With the recent introduction of a PCI-Certified Erectors program, assurance is available that concrete components will be erected to maximize their function. Erector certification provided by the Precast/Prestressed Concrete Institute complements the group's plant-certification program by ensuring that product supplied by PCI-certified facilities will meet all specifications and perform optimally due to proper installation.

“Once precast components leave the yard, no system of checks and balances has regulated how they are erected, and that absolutely makes a difference to the final project,” says Jon Schnell, general manager of the precast division operations at Spancrete Inc. in Valders, Wis., which produces and erects precast components. “There have been instances of precast components produced under PCI requirements that were fine, but due to improper installation, the owner was dissatisfied.”

Mark Biebighauser, president of Hurst, Texas-based Precast Erectors Inc., echoes that observation: “Architects and owners buy a finished structure; they don't buy a manufactured product. Without proper handling — if tolerances aren't maintained, if the joints aren't held — what the owner buys may not resemble the product that came out of the forms.”

The certification program helps ensure the designer's vision becomes reality, affirms Jorgen Clausen, vice president of operations for Coreslab Structures (L.A.) Inc. in Perris, Calif., which also erects its own precast components. “In the past, many precast plants operated so that once the precast was loaded onto trucks and out the gate, they were done with it. That didn't ensure good installation within the specifications. This program will benefit everyone in the industry, ensuring the owner receives the final product he expects.”

PCI'S A TO Z CERTIFICATION

The program extends PCI's existing certification programs to cover the entire process from manufacturing to installation, explains Gary Wildung of engineering firm FDG Inc. in Arvada, Colo., and a member of PCI's Field Certification Committee. The programs certify plants to produce specific products and personnel as trained in quality-assurance techniques. The most recent addition to PCI's certification programs was first instituted several years ago as a training course for erectors.

Field certification is available to all erectors of precast concrete products, including production plants, independent erectors, and general contractors with acceptable experience. For the project specifier and owner, Erectors PCI Certification confirms that the erector has a field quality-assurance program and the capability to erect precast components in compliance with project specifications and national industry standards. Three categories of erector certification are available (see sidebar).

One independent audit is conducted each year over the course of 1½ days during which the auditor is free to review documentation on any completed project, including safety procedures, field quality audit reports of erection crews, operations and inspections. If the erector fails the audit, deficient areas are outlined in a final report. Once shortcomings are addressed, the erector arranges a special audit to ensure procedures are satisfactory. If the company fails that audit, the erector forfeits certification.

ERECTOR BENEFITS

Regarding the advantages of certification for erectors, Greg Gibbons, president of Parker, Colo.-based Gibbons Erectors, notes, “It ensures we are prepared to address the concerns of even the most demanding contractors regarding safety and workmanship.” He reports that the process uncovered several areas where his teams had to improve, such as going through a formal rigging inspection and having a blood-borne pathogen kit at each worksite. Additionally, shuffling of personnel led to some irregularity in assigning a CPR-trained employee to each crew. “These are small things overall, but they can be critical, and the audit reminds us of each one,” Gibbons says. The program also ensures the company is ready should an OSHA audit occur. “This process should keep regulators away,” he asserts, “because they can see we are policing ourselves better than they would.”

“Certification formally demonstrates an erector's commitment to industry-accepted erection standards of safety and quality performance,” says Franc Genoese, senior director of construction at High Concrete Structures in Denver, Pa. “These attributes help distinguish an erector from those not committed to the same performance and professional standards.”

The system also provides an intangible boost to morale, adds Precast Erectors' Mark Biebighauser. “Our erectors consider themselves good craftsmen,” he explains. “They want to be held accountable for their work as well as acknowledged for their competence. This program shows we have taken steps in the field to do a good job, as it ensures recognition for quality work.” Gibbons concurs, noting that his crews wear the PCI Certified Erector stickers on their hard hats to point out the standard they use.

RISING TO THE CHALLENGE

Spancrete's Jon Schnell emphasizes that the certification process isn't easy, at least the first time: “It's definitely achievable by good erectors, but it makes even good companies raise the bar a little.” Particularly challenging is adequate documentation of processes to prove they are routine. Schnell elaborates, “A lot more documentation is needed for the audit, and initially, more time is spent bringing everything up to speed, but after you've established that accountability, it's quite easy.”

In addition to its inclusion in AIA Masterspec language, the certification process will be promoted by both architects and precasters to achieve greater program visibility. “Giving architects assurance that they are using an erector who is quality conscious,” says Schnell, “the program provides peace of mind that the project will be put together as it was envisioned. It addresses issues in the field that have not been standardized before, as it heightens awareness of the importance of those issues in the overall quality of the building.”

High Concrete's Genoese predicts that most precast erectors will join the program. “Erectors will see the respect that certification brings from owners, architects, contractors and precasters,” he says. “I'm confident that universal acceptance of these standards will result in involvement by any erector who wants to be an active player in the field.”

ERECTOR CERTIFICATION CATEGORIES

PCI's Certified Erectors program is divided along three field applications.

1. Category S1 (Simple Structural Systems) includes horizontal decking members (such as hollowcore slabs on masonry walls) or piers and single-lift wall panels attached to a structure by others.
2. Category S2 (Complex Structural Systems) includes everything contained in S1 as well as total-precast, multiproduct structures (vertical and horizontal members combined) plus single or multistory load-bearing members, including those with architectural finishes.
3. Category A (Architectural Systems) includes nonload-bearing cladding and GFRC products, which may be attached to a support structure.

More information about PCI's Certified Erectors program can be obtained at the Institute web site, www.pci.org, or www.pci.org/plant_certification/erectors.cfm.

This article was adapted from a report by Craig Shutt published in PCI's Ascent, Summer 2005.