizontally, the
vertical spacing of the rows can vary up to 20%. The horizontal
spacing of sticker columns may vary up to 12" (30 cm). 100%
of the areas tested must meet the specified tensile strength.
Related Documents: F-3ST1 (Sticker Placement Summary)
F-3ST2 (Sticker Pull Test)
QAQC 3.4.2: Pre-Mat Rebar Placement
Potential Quality Concern: Proper placement; Proper laps and splice ties; Proper
attachment to stickers; Sufficient intersection ties
Quality Control Measure: Rebar is to be inspected and documented following the
procedures of section 1.2.2 of this Plan. Pre-mat rebar
placement is to be specified by the Project Manager. Pre-mat
rebar is tied to the stickers horizontally. Vertical pre-mat bars
are to be tied to the horizontal bars at 100% of the intersections.
Lap lengths are to be in accordance with the minimums
specified in the contract documents. Lapping bars are to be
placed in contact to one another and wire tied at each end of
each splice.
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Dome Technology Quality Assurance Quality Control Plan
Quality Assurance Procedure: The pre-mat bar placement is to be inspected by the Project
Construction Superintendent or QAQC Manager who verifies
proper laps, splices, staggering, ties and placement. The daily
placement of bars is documented & a rebar checklist is
completed to verify that the pre-mat rebar has been placed
according to the quality control measures specified in this Plan.
Acceptable tolerance: Pre-mat rebar spacing, laps, splices and ties are to be within
20% of the specified dimensions.
Related Documents: F-3R1 (Rebar Placement-Dome)
F-3R2 (Rebar Checklist-Dome)
QAQC 3.4.3: Depth Gauge Installation
Potential Quality Concern: Proper gauge lengths & placement
Quality Control Measure: Depth gauges are used to verify final shotcrete thicknesses
throughout the dome. Depth gauges are also used to monitor
intermediate thicknesses for proper rebar placement &
shotcrete embedment. The design thickness of the concrete
varies throughout the dome shell in accordance with the
contract documents. Varying lengths of depth gauges are made
to correspond with these thicknesses. Depth gauges are placed
at the location of transitions in dome shell thickness as they are
specified in the contract documents. They are also placed at
equivalent distances throughout the dome. Vertical spacing of
depth gauges is not to exceed 6'-0” (1.8 meters); horizontal
spacing is not to exceed 12'-0” (3.6 meters).
Quality Assurance Procedure: The Construction Superintendent or QA Manager inspects and
verifies that gauges of the proper length are in place at the
correct locations prior to spraying the pre-mat shotcrete. The
placement of each gauge is to be documented in a depth gauge
QC log. Depth gauges are to be inspected as rebar and
shotcrete are placed to ensure proper placement and
embedment throughout the construction process.
Acceptable tolerance: When change in thickness is denoted, the depth gauge should
be placed within +6" (15 cm) of the change location; otherwise
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Dome Technology Quality Assurance Quality Control Plan
the spacing of depth gauges can vary up to 2-3 feet (60-90 cm).
Gauge depths may vary by ¼” (6 mm), gauges that are not
within this tolerance must be replaced.
Related Documents: F-3DG1 (Depth Gauge Installation QC Log)
F-3R2 (Rebar Placement-Dome)
F-3S1 (Shotcrete Placement)
QAQC 3.4.4: Mounter Wire Placement
Potential Quality Concern: Proper placement; Verification of strength to support structural
mats of rebar.
Quality Control Measure: Mounter wires are attached to the pre-mat rebar as well as
intermediate mats of steel to support consecutive mats. The
size and placement of these wires is to be determined by Project
Manager and the Project Construction Superintendent and are
placed as required to support the consecutive mats. The wires
must be in the correct position and be of adequate size and
quantity to support the required mounting bars, steel mats, and
additional steel specified around entry ways and openings.
Quality Assurance Procedure: Upon completion of the placement of the mat of steel, and prior
to applying additional shotcrete, the project Construction
Superintendent or QAQC Manager inspects the placement of
the mounting wires for proper installation. A daily rebar checklist
is to be completed and is to include a verification that the
mounter bars have been properly placed and the quality control
measures of this Plan are followed.
Acceptable tolerance: Quantity and placement is to be within 90% of the specified
spacing.
Related Documents: F-3R2 (Rebar Checklist-Dome)
Project Manager Summary Report: Mounter Wire
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QAQC 3.5: Dome Shell
QAQC 3.5.1: Shotcrete - Materials
Potential Quality Concern: Poor shotcrete quality; insufficient strength; pumping problems
Quality Control Measure:
The Construction Superintendent or QAQC Manager reviews
the batch information and follows the criteria for accepting or
rejecting the load per section 2.1.1 of this Plan. A local supplier
is to provide quality shotcrete to the project by using a shotcrete
mix design that complies with Dome Technology’s standard
design, modified as agreed upon to meet project specifications.
The basic mix design includes approximately 900 pounds of
cement powder per cubic yard (534 kg/m3). 100 pounds (45 kg)
of fly ash may be substituted for an equivalent weight of cement;
fly ash used must be in accordance with ASTM C 168. The
aggregate used in the approved shotcrete is to be
predominantly 1/4" (6mm) minus concrete sand. A range of
water-to-cement ratio is specified to provide a mix typically with
a 4-6 inch (10-15cm) slump. The slump may be adjusted in the
field to ensure the shotcrete is easily pumped; however, care is
to be taken to confirm the slump and water-to-cement ratio fall
within the range given in the design specifications.
Concrete cylinders are to be prepared from a random batch for
each 50 cubic yards (40 cubic meters) delivered, but not less
than one set each production day. The compressive strength
is to be tested by an independent testing agency. At minimum,
7 & 28 day tests should be performed and a 56 day hold cylinder
should be cast. The Engineer of Record is to be notified of the
placement of any shotcrete that does not meet the compressive
strength requirements. Recommendations provided by the
engineer are to be followed and all required corrective actions
must be taken.
Quality Assurance Procedure:
The criteria for accepting a load of shotcrete follows the quality
assurance procedure of section 2.1.1 of this Plan. A preliminary
batch of the shotcrete mix should be tested for strength and sent
through the pump to test the workability.
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Independent lab results for the cylinder breaks are to be
provided to the project Construction Superintendent or Project
Manager for review and to verify that the design strength is met.
Shotcrete test data is to be recorded and saved. At the
beginning of the job, extra cylinders to be tested for 3 day
strength may be made at the request of the Project Manager.
The 3-day breaks are reviewed against potential break curves
to confirm strength and shotcrete quality; thereby allowing early
adjustments to be made to the mix as necessary.
Acceptable Tolerance: Shotcrete must be workable and easy to pump and is to achieve
the design strength at 28 days. The compressive strength must
be verified by an independent lab. Acceptable shotcrete is to
follow the tolerances of section 2.1.1 of this Plan.
Related Documents: Concrete Testing Log
Concrete Batch Tickets
QAQC 3.5.2: Shotcrete Placement
Potential Quality Concern: Safe load limits of shotcrete placement during all construction
phases; maintain proper thickness & weight distribution
Quality Control Measure: The Project Manager and project Construction Superintendent
determine the order, the timing, and rate of thickness with which
the shotcrete is placed. A daily log is kept identifying the
shotcrete placement by specific zones and quadrants as well as
the thickness and time of application.
Quality Assurance Procedure: The project Construction Superintendent directs how the
shotcrete is applied to the zones and directs the crew day to day
as to where shotcrete is to be applied. The amount of shotcrete
applied and the zones sprayed is to be reported and verified.
The nozzlemen confirm the thickness of the shotcrete each day.
The Construction Superintendent or QAQC manager verifies
that the shotcrete is applied evenly to maintain a proper weight
distribution.
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Dome Technology Quality Assurance Quality Control Plan
Acceptable Tolerance: Although, shotcrete structures are not required to meet the
tolerance specifications of cast-in-place structures, the
thickness tolerance for Dome Technology’s thin shelled dome
construction is to meet or exceed the specifications of ACI 334.3
section 4.18. Unless otherwise specified in the contract
documents, the tolerance of dome walls 12” (30 cm) and thinner
are to be the lesser of +25% to -10% and 2" (5 cm) of the
specified thickness. Walls thicker than 12” (30 cm) are to
maintain a tolerance of +15% to -5%.
Related Documents: F-3S1 (Shotcrete Placement)
QAQC 3.5.3: Embedment of Pre-Mat Steel with Shotcrete
Potential Quality Concern:
Proper embedment of rebar; Air pressure control; Proper weight
distribution
Quality Control Measure: The embedment of pre-mat steel is a critical phase in dome
construction, the locations, thicknesses and sequence of
shotcrete placement are directed by the Project Manager and
Construction Superintendent. Although the pre-mat rebar is not
considered structural steel, it gives the structure an initial
rigidity. Great care must be taken to properly embed the bars
using the placement techniques specified in ACI 506.2. Pre-mat
rebar is to be embedded with thin layers of shotcrete that are
inspected daily.
Quality Assurance Procedure: Shotcrete is to be placed by or under the direct supervision of a
Dome Technology certified nozzleman. The shotcrete
nozzlemen controls the quality of the shotcrete application. The
nozzlemen are trained to regulate embedment thicknesses and
adjust shotcrete techniques as necessary to best meet the
requirements of each dome area. The procedures for applying
shotcrete given in ACI 506 “Guide to Shotcrete” are to be
followed.
The project Construction Superintendent or QAQC Manager
inspects the pre-mat embedment with the shotcrete foreman
throughout the dome. The shotcrete is to be inspected for
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noticeable voids as the pre-mat is embedded. Shotcrete
determined to contain voids is to be removed and replaced prior
to the next application in the same area. Thickness of
embedment is determined by the pre-mat bar thickness minus
the clear distance for the structural steel specified in the design
drawings. Depth gauges are to be checked and recorded daily
to verify the shotcrete thickness. A pour card checklist is to be
completed each day by the Construction Superintendent or
QAQC manager who verifies that the shotcrete has been
applied in accordance with the QAQC Plan.
Acceptable Tolerance: Shotcrete embedding pre-mat rebar is to be within 20% of the
specified thickness.
Related Documents: F-3S1 (Shotcrete Placement)
F-3S2 (Shotcrete Pour Card)
QAQC 3.5.4: Shotcrete Surface Preparation
Potential Quality Concern: Cleaning of overspray and rebound; verify SSD conditions;
Removal of laitance, sand pockets, dust and debris
Quality Control Measure: Prior to applying a consecutive layer of shotcrete, the shell is to
be inspected for the build-up of overspray, rebound, laitance,
sand pockets, dust and/or debris by the Construction
Superintendent or the QAQC Manager. The dome shell is
cleaned as required and shotcrete overspray, rebound, sand
pockets and laitance are removed from all areas where
additional shotcrete layers are to be applied. A blow pipe is to
be used to remove overspray as the shotcrete is placed. The
shell is also to be inspected daily to ensure that the surface is in
a surface saturated dry (SSD) condition prior to applying
additional shotcrete.
Quality Assurance Procedure: Rebound generally accumulates at the connection of the dome
shell and the dome footing. Typically the removal is completed
by blowing the materials away with an air lance as the shotcrete
is applied. However, additional roughening and chipping may be
needed if excessive overspray, sand pockets or laitance is
observed. If excessive surface evaporation has taken place
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between the shooting of successive layers, water should be
applied to the surface to ensure an SSD condition prior to
applying additional shotcrete. The adequacy of the surface
preparation is to be signed off on daily on the shotcrete pour
card by the Construction Superintendent or QAQC Manager.
Acceptable Tolerance: The surface preparation is to meet the requirements of ACI
506.2 section 3.3.2.
Related Documents: F-3S2 (Shotcrete Pour Card)
QAQC 3.5.5: Structural Rebar Placement
Potential Quality Concern: Proper steel placement; correct splice lengths & staggered
splices; appropriate size & grade of steel
Quality Control Measure: Acceptance of steel reinforcement to be used in the dome shell
is to follow the requirements of section 2.1.2 of this Plan. The
placement of the structural steel reinforcement is designated by
the structural engineer and specified on the building plans. The
attachment of the steel to the dome shell is performed under the
direction of the project Construction Superintendent. The
Superintendent directs placement to ensure proper weight
distribution and oversees attachment procedures to ensure safe
steel placement. The placement locations & amounts of steel
placed are recorded daily. The Construction Superintendent or
QAQC Manager is responsible for inspecting the placement of
the steel, verifying that bar size and splice locations are correct,
measuring and documenting spacing and splice lengths and
ensuring the approved plans are being followed. The depth
gauges are inspected daily to ensure the reinforcement is
placed at the correct embedment. Where multiple mats of steel
are specified, spacing between mats are also measured and
verified.
Quality Assurance Procedure: The project Construction Superintendent or QAQC Manager
receive the steel reinforcement on site accompanied by a mill
certification. The mill cert is to be reviewed to ensure the steel
meets the requirements for quality, type, size and grade. The
steel is physically assessed and inspected for visual
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conformance to the standards, noting rust, flaking, excess bend
damage, etc. that would cause rejection of the materials. If the
quality of the shipped steel is not acceptable details are to be
reported for why the materials are rejected. A quality control
checklist is to be completed for the rebar placed in the dome
shell. This QAQC form is to note the required rebar spacing &
splice lengths and, upon inspecting the rebar, is to be signed to
verify that the steel placement is in accordance with the plans.
Daily placement of the rebar is recorded and is to include the
locations and quantities of the reinforcement placed.
Acceptable Tolerance: Rebar placement is to meet the tolerances specified in ACI 117
section 2.2 unless otherwise specified in the contract
documents. Where 50% or more of the splices are placed in
the same location, the splice length is to be increased by a factor
of 1.3.
Steel reinforcement and embeds must meet the design criteria.
The Project Construction Manager or QAQC Manager reviews
the mill certs and rejects any steel that does not meet the
approved specifications.
Related Documents: F-3R1 (Rebar Placement-Dome)
F-3R2 (Rebar Checklist-Dome)
QAQC 3.5.6: Shotcrete Placement and Structural Steel Embedment
Potential Quality Concern: Proper embedment of rebar; Correct placement techniques;
Proper weight distribution;
Quality Control Measure: The daily placement of shotcrete including the location and
thickness is directed day to day by the Project Construction
Superintendent. As the shotcrete is applied, great care is taken
to properly embed the bars using the placement techniques
specified in ACI 506.2. Thicknesses and application rates are
monitored and recorded to verify that the shotcrete is evenly
distributed. The Construction Superintendent or QAQC
Manager inspects the work done daily and verifies that the
shotcrete quality is in accordance with the QAQC Plan. If
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Dome Technology Quality Assurance Quality Control Plan
acceptable quality is not achieved, remedial action must be
taken to ensure proper embedment.
Quality Assurance Procedure: Shotcrete is placed by or under the direct supervision of a Dome
Technology certified nozzleman. The shotcrete nozzlemen
control the quality of the shotcrete application. The nozzlemen
regulate embedment thicknesses and adjust shotcrete
techniques as necessary to best meet the requirements of each
dome area. The procedures for applying shotcrete given in ACI
506 “Guide to Shotcrete” are to be followed.
The project Construction Superintendent or QAQC Manager
inspect the embedment of the structural reinforcement
throughout the dome. The shotcrete is inspected for noticeable
voids as the bar is embedded. Shotcrete determined to contain
voids or excessive shadowing or sand pockets are to be
removed and replaced prior to the next application in the same
area. Thickness of embedment is determined by measuring the
depth gauges which are inspected daily. A pour card checklist
is to be completed each day by the Construction Superintendent
or QAQC manager who verifies that the shotcrete has been
applied in accordance with the QAQC Plan.
Acceptable Tolerance: The tolerance for steel embedment is per ACI 117 or as
otherwise specified in the approved construction drawings.
Embedment is measured against the depth gauges. This
tolerance applies to dimensions between mats of steel as well
as clear distances. Tolerances for the total thickness of finished
shotcrete are to be in accordance with section 3.5.2 “Shotcrete
Placement”.
Related Documents: F-3S1 (Shotcrete Placement)
F-3S2 (Shotcrete Pour Card)
QAQC 3.5.7: Final Shell Completion
Potential Quality Concern: Correct wall thickness & rebar cover; Acceptable finish
Quality Control Measure: Upon completion of the dome shell the Construction
Superintendent or QAQC Manager is to verify that the wall
thicknesses and rebar cover are within the design tolerances.
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The depth gauge locations are to be inspected and the walls
between the gauges examined to ensure that a consistent wall
thickness has been achieved and the finish is in accordance
with the contract specifications.
Quality Assurance Procedure: Upon approving the quality of the finished shell, a walk through
with the General Contractor or Owner’s Onsite Representative
is to take place. The walk through serves as a final inspection
of the work performed and the shell finish. A substantial
completion form is to be signed by the General Contractor or
Owner’s Representative and any deficiencies or items that are
found in need of completion prior to final approval are to be
listed.
Acceptable Tolerance: Finish tolerances are to be in accordance with the contract
specifications and verified and signed off on by General
Contractor or Customer’s Representative in a substantial
completion form.
Related Documents: Notice of Substantial Completion
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Dome Technology Quality Assurance Quality Control Plan
QAQC 4.0: Tunnel Construction
QAQC 4.1: Precast Sections
QAQC 4.1.1: Precast Forms
Potential Quality Concern: Acceptable form tolerances; damaged bracing or work platforms;
broken welds or additional damage; bonding to concrete.
Quality Control Measure: Form placement is to be in accordance with section 2.2.1 of this
Plan. The precast forms are to be measured for correct tolerances
and inspected for any structural damage prior to pouring concrete.
All fasteners, clamps and braces must also be inspected and be
in good working condition prior to each pour. A form-release
agent that does not bond or affect precast concrete surfaces is to
be used. Block-outs are to be placed as specified.
Quality Assurance Procedure: The project Construction Superintendent or QAQC Manager
verifies the dimensions of the fully assembled precast forms prior
to concrete being delivered. A form-release agent is to be used
and documented to prevent bonding of concrete surfaces. A
precast report is completed each day during this phase of
construction and serves to verify that the quality control measures
in this Plan have been followed. Block-outs, as specified in the
approved drawings, are to be documented and referenced in the
precast report.
Acceptable Tolerance: The distance at the base of the tunnel may vary by +/- ¼” (6 mm).
The overall height of the tunnel may vary by +/- ¼” (6 mm).
Related Documents: F-4PC1 (Pre-Cast Tunnel Section QA)
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QAQC 4.1.2: Precast Sections - Rebar & Embed Placement
Potential Quality Concern: Incorrect size or quantity of rebar; rebar incorrectly placed within
the form, missing dogbones or embeds.
Quality Control Measure: Acceptance of steel reinforcement to be used in the dome shell
is to follow the requirements of section 2.1.2 of this Plan. The
placement of the steel reinforcement is designated by the
structural engineer and is to be placed as specified in the
approved construction drawings. The rebar is placed in the
precast forms under the direction of the project Construction
Superintendent. Dogbones or embeds are to be cast into the
sections for picking as designated by the construction
documents.
Quality Assurance Procedure: The project Construction Superintendent or QAQC Manager
receive embeds, if applicable, on site accompanied by a mill
certification. The mill cert is to be reviewed to ensure the steel
meets the requirements for quality, type, size and grade. A
quality control checklist is completed for the rebar placed within
the precast forms. This QAQC form is to note the required rebar
spacing, splice lengths and coverage and is to document the
placement of any embeds that are specified.
Acceptable Tolerance: When the number of bars per section is specified, the spacing
of the steel is not as critical as having the correct amount of steel
in place. Although equivalent spacing is preferred, it may vary
by up to 25%. The concrete cover of the rebar is to meet the
tolerances specified in ACI 117 section 2.2.2 unless otherwise
specified in the contract documents.
Where 50% or more of the splices are placed in the same
location, the splice lengths are to be increased by a factor of 1.3
unless otherwise specified in the contract documents.
Steel reinforcement and embeds must meet the design criteria.
The project Construction Manager or QAQC Manager reviews
the mill certificates and rejects any steel that does not meet the
approved specifications.
Related Documents: F-2R1 (Rebar Checklist-Concrete)
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F-4PC1 (Pre-Cast Tunnel Section QA)
QAQC 4.1.3: Precast Sections - Concrete Placement and Curing
Potential Quality Concern: Poor concrete quality; bad consolidation; improper curing
techniques or time.
Quality Control Measure: Concrete quality is to be verified in accordance with section
2.1.1 of this Plan. The precast concrete is placed by or under
the direction of a qualified concrete foreman. Vibrators are
staged on hand prior to the pour. The concrete is vibrated as it
is poured in a manner which properly consolidates it around the
rebar and prevents honeycombing in corners, on form walls and
around blockouts. Curing materials are also on hand to provide
proper curing. Hot or cold weather plans are to be developed
as applicable and followed throughout the curing process.
Quality Assurance Procedure: Proper vibration techniques are used to consolidate the
concrete following the recommendations given in ACI 309.
Concrete curing meets the specifications of ACI 308. The
project Construction Manager or QAQC Manager inspects and
documents the precast concrete placement. A concrete pour
card is to be filled out each day prior to pouring concrete.
Acceptable Tolerance: Concrete quality tolerances are to be in accordance with section
2.1.1 of this Plan. Acceptable curing follows the criteria given in
ACI 308 & consolidation the criteria of ACI 309.
Related Documents: F-2C1 (Concrete Pour Card)
F-4PC1 (Pre-Cast Tunnel Section QA)
Concrete Testing Log
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QAQC 4.2: Invert
QAQC 4.2.1: Invert Steel
Potential Quality Concern: Incorrect size or quantity of rebar placed; rebar incorrectly
placed within the formwork; missing dowels, embeds or
anchors
Quality Control Measure: Acceptance of steel reinforcement is to follow the requirements
of section 2.1.2 of this Plan. The placement of the rebar is
designated by the structural engineer and is to be placed as
specified in the approved construction drawings. The rebar is
placed within the invert formwork under the direction of the
project Construction Superintendent.
Quality Assurance Procedure: Proper placement of dowels, embeds and anchors are verified
and documented as the steel is placed. A quality control
checklist is completed for the rebar placed within the invert
formwork. This QAQC form is to note the required rebar
spacing, splice lengths and coverage.
Acceptable Tolerance: Rebar placement is to meet the clearance & tolerances
specified in ACI 117 section 2.2 unless otherwise specified in
the contract documents.
Where 50% or more of the splices are placed in the same
location, the splice length is to be increased by a factor of 1.3
unless otherwise specified in the contract documents.
Steel reinforcement and embeds must meet the design criteria.
The Project Construction Superintendent or QAQC Manager
reviews the mill certificates and rejects any steel that does not
meet the approved specifications.
Related Documents: F-2R1 (Rebar Checklist-Concrete)
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QAQC 4.2.2: Invert Concrete
Potential Quality Concern: Poor concrete quality; bad consolidation; improper curing
techniques or time; improper finishing
Quality Control Measure: Concrete quality is to be verified in accordance with section
2.1.1 of this Plan. Invert formwork is to meet the requirements
of section 2.2.1 of this Plan. The concrete is placed by or under
the direction of a qualified concrete foreman. Vibrators &
finishing tools are staged on hand prior to the pour. The
concrete is vibrated as it is poured in a manner which properly
consolidates around the rebar and prevents honeycombing in
corners and on formwork walls. Finishing work uses proper
techniques and is done in a timely manner to meet the project
specifications. Curing materials are also on hand to provide
proper curing. Hot or cold weather plans are to be developed
as applicable and followed throughout the curing process which
is to last 7 days unless otherwise specified in the contract
documents.
Quality Assurance Procedure: Daily inspection and QAQC forms are to be completed to ensure
the construction plans are followed. Proper vibration techniques
are used to consolidate the concrete following the
recommendations given in ACI 309. Concrete curing meets the
specifications of ACI 308. The Project Construction Manager or
QAQC Manager inspects and documents invert concrete
placement. A concrete pour card is filled out each day prior to
pouring concrete and a concrete pour inspection is completed
to document the pour. The placement of embeds, anchors &
dowels are to be inspected and documented. Invert elevations
are verified and are to meet the acceptable tolerances.
Acceptable Tolerance: Concrete quality must be in accordance with section 2.1.1 &
formwork the criteria of 2.2.1 of this Plan. Acceptable curing
follows the criteria given in ACI 308 & consolidation the criteria
of ACI 309. Invert finish elevations are to meet the tolerances
given in ACI 117.
Related Documents: F-2C1 (Concrete Pour Card)
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F-2C2 (Concrete Pour Inspection)
F-2F1 (Forms Checklist)
Concrete Testing Log
QAQC 4.3: Tunnel Placement & Finishing
QAQC 4.3.1: Placing Precast Sections
Potential Quality Concern: Damaging the sections during transport and setting; placing the
hopper sections in the wrong location; damaging the invert
dowels
Quality Control Measure: When using a crane to set the forms, the dogbones are to be
utilized to lift the sections. The pick points are to be approved
by the design engineer. A tagline is used to keep the section
under control as it is moved into place and a spotter assists in
directing each section into its final position. When using a forklift
to set the sections, the forks are to be covered with a material
that does not scrape, chip, or damage the underside of the
sections. A spotter is similarly used to guide the forklift as the
sections are placed.
Quality Assurance Procedure: Equipment operators verify that all safeguards are in place on
their equipment prior to moving a tunnel section. A quality
checklist for the placement of the precast is filled out each day
sections are placed. The precast number and position are to be
recorded. Job specific training is given to the crew outlining the
sequencing and importance of quality control while placing the
precast sections. The tunnel invert is marked prior to setting the
sections to ensure placement precision.
Acceptable Tolerance: Precast sections may vary in their placement by +/- ½” (13
mm).
Related Documents: F-4PC2 (Precast Placement Checklist)
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QAQC 4.3.2: Closure Pour
Potential Quality Concern: Poor concrete quality; bad consolidation, especially under
precast section legs; improper curing techniques or time
Quality Control Measure: Concrete quality is to be verified in accordance with section
2.1.1 of this Plan. Closure pour formwork is to meet the
requirements of section 2.2.1 of this Plan. The concrete is
placed by or under the direction of a qualified concrete foreman.
Vibrators & finishing tools are to be staged on hand prior to the
pour. Great care is to be taken to vibrate the concrete
underneath the precast legs to completely consolidate the
concrete in and around the precast hooks and invert dowels.
Curing materials are also to be on hand to provide proper curing.
Hot or cold weather plans are to be developed as applicable and
followed throughout the curing process which lasts 7 days
unless otherwise specified in the contract documents. Daily
inspection and QAQC forms are completed to ensure the
construction plans are followed.
Quality Assurance Procedure: Proper vibration techniques are used to consolidate the
concrete following the recommendations given in ACI 309.
Concrete curing is to meet the specifications of ACI 308. The
project Construction Manager or QAQC Manager inspects the
concrete and formwork placement for the closure pour. A
concrete pour card is to be filled out each day prior to pouring
concrete and a concrete pour inspection is to be completed to
document the pour.
Acceptable Tolerance: Acceptable curing follows the criteria given in ACI 308 &
consolidation the criteria of ACI 309. Concrete quality must be
in accordance with section 2.1.1 & formwork the criteria of 2.2.1
of this Plan.
Related Documents: F-2C1 (Concrete Pour Card)
F-2C2 (Concrete Pour Inspection)
F-2C3 (Concrete Testing QA)
F-2F1 (Forms Checklist)
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QAQC 4.3.3: Hopper Concrete Walls
Potential Quality Concern: Poor concrete quality; bad consolidation; improper curing
techniques or time; Incorrect dimensions or out of plumb
Quality Control Measure: Concrete quality is to be verified in accordance with section 2.1.1
of this Plan. Prior to pouring concrete, the wall elevations,
dimensions & plumbness are to be verified and must meet the
acceptable tolerances; formwork is to meet the requirements of
section 2.2.1 of this Plan. The concrete is placed by or under the
direction of a qualified concrete foreman. Vibrators & finishing
tools are staged on hand prior to the pour. The concrete is
vibrated as it is poured in a manner which properly embeds the
rebar and attains satisfactory consolidation. Particular attention is
to be paid to dimensions & plumbness to ensure that the
manufactured hoppers fit as specified. Curing materials are also
staged on hand to provide proper curing. Hot or cold weather
plans are developed as applicable and followed throughout the
curing process which lasts 7 days unless otherwise specified in
the contract documents. Daily inspection and QAQC forms are to
be completed to ensure the construction plans are followed.
Quality Assurance Procedure: Proper vibration techniques are to be used to consolidate the
concrete following the recommendations given in ACI 309.
Concrete curing is to meet the specifications of ACI 308. The
project Construction Manager or QAQC Manager is to inspect and
document the concrete placement for these walls. A concrete
pour card is to be filled out each day prior to pouring concrete and
a concrete pour inspection is to be completed to document the
pour.
Acceptable Tolerance: Concrete quality must be in accordance with section 2.1.1 &
formwork the criteria of 2.2.1 of this Plan. Acceptable curing is to
follow the criteria given in ACI 308 & consolidation the criteria of
ACI 309. The finish dimensions of the hopper concrete walls are
to meet the tolerances given in ACI 117.
Related Documents: F-2C1 (Concrete Pour Card)
F-2C2 (Concrete Pour Inspection)
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F-2F1 (Forms Checklist)
Concrete Testing Log
QAQC 4.3.4: Waterproofing
Potential Quality Concern: Damaged, missing, or incorrectly installed waterproofing
elements
Quality Control Measure:
The crew installing the waterproofing is to undergo job specific
training to understand the sequencing and quality expectations
for placing the waterproofing. During application, the
waterproofing application is inspected to ensure that it is installed
correctly and meets industry standards and the manufacturer’s
recommendations. Any waterproofing that is damaged during
construction is to be documented and repaired; all corrective
actions are to be recorded.
Quality Assurance Procedure: The project Construction Manager or QAQC Manager is to
inspect and report on daily waterproofing placement. A
waterproofing checklist is completed and notes any defects or
damage observed during placement. The checklist is also used
to document that the waterproofing has been installed per the
approved recommendations.
Acceptable Tolerance: Material tolerances for application & thickness are to follow the
manufacturer’s recommendations; Overlapping of layers may be
+/- 1” (25 mm) or as otherwise recommended by the
manufacturer.
Related Documents: F-4W1 (Waterproofing Checklist)
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QAQC 5.0: Additional Dome Elements
QAQC 5.1: Curbs & Piers
QAQC 5.1.1: Curbs & Piers - Rebar
Potential Quality Concern: Incorrect size or quantity of rebar placed; rebar incorrectly placed
within the formwork; missing dowels, embeds or anchors
Quality control procedure: Acceptance of steel reinforcement is to follow the requirements
of section 2.1.2 of this Plan. The placement of the rebar is
designated by the structural engineer and is to be placed as
specified in the approved construction drawings. The rebar is
placed within the formwork under the direction of the project
Construction Superintendent. All embeds & anchors are to be
inspected and the placement verified with the construction
drawings. Extra care should be used when placing dowels
through the dome shell when constructing curbs and piers at the
apex of the dome. The dowels may be placed before access to
the apex is opened or approved for construction.
Quality Assurance Procedure: The project Construction Superintendent or QAQC manager
receive embeds & anchors and review the mill certifications for
dimensions, steel grade & quality. Proper placement of dowels,
embeds and anchors are verified and documented as the steel is
placed. A quality control checklist is completed for the rebar
placed within the formwork of the curbs or piers. This QAQC form
is to note the required rebar spacing, splice lengths and coverage
and is to list the dowels, embeds, anchors and ties placed. The
spacing and splice lengths are also to be listed and verified.
Acceptable Tolerance: Rebar placement is to meet the clearance & tolerances specified
in ACI 117 section 2.2 unless otherwise specified in the contract
documents.
Where 50% or more of the splices are placed in the same
location, the splice length is to be increased by a factor of 1.3
unless otherwise specified in the contract documents.
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Steel reinforcement, anchors & embeds must meet the design
criteria. The Project Construction Superintendent or QAQC
Manager reviews the mill certificates and rejects any steel that
does not meet the approved specifications.
Related Documents: F-2R1 (Rebar Checklist-Concrete)
F-3R1 (Rebar Placement-Dome)
QAQC 5.1.2: Curbs & Piers - Forms
Potential Quality Concern: Acceptable form tolerances; damaged bracing or work platforms;
broken welds or additional damage; bonding to concrete.
Quality Control Procedure: Form placement is to be in accordance with section 2.2.1 of this
Plan. The curb and pier forms are to be measured for correct
tolerances and inspected for any structural damage prior to
pouring concrete. All fasteners, clamps and braces must also be
inspected and be in good working condition prior pouring
concrete. A form-release agent that does not bond or affect
precast concrete surfaces is to be used. Block-outs are to be
placed as specified. Forms are assembled and measured for
correct location. When placing formwork at the apex of the dome,
formwork is to be inspected for proper fit along the curvature of
the dome.
Quality Assurance Procedure: The project Construction Superintendent or QAQC Manager
verifies the dimensions of the fully assembled forms prior to
concrete being delivered. A form-release agent is to be used and
documented to prevent bonding of concrete surfaces. A daily
report is completed as formwork is placed and is to verify that the
quality control measures in this Plan are being followed. Block-
outs, as specified in the approved drawings, are to be
documented and referenced in the report. When placing
formwork at the top of the dome, top of wall elevations must be
confirmed with the construction drawings. Changes made to the
elevations of curbs and piers must be approved by the Engineer
of Record.
Acceptable Tolerance: The top of the Curbs/Piers may vary +/- ¼” (6 mm) from design.
Related Documents: F-2F1 (Forms Checklist)
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QAQC 5.1.3: Curbs & Piers - Concrete
Potential Quality Concern: Poor concrete quality; bad consolidation; improper curing
techniques or time; improper finishing
Quality control procedure: Concrete quality is to be verified in accordance with section 2.1.1
of this Plan. The concrete is placed by or under the direction of
a qualified concrete foreman. Vibrators & finishing tools are
staged on hand prior to the pour. The concrete is vibrated as it is
poured in a manner which properly consolidates around the rebar
and prevents honeycombing in corners and on formwork walls.
Finishing work uses proper techniques and is done in a timely
manner to meet the project specifications. Curing materials are
also on hand to provide proper curing. Hot or cold weather plans
are to be developed as applicable and followed throughout the
curing process which is to last 7 days unless otherwise specified
in the contract documents.
Quality Assurance Procedure: Proper vibration techniques are used to consolidate the concrete
following the recommendations given in ACI 309. Concrete
curing meets the specifications of ACI 308. The Project
Construction Manager or QAQC Manager inspects and
documents the curb and pier concrete placement. A concrete
pour card is filled out each day prior to pouring concrete and a
concrete pour inspection is completed to document the pour. The
placement of embeds, anchors & dowels are to be inspected and
documented. Top of pier/curb elevations are verified and are to
meet the acceptable tolerances.
Acceptable Tolerance: Concrete quality must be in a accordance with section 2.1.1.
Acceptable curing follows the criteria given in ACI 308 &
consolidation the criteria of ACI 309. Curb & pier dimensions are
to meet the tolerances given in ACI 117.
Related Documents: F-2C1 (Concrete Pour Card)
F-2C2 (Concrete Pour Inspection)
Concrete Testing Log
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QAQC 5.2: Entryway
QAQC 5.2.1: Entryway - Rebar
Potential Quality Concern: Incorrect size or quantity of rebar placed; rebar incorrectly placed
within the formwork; missing dowels
Quality control procedure: Acceptance of steel reinforcement is to follow the requirements
of section 2.1.2 of this Plan. The placement of the rebar is
designated by the structural engineer and is to be placed as
specified in the approved construction drawings. The rebar is
placed within the entry formwork under the direction of the project
Construction Superintendent.
Quality Assurance Procedure: Proper placement of dowels is verified and documented as the
steel is placed. A quality control checklist is completed for the
rebar placed within the entry formwork. This QAQC form is to
note the required rebar spacing, splice lengths and coverage.
Acceptable Tolerance:
Rebar placement is to meet the clearance & tolerances specified
in ACI 117 section 2.2 unless otherwise specified in the contract
documents.
Where 50% or more of the splices are placed in the same
location, the splice length is to be increased by a factor of 1.3
unless otherwise specified in the contract documents.
Related Documents: F-2R1 (Rebar Checklist-Concrete)
QAQC 5.2.2: Entryway - Forms
Potential Quality Concern: Acceptable form tolerances; damaged bracing or forms; bonding
to concrete.
Quality control procedure: Form placement is to be in accordance with section 2.2.1 of this
Plan. The entryway forms are to be measured for correct
tolerances and inspected for any structural damage prior to
pouring concrete. All fasteners, clamps and braces must also be
inspected and be in good working condition prior pouring
concrete. When the entryway is poured in multiple lifts, formwork
on the first lift may remain in place to facilitate the placement of
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the formwork of the second lift and extra care must be used when
inspecting multiple lifts for plumb. A form-release agent that does
not bond or affect precast concrete surfaces is to be used. Forms
are assembled and measured for correct location. When placing
formwork along the dome shell, formwork is to be inspected for
proper fit along the curvature of the dome.
Quality Assurance Procedure: The project Construction Superintendent or QAQC Manager
verifies the dimensions of the fully assembled forms prior to
concrete being delivered. A form-release agent is to be used and
documented to prevent bonding of concrete surfaces. A daily
report is completed as formwork is placed and is to verify that the
quality control measures in this Plan are being followed. Top of
wall elevations are to be confirmed to be in accordance with the
construction drawings.
Acceptable Tolerance: The Entryway dimensions may vary +/- 1” (25 mm) from design.
Related Documents: F-2F1 (Forms Checklist)
QAQC 5.2.3: Entryway - Concrete
Potential Quality Concern: Poor concrete quality; bad consolidation; improper curing
techniques or time; improper finishing; Proper construction joints.
Quality control procedure: Concrete quality is to be verified in accordance with section 2.1.1
of this Plan. The concrete is placed by or under the direction of
a qualified concrete foreman. Vibrators & finishing tools are
staged on hand prior to the pour. When pouring walls over 6’-0”
(1.8 meters) care is taken during concrete placement to prevent
aggregate segregation by dropping the concrete. The concrete
is vibrated as it is poured in a manner which properly consolidates
around the rebar and prevents honeycombing in corners and on
formwork walls. Construction joints must be placed per plan or
be approved by the Engineer of Record. Finishing work uses
proper techniques and is done in a timely manner to meet the
project specifications. Curing materials are also on hand to
provide proper curing. Hot or cold weather plans are to be
developed as applicable and followed throughout the curing
process which is to last 7 days unless otherwise specified in the
contract documents.
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Quality Assurance Procedure: Daily inspection and QAQC forms are to be completed to ensure
the construction plans are followed. Proper vibration techniques
are used to consolidate the concrete following the
recommendations given in ACI 309. Concrete curing meets the
specifications of ACI 308. The Project Construction Manager or
QAQC Manager inspects and documents entryway concrete
placement. A concrete pour card is filled out each day prior to
pouring concrete and a concrete pour inspection is completed to
document the pour. The placement of dowels is to be inspected
and documented.
Acceptable Tolerance:
Concrete quality must be in accordance with section 2.1.1.
Acceptable curing follows the criteria given in ACI 308 &
consolidation the criteria of ACI 309. Entryway finish elevations &
dimensions are to meet the tolerances given in ACI 117.
Related Documents: F-2C1 (Concrete Pour Card)
F-2C2 (Concrete Pour Inspection)
Concrete Testing Log
QAQC 5.3: Floor Construction
QAQC 5.3.1: Floor Construction - Rebar
Potential Quality Concern:
Incorrect size or quantity of rebar placed; rebar incorrectly placed;
missing dowels and embeds or anchors; proper construction
joints
Quality control procedure: Acceptance of steel reinforcement is to follow the requirements
of section 2.1.2 of this Plan. The placement of the rebar is
designated by the structural engineer and is to be placed as
specified in the approved construction drawings. The rebar is
placed under the direction of the project Construction
Superintendent. Proper lap splices are placed and verified.
Termination of bar or proper laps at contraction joints and/or
construction joints are placed per plan and verified.
Quality Assurance Procedure: Proper placement of dowels & embeds are verified and
documented as the steel is placed. A quality control checklist is
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completed for the rebar placed. This QAQC form is to note the
required rebar spacing, splice lengths and coverage required.
Acceptable Tolerance: Rebar placement is to meet the clearance & tolerances specified
in ACI 117 section 2.2 unless otherwise specified in the contract
documents.
Where 50% or more of the splices are placed in the same
location, the splice length is to be increased by a factor of 1.3
unless otherwise specified in the contract documents.
Related Documents: F-2R1 (Rebar Checklist-Concrete)
QAQC 5.3.2: Floor Construction - Concrete
Potential Quality Concern:
Poor concrete quality; bad consolidation; improper curing techniques
or time; placement of joints; improper finishing
Quality control procedure: Concrete quality is to be verified in accordance with section 2.1.1 of
this Plan. The concrete is placed by or under the direction of a qualified
concrete foreman. Joints are placed as specified in the approved
drawings. Vibrators & finishing tools are staged on hand prior to the
pour. The concrete is vibrated as it is poured in a manner which
properly consolidates around the rebar and prevents honeycombing in
corners and on formwork walls. Finishing work uses proper techniques
and is done in a timely manner to meet the project specifications.
Curing materials are also on hand to provide proper curing. Hot or cold
weather plans are to be developed as applicable and followed
throughout the curing process which is to last 7 days unless otherwise
specified in the contract documents.
Quality Assurance Procedure: Daily inspection and QAQC forms are to be completed to ensure the
construction plans are followed. Proper vibration techniques are used
to consolidate the concrete following the recommendations given in
ACI 309R. Concrete curing meets the specifications of ACI 308R. The
Project Construction Manager or QAQC Manager inspects and
documents the floor slab concrete placement. A concrete pour card is
filled out each day prior to pouring concrete and a concrete pour
inspection is completed to document the pour. The placement of
embeds are to be inspected and documented. Floor elevations are
verified and are to meet the acceptable tolerances.
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Dome Technology Quality Assurance Quality Control Plan
Acceptable Tolerance: Concrete quality must be in accordance with section 2.1.1 & formwork
the criteria of 2.2.1 of this Plan. Acceptable curing follows the criteria
given in ACI 308R & consolidation the criteria of ACI 309R. Floor slab
finish elevations are to meet the tolerances given in ACI 117.
Related Documents: F-2C1 (Concrete Pour Card)
F-2C2 (Concrete Pour Inspection)
Concrete Testing Log
QAQC 5.4: Post Tensioning
QAQC 5.4.1: PT Ducts
Potential Quality Concern:
Incorrect size or placement; Insecurely fastened or improperly
connected
Quality control procedure: The placement of the PT ducts is designated by the structural
engineer and is to be placed as specified in the approved
construction drawings. The PT ducts are placed under the
direction of the Project Construction Superintendent who is
responsible for training the crew on proper installation. Ducts are
to be inspected and accepted then properly stored before
installation. The center of the ducts are to be placed at the correct
elevations and must be placed in a smooth shape with no kinks
or severe irregularities. Inspections are made to ensure there are
no conflicts with the duct placement and steel reinforcement,
utilities or blockouts. Duct joints must be properly connected at
all joints and any crack or hole must be sealed to prevent the
intrusion of concrete. Ducts must be securely fastened to prevent
movement when shotcrete is applied or concrete poured. Ducts
are to be capped at the end to prevent contaminants from
entering prior to grouting.
Quality Assurance Procedure: Proper placement of PT ducts are verified and documented as
the steel is placed. The number of ducts placed is to be recorded
and proper placement is to be verified. A quality control checklist
(F-5PT1) is completed each day for the ducts placed. This form
will serve to verify that all the required quality control procedures
are followed.
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Acceptable Tolerance: The duct specified in the contract documents is to be used. Ducts
are to be semi-rigid and must bend without crimping or flattening.
Placement of ducts are as indicated in the approved drawings.
Tolerances for duct placement are to meet the requirements of
ACI 117 section 2.2.6.1 unless otherwise specified in the contract
documents.
Related Documents: F-5PT1 (PT Duct Checklist)
QAQC 5.4.2: PT Anchorage
Potential Quality Concern:
Poor anchorage quality; Improper confinement steel; Incorrect blockout
or bearing plate sizes or positions
Quality control procedure: PT anchorage quality is to be verified in accordance with this Plan. The
PT anchorage is placed under the direction of the Project Construction
Superintendent. Anchorage assemblies are inspected and approved
to meet the requirements for design and quality when received on site.
Plates, wedges and spirals must be free from rust, corrosion, grease
or other contaminants. Confinement steel is to be correctly sized and
spaced and be concentric to the trumpets. Blockouts and bearing plate
size and position are to meet the design requirements. Bearing plates
are to be placed perpendicular to the PT strands. Al anchorage support
is to be securely fastened to prevent movement during the placement
of concrete. Congestion of steel around the anchorage is to be
minimized to allow proper consolidation of concrete in the compression
block.
Quality Assurance Procedure: Inspections and a QAQC checklist (F-5PT2) are to be completed daily
to ensure the construction plans are followed. The Project Construction
Manager or QAQC Manager inspects and documents the adequacy of
the PT anchorage placement. Special instructions, confinement steel
& bearing plate sizes and blockout dimensions are documented and
confirmed. All additional reinforcement required in the compression
block is verified and documented on form F-2R1. Formwork, including
anchorage blockouts, are verified and recorded on form F-2F1.
Acceptable Tolerance: Steel reinforcement quality must be in accordance with section 2.1.2 &
formwork the criteria of 2.2.1 of this Plan. Bearing Plate placement
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tolerances are to meet the requirements of ACI 117 section 2.2.9
unless otherwise specified in the contract documents.
Related Documents: F-2F1 (Forms Checklist)
F-2R1 (Rebar Checklist-Concrete))
F-5PT2 (PT Anchorage Checklist)
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QAQC 6.0: Steel
QAQC 6.1: Bulkhead Doors
QAQC 6.1.1: Door Fabrication/Installation
Potential Quality Concern: Door located incorrectly, incorrect steel grade or members,
poor welds, poor galvanization or paint
Quality control procedure: All steel used is to be inspected upon receipt and verified for
quality, type & grade. Steel is to be fabricated according to the
specifications contained in the approved structural drawings &
shop drawings. Welding procedures, electrodes and welder
qualifications are to conform to the “Code for Welding in Building
Construction”, American Welding Society (AWS) and the AISC
“Specifications for the Design, Fabrication and Erection of
Structural Buildings”. Galvanizing/Paint is applied according to
the requirements specified in the contract documents. The door
is to be properly prepped for shipment to minimize damage to
the doors. Once received onsite the door location is to be
verified and the doors are to be installed per the approved
specifications.
Quality Assurance Procedure: Prior to fabrication, the steel members are to be verified and
documented. During fabrication dimensions, welds, paint quality
and thicknesses are to be documented and verified to meet the
design specifications. Shipping preparations must be signed off
on prior to shipping the doors to the job site.
Acceptable Tolerance: Tolerances are per the approved structural drawings.
Related Documents: F-6D1 (Door Installation Checklist)
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Sample Forms
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Revisions
June 2014: Issued as Rev A for initial review and comment
August 2014: Issued as Rev B for review and comment
September 2014: Issued as Rev 0
May 2015: Issued as Rev 1; Revisions to foam testing methods & added updated forms
October 2015: Issued Rev 2; Complete revision of QAQC form/report templates; added sections for
pile/pier foundations & concrete post tensioning