Good afternoon. Welcome to PCI's webinar series. Today's presentation is the M&L 116-21 Summary of Revisions. I'm Royce Covington, Manager of Member Services at PCI, and I'll be your moderator for this session. Before I turn the controls over to your presenter today, I have a few introductory items to note. Earlier today, we sent an email to all registered attendees with handouts of today's presentation. The email contained a webinar sign-in sheet, a guide to downloading your Certificate of Continuing Education, and a copy of today's presentation. The handouts are also available now and can be found in the handouts section of your webinar pane. If there are multiple listeners on your line, please circulate the sign-in sheet and send the completed attendance sheet back to PCI per the instructions on the form. The attendance sheet is only for use at locations with multiple listeners on the line. 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I'll be keeping track of them to read to the presenter during the Q&A period. Also, a pop-up survey will appear after the webinar ends. Today's presentation will be recorded and uploaded to the PCI eLearning Center. PCI has met the standards and requirements of the Registered Continuing Education Program, RCEP, of the National Council of Examiners for Engineers and Surveyors, NCEES. Credit earned on completion of this program will be reported to RCEP. A Certificate of Completion will be issued to each participant. As such, it does not include content that may be deemed or construed to be in approval or endorsement by NCEES or RCEP. Our presenter for today is Mike Kesselmeier, Managing Director of Quality Programs at PCI. I'll now hand the controls over so that we can begin the presentation. Thanks, Royce, and welcome to everyone, and I appreciate the opportunity to talk with you here this afternoon. The objectives of our training here today are to explain the significant changes in requirements that were made with the fifth edition of M&L 116. Please note that it's important that you understand the presentation will not cover all changes in the requirements. There were just too many of them. Our focus today is on the significant changes. There were also many changes in the commentary section of the manual, and we'll occasionally talk about some of these changes, but they're not the focus of the presentation today. So, it's important that you take the time to review the manual in more detail on your own. So, once these changes are understood today, this will facilitate the ability of architects, engineers, and other specifying agencies, such as DOTs, to update their specifications and project requirements. It will also allow precast producers to update their production processes and quality procedures, suppliers to the precast industry to adapt their products and services to the new requirements, and inspection agencies to update their processes. So, before we cover some of the specific revisions, it would be helpful to understand some of the major global changes that were included in this revision of M&L 116. The prior revision of 116 did not include requirements for SCC. These were previously outlined in PCI's TR6 document. These requirements have been incorporated into the fifth edition of M&L 116. Appendix B previously contained tolerances for structural precast products. These generally duplicated those in M&L 135. Since PCI is now developing a new standard for tolerances, PCI 135, and we're updating the tolerance manual, it's more appropriate to have these in a single source for tolerances. So, now instead of the old Appendix B, the manual just references M&L 135. There have also been significant changes to PCI's architectural certification program with the transition to the new categories in October of 2021. Reference to the new categories has been incorporated into the new edition. However, the provisions for special finishes still remain in 116 until such time as M&L 117 is revised. And finally, obviously, PCI's QC manuals need to align, and that was a primary focus for these revisions. Plants that are certified in the architectural group and have been following M&L 117 will note that many of the requirements being presented here today are already a part of their processes and procedures. So, let's dive into it and start working through some of the specific changes in each of the divisions here. Section 122 provides a list of documented procedures that must be included in the quality assurance program. Two changes were made to this list. Section 122F was added. This requires procedures for the inspection and verification of adequacy and sealing of the forms and molds to produce units in compliance with surface finish requirements. Section G was revised. It now includes provisions for inspection of the fabrication of the reinforcing in addition to the other items that were previously listed. There's a concern, obviously, for ensuring compliance with the barbending requirements of ACI. Plant management must establish and support fundamental quality requirements. Section F includes engineering operations that ensure compliance with the required codes, standards, and specifications and in-plant performance requirements. The added commentary calls to our attention that it's important to bear in mind that other codes and standards can apply to the producer's work beyond those cited in M&L 116. And you'll note that AASHTO was provided here. The AASHTO specifications were provided as one example. BCI certified plants are required to have at least one ACI certified field testing technician on staff. If the plant produces prestressed products, they're required to have at least one PCI level 2. If they don't prestress, they're required to have at least one level 3. Those are not new requirements. However, what we've put in here does clarify some language previously contained in other sections of M&L 116. We're going to discuss the personnel training further with some new requirements when we get into Division 6. So this is the first of the references to SCC that has been added. It should go without saying, of course, as you read through this, the QC inspectors should be trained on how to properly perform the tests they run and how to evaluate those test results. There are some significant differences between SCC and conventional concrete in what seem to be similar standard practices. Take, for example, the molding of a cylinder for compressive strength testing. SCC cylinders do not require the multiple lifts with rotting and tapping of the sides of the mold as required for conventional concrete. And not following these practices is a common non-conformance. As I mentioned earlier, we'll discuss the training requirements in more detail when we get into Division 6. Finished samples are a very important quality tool for the project architect, engineer, and the producer. Finished samples help establish the expectations for the project. It's important that this agreement be documented in writing and the requirement in bold was added. The sample approval can be documented directly on the unit with reference to the correct sample code number. Approval of the sample by the architect engineer should indicate authorization to proceed with production unless such authorization is expressly withheld. An additional detail concerning these samples was added in the commentary and I would certainly encourage you to review this commentary as well. As I noted in the prior slide, samples and mock-ups set the expected standard for performance within the variations of workmanship and materials that are expected for the project. This requirement was noted in the provision for special finishes section of Division 1. In cases where mock-up units are not specified, there still needs to be a method for verifying expectations with the architect engineer and that those are being met. Approval of the initial production components can be used for this purpose. Range samples were added to this section. Range samples established the acceptable range for color, texture, and surface variations, as well as the overall appearance of the products. As you review this, you'll note that the minimum size and number of range panels was also specified in this section. So, let's talk a little bit about the changes here in Division 2, talking about production practices. The prior edition of M&L 116 addressed maintaining minimum concrete temperatures. The requirements for controlling the maximum concrete temperature during the initial curing period, that's before preset, before initial set, these were added to section 226. Table 231 was updated as follows. A441 steel was added to the list. Minimum preheat temperatures for the last two thickness categories were reduced, as you see those here on the right. Some information previously found in the text of the manual was also incorporated as footnotes into the table. Clarification was added to section 231 about the requirements for cleaning stainless steel after welding. Stainless steel brushes are to be used so that the corrosion resistance of the steel is not affected. Table 232 was also updated here. The highest carbon equivalent range used to be over 0.66. We split this range into two categories, over 0.66 to 0.75 and over 0.75. The minimum preheat temperatures for several carbon equivalent ranges were revised, and for A615 bars where the carbon equivalent is not known, we're telling folks, the requirements are that we use over 0.75 category. Previously the 0.66 category was used. We have a change of requirements here as well in section 232 on welding. The requirements for TAC welding were revised here in this section. As you look at the new requirements and compare them to the previous edition, you can see that the prior requirements were somewhat nonspecific. The requirements have been revised to reflect reference to the requirements of AWS D1.4. The length of studs that we use will typically be reduced during the welding process. The requirement to check this length reduction during production welding has been added. This is as a confirmation of the effectiveness of the welding process. Two requirements were added to section 25 on hardware installation. The first is a check that should be part of every pre-bore inspection, verifying that the proper embeds are being used. The second check has to do with verifying proper bearing for the angles, although this was not specifically noted in the prior edition of M&L 116. These are practices that really should have already been employed by the plants. So section 25 on hardware installation used to allow lumber to be cast into the concrete as long as it met certain conditions, and that requirement was removed. Placing wood in concrete should be avoided because the tendency of wood to swell under moist conditions can cause cracking of the concrete, even if the wood is sealed. Plants should have a system for evaluating product deficiencies so their problems and their sources can be identified. This kind of gets back to the whole root cause thing. Problems that occur when products are stripped can't be easily resolved if they're not identified before product storage. Of course, it's equally important to identify these issues promptly so they're not repeated for subsequent years. This added section previously found in the special finishes provisions for this division. It was moved to the main section so it applies to all precast units. The commentary also notes that a small area should be cleaned and evaluated to be certain there's no adverse effect on the surface finish before proceeding with the work. The first sentence in this requirement was in the commentary in the previous edition of M&L 116, and it's been moved to the standard or the required section. The second sentence was added. It's already an M&L 117 requirement. The initial concern, of course, is that we shouldn't start troweling before the surface has been floated and bleed water has been given the opportunity to evaporate. There was similar language in the commentary in the prior edition of the manual. That information has been moved into the standard and it's been expanded because of the importance of the skill, experience, and training of the operators and the consistency of material in the process to the uniformity of the pieces. As always, we refer to the products matching the approved samples. These two sections were added. Similar language already exists in M&L 117. And as I noted in the prior slide on abrasive blasting, skill, experience, and training of the operators and the consistency of the process are very important to the uniformity of the pieces. And again, we refer to matching the approved samples. Manual requires protection of metals cast into the unit prior to acid washing. However, in the event that the galvanized coatings are still damaged, even though they're protected, they need to be repaired with a zinc-rich compound. The requirements for the bond breakers between the concrete and the natural stone were revised. The use of polyethylene sheets or polyethylene foam is still permitted, but the thicknesses have been increased. Previously, M&L 116 allowed the use of liquid bond breakers and that has been removed. Also, M&L 116 used to previously require a strip be left between the edge of the stone and the precast concrete. No specific dimension was previously provided. The dimension of that strip has now been defined as one-half inch. Both of these changes are consistent with M&L 117. The prior revision of M&L 116 provided a series of characteristics for the thin brick. Those have been removed and instead there's been a reference to the more comprehensive PCI specification for embedded clay thin brick. So, let's talk for a few minutes here on Division 3 about raw materials and accessories. From a format perspective, you may note that the fine and the coarse aggregates were combined into a single section on aggregates. The list of criteria for the maximum size of coarse aggregates was also expanded to include item 1, shown here in bold, that relates to the dimensions between the sides of the form and the mold. So, mixing water needs to comply with ASTM C1602. This new requirement is primarily significant to those plants that don't exclusively use potable water for their concrete. C1602 establishes a series of additional chemical requirements and qualification testing for mixing water that includes both non-potable water and reused water for concrete production operations. This testing is performed prior to the first time these waters are used in the concrete and also periodically thereafter. There are two new requirements related to galvanized and epoxy-coated reinforcing bars. The focus of these new requirements is to ensure that small areas where the coatings have been damaged or properly repaired and that the coated bars with significant damage aren't used at all. Estimating the percentage of area damage can be difficult. There are a couple of tables that have been added to the commentary section which should help you with that. You'll also note that the requirement to protect epoxy-coated bars from environmental exposure has been added here. So there are two sections that were added here into Section 321. In the first section, the requirement to have mil-certs for your strand is not new. The requirement to have modulus of elasticity values for the individual strand reels is in M&L 117 and it's now been added here in M&L 116. The requirements for test reports with strand bond per ASTM A1081 have been in place for over a year and they've now been added here into this revision of M&L 116. To be fair, these requirements have caused a fair amount of confusion over the last year or so. So let me just kind of run through what the current requirements are. First, plants need to have the results of A1081 testing for both 0.5 and 0.6 inch strands if you use both sizes. Testing is not required for other sizes. The tests need to have been performed no less frequently than annually. Third, the test results must state the manufacturing facility where the strand was produced and the test results need to apply to the strand produced at that facility. And of course, that should be the location that supplied the strand that was purchased by the plant. Finally, the test results should indicate the strand size tested, whether it's 0.5 or 0.6 inch. So I thought it might be helpful for us to perhaps take just a short detour here. From time to time, we do make some changes to the QC manuals 116, 117, and 130. And of course, when we make those changes, it's not really practical to reissue an entire manual. And well, it's just not practical to do that. So I wanted to just show you a little bit on how we handle those types of situations. So if you go out to the PCI website, pci.org, and if you click on the certification tab that I've circled here at the top, and look at that page, and if you scroll down that page, it talks about the architectural certification program at the top, and then it talks a little bit about each of our three certification programs, plant, director, and personnel. And as you get down toward the bottom of the page, you can see that in that kind of white rectangle here at the bottom right, where it says certification program updates. And in that first area there, that first link that I've circled, that's where we post any quality control manual addenda that have worked their way through the process. They've gone through plant certification committee, through the QAC, and through TAC to be approved. So this is where we put those, that's where we put those addenda. And I just thought I'd show you what we have out there right now. And it's a pretty short list. It's just, there's just the one addendum. And this particular addendum does speak to the ASTM A1081 testing for strand bond. And as you look through this, you'll see that it does list all those requirements that I just talked to you about a couple of slides ago here, in terms of what the requirements are for strand bond testing. So today, this is the only addendum that's out there, and it's applicable to both M&L 116 and 117. But there are other addenda working their way through the approval process. So what we do before, or when we post these out here, when they're all approved, there will be a notice in our certification newsletter, and we'll send out an email to the plants through the same distribution there, through all our certified plants, so that you're aware that a new addendum has been posted out there. So again, just keep an eye out for these as they come out there, look for the notices on those. And of course, the auditors, as they're doing their plant audits, will be aware of these, and they'll be talking to you about them as well. So maybe we, after this little sidebar, you know, maybe it's time we go back to the rest of the presentation here. So a new section on phase mixture aggregates and two subsections on final course aggregates were added to the provisions for special finishes section of this division. We're not going to spend any time on those requirements as they mirror M&L 117. And of course, architectural plants should already be following these. However, plants certified in the new AD category should take some time to review these as they may be new to you. Bridge and commercial producers who have clients requiring special finishes might also be affected, and reviewing these requirements would be good for you as well. So let's talk a little bit about concrete. Occasionally, there's some questions about the difference between flowable concrete and SCC. A brief description of flowable concrete and when a plant might choose to use this type of mix over an SCC was added in the commentary in section 411. As with all commentary, just please keep in mind that this is supplemental information. Commentary is not requirements. That's the standard part of the document here. There were some extensive revisions in section 412 on the qualification of concrete mixes. The first is adding a requirement to comply with the requirements of the applicable exposure class as assigned in ACI 318. There were a few requirements related to SCC that were added. Much of it was included in TR 6, but has now been added in M&L 116. The first of these included a listing of the required SCC qualification tests. There are a number of factors that must be considered when designing an SCC mix. Items such as the type of mixing equipment, the materials, batching sequence, mixing time, horizontal and freefall distances, while the list goes on and on. And these requirements are listed in this section. Commentary in this section has also been expanded greatly. It discusses some of these factors just mentioned, as well as production requirements, the qualification testing, quality control, and the sensitivity of SCC mixtures. Please take some time to review this information. And finally, as with all normal high-performance concrete, the capacities for strand lifting loop configurations used for lifting the products fabricated from SCC, they must be qualified by testing. There have been a couple of changes to Table 416, which provides the total air content for various sizes of aggregates and exposures. And I've highlighted these here. The air content for the one-inch aggregate in moderate exposure environment decreased from five to four and a half percent. And the air content tolerance on these values changed from plus or minus a half percent to plus or minus one and a half percent. And these changes now align with ACI 301 and M&L 117. So there were some changes in the recommended maximum limits on SCM in the commentary for Section 4.1.12. These limits are from ACI 211.1. They're provided for use in preparing estimated proportions for the first trial batch or for a series of trial batches when you don't have prior information regarding proportions for these materials. They're a place to start and they're based on the total weight of the cementitious material that's used in the batch. Just a quick note, these are different than the percentages provided in M&L 117 for architectural precast. Those products, those architectural products are more color sensitive, of course, and fly ash and the gray silica fume can cause color variations. There were some changes to the batching equipment tolerances in Section 4.1.1. This first section on admixtures was added. It addresses the batching of pigments in powder form for individual batching equipment. These admixtures are used in small dosages and are batched by hand from small pre-measured containers. Tolerance on that dosage is plus or minus one percent by weight. The second change shown here relates to the volumetric batching of water. The text in bold was added and note that the tolerance for the batching of this water is substantially reduced for batch sizes less than two cubic yards. This section was previously applicable to admixtures. The title on it was just admixtures. It's now been expanded to reference solid admixtures as well as liquid pigments. The calibration intervals for water measuring equipment were revised for those devices measuring water by weight by adding that text shown there in bold. These new requirements now align with MNL 117. The prior requirement in this section was that inline moisture meters used during the batching of aggregates should be able to detect changes of one percent. For SCC mixes, this tolerance has been decreased to half a percent. As before, the moisture meters must be positioned so that the moisture values are representative of the aggregate being placed in the mixer. And if you're not using inline moisture meters, the free moisture of the final aggregate needs to be determined at least daily, or for SCC at the beginning of each batching operation and at four hour intervals during the continuous batching operations, or, of course, anytime there's a change in moisture content that becomes apparent. And moisture content testing is performed in accordance with ASTM C70 or ASTM C566. Changes were made to both the cold weather mixing and the hot weather mixing requirements. From a cold weather mixing standpoint, the upper limit of 95 degrees for the concrete mix was added. The lower limit of 50 degrees remained unchanged. The maximum temperature of the aggregate was reduced from 180 degrees to 150 degrees. And the maximum water temperature was added here as well. For hot weather mixing, the upper temperature limit of 150 degrees for the cementitious materials was added to this section. This revision catches up M&L 116 with M&L 117 and the recommended practices that have been placed for some time. The 180 degree cap has been removed. If you look at what's replaced it, you're going to notice two things here. The first is a reference to the curing temperatures in Section 495, which discusses accelerated curing. And we're going to talk about that a little bit more here on the next slide. Second is these temperature provisions apply whether or not supplemental heating is being used in the curing process. And if you think about it, this makes sense because the concrete doesn't care how it gets that hot, whether it's by supplemental heat or through the combination of heat, hydration and environmental conditions. The detrimental effects associated with heating the concrete above these thresholds are going to occur anyway. So here are the curing temperature thresholds that I mentioned in the prior slide. You're going to note that there are now three separate thresholds, and that the type of service environment for the product will control which of these applies. And these requirements, again, align with 117 on the architectural product side. The commentary for this section provides a description of the examples and what is intended by each of these conditions here. So I really would encourage you to look through those and to make sure you're comfortable with what those are. The other term that bears mentioning here is this term mitigation concrete mixture proportion. The commentary for this section provides a list of possible mitigation measures. These typically involve removing some percentage of cement and replacing it with FCMs, such as fly ash, silica fume or slag cement. So let's talk for a few minutes here about reinforcement and prestressing. In the prior edition of M&O 116, an average area and modulus of elasticity for the strand could be used to calculate the strand elongation, provided that the force fell within the tolerance limit of 5%. If it didn't, the elongation was calculated using the modulus and steel area from the mill certificates that were provided by the strand manufacturer. With this revision, an average area and modulus may be used to calculate the strand elongation, provided that the strand area multiplied by the strand modulus of elasticity for each pack or coil is within 2.5% of the average area and modulus for all packs and coils. If it's not the case, the elongation has to be calculated using the modulus and steel area from the mill certificates provided by the strand manufacturer. The endpoints that establish the temperature range when a force correction is needed, they've been redefined. The temperature of the steel at the time of stressing remains the same, that's the beginning point. The other endpoint is the temperature of the concrete at the time of initial set, as you see I've highlighted it here. This endpoint was previously defined as the temperature of the concrete when it begins to set, which was a very ambiguous term. Typically, from a practical standpoint, the temperature that was used was the concrete temperature at the time of placement. So with this new defined endpoint here, it's important that, especially when production operations are outdoors in cold weather, that plants take a look at that because this could have a significant effect on the size of the thermal correction that's needed. This revision relates to the final tensioning procedures for harped strand. In the harped position, it does not relate when it's partially tensioned straight and then lifted or depressed into the harped position. In the prior edition of M&L 116, there was a requirement to check the force in at least two strands at the far end of the bed, even if the elongations were within tolerance. With this revision, the requirement for verifying the force in two strands at the far end has been removed, provided that the elongations in force are within 5% of the theoretical values and no more than 5% apart for each strand. If the theoretical elongation is not attained at the one end of the bed when the force is exceeded by 5%, strands can be jacked from the other end of the bed to achieve the total theoretical elongation. If this requires an overstress, an excess of 5% overload, the number of deflection points on the bed are to be reduced until the elongation can be attained with no more than a 5% overload, or the hardware needs to be improved to reduce friction. Out of the division with the most changes, the quality control division. Section 612 of M&L 116 describes the scope of inspections to be performed by the plant. The specific requirement to check initial camber on at least 25% of each day's production within 72 hours after transfer of prestressed force has been removed. So instead, there are some less specific requirements. Section 132 states that the precast engineer shall be responsible for prescribing or approving methods and procedures for measurements for camber and deflections. And section 612 requires that the plant's records include measurements of member dimensions and camber. There are a number of changes in section 621 of M&L 116. The first of these involves the qualifications for QC labs. If the plant subcontracts any quality control functions that need to be performed by an outside independent laboratory, the outside laboratory shall conform to the requirements of ASTM E329 and C1077. E329 speaks to agencies engaged in construction, inspection, testing, and special inspection. C1077 requirements are more specific and they relate to the agency's testing concrete and concrete aggregates. Both of these are fairly rigorous standards, but the precast plant QC labs are not required to fully comply with these. Precast plant QC labs are required to comply with section 7 of C1077. This section lists a series of concrete and aggregate standard tests that the lab must follow for concrete. Those tests include the ASTM methods for sampling, slump, air content, unit weight testing, temperature, making specimens, and so on. For aggregates, these tests include sieve analysis, 200 wash, and specific gravity and absorption. This section also requires the lab to have access to current test standards and to use the standards within one year of their publication. Section 8 of C1077 requires that the lab have the equipment facilities necessary to properly perform the tests described in the standards. As I mentioned early in the presentation, there are a few changes that relate to the training of QC technicians and this is the first of those. And I'm just going to give you a second to kind of scan through things here. So this is a general requirement that relates to technicians performing aggregate gradations, fresh concrete, or concrete compressive strength testing. Technicians performing these tests need to meet one of two sets of requirements. Either one, be certified in the test they perform through a program that meets the requirements of ASTM C1077 and that program would require both a written and a performance exam. Or two, they need to receive in-house training and pass a performance exam to demonstrate their ability to properly perform a test. This performance exam is to be administered by either an independent examiner, not the employment of the plant, or by a professional engineer. So in the case of the first option, C1077 provides criteria that the certification program must meet and certainly programs such as those provided by ACI would comply with those. In the second option, the performance examination will be administered by either a competent individual who is not an employee of the plant or by a PE. The PE can be an employee of the plant, but in either case the training and performance exam must be documented. We understand that implementing the system is going to take some time and we're not enforcing this requirement at this time. The Plant Certification Committee is currently developing additional guidance and resources that are intended to assist the plant in this regard. So this is the second of the changes that relates to the technician qualification testing and training. And it relates specifically to technicians performing fresh concrete testing. So the plant must have at least one technician who's currently ACI certified for fresh concrete testing. We talked about that a little bit earlier and that's not a new requirement. You can also use a PCI approved non-ACI certification to meet this requirement. Technicians who perform fresh concrete testing who are not certified must still receive in-house training as we talked about on the previous slide, but they must also have passed a performance exam that's administered by an independent examiner not the employment of the plant. A professional engineer is not an option as it was with the previous section. So as noted before, the training and performance exam must be documented. Also, as I noted before, we understand that implementing the system is going to take some time and we're not enforcing this requirement at this time either. Look for some additional guidance and resources in the coming months. The discussion of acceptance testing continues with aggregate testing in section 6222. There were several changes in this section that we'll see in the next couple of slides and we're just going to mention them briefly. And please, please take some time to review them on your own in more depth when you have a few minutes. A reference was added to the use of ASTM D75 which is the appropriate standard to use when sampling aggregates from stockpiles or conveyor belts. After sampling, the sample size needs to be reduced to the appropriate size for testing using C702. Clarification was added concerning the necessity for soundness testing for ASTM C88 and LA abrasion testing using C131. So when an aggregate is judged to be susceptible to alkali carbonate reaction using ASTM C295, MNL 116 requires that it be further evaluated using ASTM C586 and C1105. The three-month, six-month, and one-year limits have been added to this section. A reference was added to the use of ASTM D4791 to determine the percentage of flat or elongated particles in crushed coarse aggregate. Limits for flat or elongated particles have also been established, depending upon where the aggregate is being used. I've just abbreviated this section. If these types of aggregates are applicable to your plant, you're going to want to take some time to review these requirements in more detail. Tests for deleterious substances and organic impurities were required in the prior revision of MNL 116. This revision includes a reference to the limits in ASTM C33, but also includes some exceptions to those limits. This is a fairly lengthy list and we don't have time in this venue to review these. I would encourage you to review these on page 6.7 of MNL 116. Additional requirements for coarse aggregates with an iron sulfide content that could result in unsightly stains was added. If ASTM C295 indicates the presence of iron sulfide, then aggregates tested by ASTM C641 must show a stain index less than 20. There were several changes made in section 6.2.2.10 on compressive strength testing of concrete. The bolded text indicates what was added. The essence of these changes was to further recognize the use of 4x8 cylinders and to incorporate the provisions for SCC. Changes were not shown on a separate slide, but there were also changes to the following sections which incorporated the specific requirements for SCC. These included ASTM C1611 into the section on testing for slump and slump flow, and for C1758 into the sections on density and unit weight and air content testing. A reference to PCI's guidelines for the use of self-consolidating concrete in precast pre-stressed concrete, which is TR6, was also added. The bolded text that I've shown here highlights the changes in this paragraph. Continuous moisture determination replaced moisture meters, and at the beginning of any batching operation replaced daily. The reference to changes in mixture consistency as a time when free moisture determination should be made was added. This requirement for more frequent moisture testing when using SCC and flowable concrete was also added. Specific gravity testing of lightweight aggregates is required for each shipment and monthly thereafter when the lightweight aggregate is being used. This testing shall also include the oven dry loose unit weight. This is the first of two slides discussing changes made to the section on concrete strength in production testing. So similar to the acceptance testing section, 4-inch cubes are now acceptable as test specimens for production testing as long as there's documentation of proper correlation with standard 6x12 inch or 4x8 inch cylinders. When making test specimens of flowable concrete mixtures with slump flows of 20 inches or greater, the procedures in ASTM C1758 are to be used. Flowable mixes with slump flows less than 20 inches are to be consolidated by rotting according to ASTM C31. This third edition here allows special cube sizes to be used when they more adequately represent the particular products. Again, as long as there's correlation to the 6x12 inch cylinders that's provided. Previously, this requirement was for a minimum of four specimens for compressive strength testing. This only referred to 6x12 inch cylinders. A minimum of five 4x8 inch cylinders must be cast from each day's production of each mix used. This is for each 75 cubic yards or fraction thereof. The prior revision of M0116 stated that the strength of concrete was to be determined by the average of two specimens. For the smaller 3 inch and 4 inch diameter cylinders, three specimens are required if you're testing at 28 days or later. Allowance, if you only use one cylinder to determine stripping or stress transfer strength during production, that requirement still remains. Part B of the concrete strength acceptance criteria was modified significantly. Part B of the prior revision of M0116 simply required that no individual strength test could be more than 500 psi below the specified strength. The new revision retains the 500 psi threshold for specified strengths of 5,000 psi or less, but it establishes a 90% requirement for specified strengths above 5,000 psi. This section was previously titled slump. With the addition of SCC into the manual, a second section, slump flow T50 and VSI, was added. Part A provides a series of tolerances for concrete mixtures of various slumps. These have been revised slightly from the prior edition of M0116. Part B is a new section resulting from the incorporation of SCC into the manual. Various requirements have been noted, which were largely contained in PCI's TR-6. Many of these are listed here, but you should still take time to review both of these sections. Density unit weight tests of flowable concrete and SCC must be conducted daily. The density tests of normal or conventional concrete are to be conducted at least once a week in accordance with ASTM C138 for each regularly used mixture. Lightweight concrete shall be tested daily in accordance with ASTM C567 to confirm matching consistency. The prior revision of M0116 included various requirements for personnel and processes that paralleled AWS requirements, such as those for the qualifications of personnel responsible for the acceptance or the rejection of welds. Several of these have simply been replaced by a requirement to conform to AWS code. So, the inspection and testing requirements for downhand welding of studs prior to the start of a day's production still include the requirements for visual inspection and bend testing of at least two studs. The prior revision of M0116 only required two studs to be bend tested for other types of studs, similar to the requirements for downhand welding of studs. This has been increased to 10 studs for positions other than downhand or studs welded to the eel of an angle or into the fillet of an angle. You'll note in the associated commentary that successfully completing 10 stud tests is considered adequate qualification of the process and the operator for production non-downhand welding in the out-of-position configuration of other application details. In most precast concrete units, the heat generated by the hydrating cement is dissipated almost as fast as it's generated and there's little temperature differential from the inside to the outside of the member. That's not the case with all precast units. Extreme differences between internal and external temperatures of massive members may result in surface cracking, therefore it's important to verify the temperatures of these units. The maximum allowable temperature was decreased from 180 degrees to 158 degrees as shown here in the bowl type. Various equipment calibration inspection intervals were added to section 642 for convenience. These align with those in their respective ASTM standards. So let's talk for just a couple minutes here on the final division on product tolerances. There were two significant changes in the first paragraph here of Division 7. First, Appendix B in M&L 11699 included tolerances for numerous precast elements as I mentioned earlier. Appendix B has been removed and reference is made instead to M&L 135, PCI's tolerance manual. This allows all tolerances to be in a single location which makes them easier to reference, update, and keep consistent. Secondly, the prior revision made reference to the tolerances in the manual as governing unless there are other tolerances in the project specifications. That provision was intended that the manuals tolerances would be the minimum tolerances that the project specifications will only govern to the extent that those tolerances were more stringent. However, that was not stated very clearly and this revision clarifies that situation. The appendices provide useful supplemental information for the manual but these are not considered mandatory. I'm just going to give them just a real quick overview here. Appendix A on finishes. Previously, Appendix A was the guide for developing the plant QSM. The QSM requirements are now contained in QSM 1 which are the preparation guidelines for a quality system manual of a PCI certified plant and we've provided those to everybody here, to all the certified plants. The current Appendix A, this used to be Appendix C and various revisions remain to the descriptions of the finishes to make them more consistent and to a better align them with the descriptions in ACI 301-20 to the extent that was practical. Appendix B on strand chuck use and maintenance, we really didn't make any significant changes in that section. Appendix C, which has some sample record forms, the changes made there were just minor editorial and format revisions that were made to some of the forms. Appendix D on the PCI plant certification program, the descriptions of the PCI plant and personnel certification programs were updated but much of the detail was removed and instead we just substituted some references to the PCI website for additional information. Appendix E on the reference literature, this is just a list of all the documents that are referenced throughout the manual. Appendix F on sample tensioning data calculations, we made a number of revisions to the examples and the associated sample calculations. And finally on Appendix G on metric conversions, there was only a slight format revision to one conversion. So that's kind of what I had for you here today. I appreciate your time and attention and I think Royce I'm going to turn it back over to you. On behalf of PCI, I'd like to thank Mike for a great presentation. Unfortunately, it does not look like we have enough time for questions today but all questions will be forwarded to the presenter along with your contact information. As a reminder, certificates of continuing education will appear in your account at www.rcep.net within 10 days and a pop-up survey will appear after this presentation ends. If you have any further questions about today's webinar, please email marketing at PCI.org. Thank you again, have a great day, and please stay safe.

M&L 116-21 manual revisions

Mike Kesselmeier

fifth edition changes

self-consolidating concrete requirements

qualification and training requirements

testing and inspection specifications

special finishes provisions

concrete strength testing

personnel qualifications