Statistical Quality Inspection Methodology in Production of Precast Concrete Elements

Abstract

Today, prefabricated concrete elements are used in many construction areas, including in industrial, public, and residential construction; this was confirmed via questionnaire research. In the article, the prospects for precast concrete development are presented, and the factors determining the use of this technology are defined. Based on a review of the literature, it was shown that currently, higher-quality prefabricated elements are primarily created through the implementation of innovative materials and production technologies. For this reason, the lack of research regarding quality control in prefabricated elements based on statistical quality control is particularly noticeable. The quality control process is one of the most important distinguishing features in prefabrication due to the increasingly stringent expectations of customers; it helps to ensure that the desired durability of implemented constructions is achieved. Issues related to assessing the effectiveness of standard procedures presented in this paper were analyzed using statistical methods in the form of OC (operating characteristic) and AOQ (average outgoing quality) curves. Thus, a new approach was proposed because these methods have not been previously used in precast concrete. The shape of the curves obtained confirmed the significant dependence of the value of the acceptance probability on the defectiveness of production. In AQL control systems based on OC and AOQ curves, it is necessary to calculate the current average defectiveness, which should be treated as a basis for the decision to switch from one type of control (normal, tightened, or reduced) to another. In this respect, the standard requirements of quality control have been simplified, and it has not been considered necessary to determine the average defectiveness value in production processes. The examples included in this study, including the analysis of curb production data, clearly show the harmful effects of ignoring the actual process defectiveness. As a result of the calculations, it was found that the average actual defectiveness of the curbs produced could not be equated with batch defectiveness. The analyses carried out in this study prove that equating batch defectiveness with process defectiveness is not an appropriate approach, which was confirmed through the producer’s/customer’s risk analysis. The approach proposed in this study, the analysis of OC and AOQ curves, is an innovative solution in prefabrication and can be an effective tool for managing the quality of prefabricated products, taking into account economic boundary conditions.