Plant Certification FAQs - Certification

A: The NPCA Plant Certification Program is an exciting way for
precast and prestressed concrete plants to demonstrate their
commitment to production of high-quality products. The basis of
this voluntary certification program is the Quality Control Manual
for Precast and Prestressed Concrete Plants (NPCA Quality
Control Manual) published by NPCA. The program covers all
aspects of a precast operation necessary for quality assurance
during the production of high-quality precast or prestressed
concrete products. Compliance with the Quality Control Manual
is verified through annual inspections of certified plants. The
program certifies that plants meeting the requirements set forth
in the NPCA Quality Control Manual are capable of producing
high-quality products. The program does not certify products
themselves.

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Q: What products are covered in the NPCA Quality Control Manual?

A: Virtually all precast concrete products composed of both normal
and no-slump (dry-cast) concrete, including prestressed, are
covered in the manual. Typically, NPCA certified plants produce
precast and prestressed components that can be classified into
one of the following categories:

• Water & Wastewater Products
• Sanitary & Stormwater Products
• Utility & Industrial Products
• Transportation Products
• Building, Housing, Landscaping and Specialty Products
• Prestressed Concrete Products

Q: Why should a precast concrete plant consider becoming certified under the NPCA Plant Certification Program?

A: There are many benefits to precasters who participate in the Plant Certification Program. A summary of these advantages can be found by clicking here.

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Q: What is the process of becoming certified?

A: To begin the process, a plant must first complete the
application/contract for NPCA Plant Certification and return it,
along with the required payment, to NPCA. A copy of this
application/contract can be found in the NPCA Quality Control
Manual or can be obtained directly from NPCA by calling (800)
366-7731 or at precast.org/certify. The inspection agency will
then contact the plant to schedule the inspection. During the
inspection, plant personnel have the opportunity to accompany
the inspector and learn of possible operation and plant
improvements. The inspection agency then provides written
reports of its findings, suggestions for improvement and
corresponding grading schedule to the plant.

Q: How long does it take for a precast plant to become certified?

A: The initial certification process takes about six weeks from the
time a plant's application is received, through the plant
inspection and notification of results. NPCA will make every
effort to accommodate plants that need an expedited inspection.
Please note all plants must be inspected within 90 days of
application, or 180 days of application if participating in NPCA’s
voluntary Plant Consultation program.

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Q: How often are inspections performed?

A: Inspections are performed at each participating plant once per
year. Each year 10 percent of the plants participating in the
NPCA Plant Certification Program will receive an additional
unannounced inspection at NPCA’s expense as a commitment to
quality and continuous improvement for the program.

Q: When are inspections performed?

A: Initial inspections are scheduled between the plant and the
inspector on a mutually convenient date, within the 90-day
window from application (or 180 days for plants in the voluntary
NPCA Plant Consultation program). Subsequent inspections are
performed on an unannounced basis, and can occur any time
during the year. NPCA makes every effort to avoid scheduling
inspections during NPCA meetings such as the Annual
Convention and NPCA’s annual trade show.

Q: Who performs the inspections?

A: A representative from one of three independent engineering
firms performs the on-site plant audits. This representative is
responsible for scheduling and performing the inspection and
then providing a report to NPCA detailing the inspection findings
and grade.

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What is required to pass an inspection?

A: Inspections are performed to verify compliance with the NPCA
Quality Control Manual. A standard grading schedule included in
the manual is used for all inspections. A plant must achieve a
score of 75 points or better (out of a possible 100) in order to
pass.

What should a plant expect during an inspection?

A: The inspector will begin the plant’s audit in the morning,
typically when stripping operations are still being carried out. It
is best to designate a plant representative to be the liaison to
the inspector during the entire inspection process. The inspector
will observe typical operations that include all normal production
operations and quality control testing. The inspector will also
review all required quality control documentation. At the
conclusion of the audit, the inspector will conduct an exit
interview and will provide immediate feedback with plant
representatives regarding initial findings. These meetings usually
last about an hour and are conducted casually in order to
facilitate positive discussion. This is one of the best
opportunities for plant representatives to ask questions and take
note of the inspector's positive and constructive comments.

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What topics does the Plant Certification Program cover?

A: All of the requirements for the program are clearly described in
the NPCA Quality Control Manual for Precast and Prestressed
Concrete Plants. The general topics covered include:
• Plant quality control procedures and management policies
• Plant safety
• Concrete, reinforcement and miscellaneous raw materials
• Concrete mixes
• Batching and mixing
• Production practices
• Fabrication of reinforcement and blockouts
• Pre-pour, casting, curing, stripping and repair operations
• Post-pour and final inspections
• Product handling, storage and shipment
• Concrete and aggregate testing
• Quality control recordkeeping

What is the best way for a plant to prepare for an inspection
and become certified?

A: Thoroughly review the NPCA Quality Control Manual. This
manual covers all of the requirements for the program and is the
basis for the inspections. If plant personnel have further
questions after reading the manual, they can contact the NPCA
Technical Services Department for assistance.

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What if a precast concrete company has more than one plant?

A: The purpose of the NPCA Plant Certification Program is to
certify individual production facilities. If a company has more
than one plant operating in different locations, each plant must
apply for certification and receive a separate inspection.

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Q: How difficult is it to pass an inspection?

A: Passing the inspection is not as difficult as you may think. In
general, companies that are interested in the Plant Certification
Program already have the inherent characteristic found in other
successful plants – a commitment to quality. These plants will
likely perform very well during an inspection, since they are
already performing many of the quality control operations
required in the NPCA Quality Control Manual.

Q: What is the best indicator that a plant will likely pass an inspection?

A: Management's commitment to quality is fundamental for a plant
seeking to develop a successful quality assurance/quality control
program. Without this commitment, most QA/QC programs will
likely fail.

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Q: Must a plant be a member of NPCA to participate in the Plant Certification Program?

A: No. A plant need not be a member of the association to be
certified. However, it is in the plant's best interest to join NPCA
in order to take advantage of the extensive benefits, discounts
and technical assistance NPCA has to offer.

Q: Is it cost effective to be certified?

A: In most cases, yes. Numerous plants have indicated that plant
certification actually pays for itself through increased operating
efficiencies, reduction of defective and returned products and
increased business due to better customer satisfaction.
Compared to the cost of other industry certification programs,
the NPCA Plant Certification is very inexpensive.

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Why has NPCA created a Prestress Certification Program?
A: NPCA’s Prestress Certification Program is a natural expansion of NPCA’s already mature Precast Concrete Certification Program. As a representative of manufacturers that produce precast, prestressed and concrete pipe products, NPCA’s mission is to raise quality standards throughout the industry. The Prestress Certification Program provides prestressed concrete producers an additional option in the marketplace for independent third-party certification of their plants. NPCA supports all third-party certification efforts for the industry because they raise the quality standards while minimizing the inspection burden for specifiers and regulators.

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When was it launched?
A: The Prestress Certification Program was approved in the fall of
2007.

Who created the Prestress Certification requirements?
A: NPCA’s Quality Assurance Committee, with the support of the NPCA Technical Committee oversaw the development of the Prestress Certification Program, which is an extension of NPCA’s longstanding, nationally recognized Precast Certification Program. As part of NPCA’s commitment to developing a rigorous and thorough certification program, NPCA consulted closely with two ENR Top 500 design firms; several state DOT organizations; multiple prestressed concrete manufacturers; and professors with several top civil engineering university programs.

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How is the Prestress Certification Program similar to the Precast Certification Program?
A: The two programs are parts of the same whole. The Prestress
Certification Program quality requirements are in addition to NPCA’s Precast Certification Program. In order to earn a Prestress Certification designation a plant must meet all applicable requirements in the current NPCA Quality Control Manual for Precast and Prestressed Concrete Plants (NPCA QC Manual) in addition to the requirements of the Prestress Certification Program. These additional requirements are detailed in chapter 7 of the NPCA QC Manual.
Plants that elect to participate in the traditional Precast Certification Program will continue to refer to chapters 1-6 of the NPCA QC Manual for requirements applicable to their certification.

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How does the Prestress Certification Program differ from the Precast Certification Program?
A: In addition to the requirements specific to prestressed concrete, the Prestress Certification Program will conduct two unannounced inspections annually. The Precast Certification Program will continue to have one unannounced inspection each year. In addition to these required inspections, NPCA conducts an additional unannounced inspection at 10 percent of the plants participating in the program. These inspections are conducted at no additional cost to the plants, and are an added measure of quality control for the program.

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How much does the Prestress Certification Program cost?
A: The annual prestress certification fee for NPCA members is $12,000, which includes the fee for plant certification. The fee for nonmembers is $17,000. This fee includes at least two inspections per year. The fee for precast certification only (without prestressed) will continue to be $3,450 for NPCA members and $6,000 for nonmembers, and will include at least one inspection annually.

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Who performs the inspections?
A: A representative from one of three independent engineering firms performs the on-site plant audits. This representative is responsible for scheduling and performing the inspection. The inspector then provides a report to NPCA detailing the inspection findings and grade. NPCA will forward the report to the plant.

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What resources does NPCA have to help me prepare for the Prestress Certification Program?
A: NPCA’s Technical Services staff is always willing to discuss the requirements of the program with you, as well as an optional precertification consultation program that can help you prepare for the Prestress Certification Program.

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