Achieving project success through product and material testing

by arslan_ahmed | April 13, 2023 10:00 am

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By Heather Stahl-Figueroa

Designing and constructing a building is increasingly complex. The construction industry faces a myriad of challenges, such as completing projects on schedule, ensuring the quality and safety of products and materials, overseeing the costs so they do not exceed the budget, and complying with corporate environmental and social responsibility standards; all while applying effective risk management at every step. Appropriate testing, whether it is of materials or products, is at the core of successful projects. Material and product testing have distinct considerations, and both are explored in this article.

Begin with the basics

The safety and integrity of any construction project, relies heavily on material testing and inspections. Material testing puts resources such as soil, concrete, rebar, structural steel, and masonry, through a series of tests which examine and analyze the material’s performance before and during construction. It does not matter whether the project is new construction, an addition to an existing facility, or renovations and upgrades to older construction projects. Material testing and site inspections are necessary throughout the process to ensure quality upon completion.

However, not all testing services are necessary for every project. The required services are determined by the type of project, land, foundation, and location it is built upon.

Types of construction material testing

Construction material testing can be divided into two categories: field testing, which occurs at the project site, and laboratory testing, which involves taking samples from the site and back to an off-site location for further analysis. The outcome of each is to ensure the materials are safe and reliable.

Repeated testing with inspections is recommended throughout the building process. These can be done at regular intervals, anytime from the beginning to completion, and will help avoid potential risks later.

Field testing

Field testing is done at the project site. Certified professionals carry out these services for various construction projects and it can include roadways, bridges, utility projects, airports, and building developments. Typically, it starts with soil testing, which is a method of collecting samples of sub-surface earth materials. These soil samples can be evaluated on-site or taken back to the lab for further testing. The technicians check for moisture and compaction, which will influence the structural design of foundations.

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It seems obvious, but it is critical to have a strong foundation, matched to soil properties, before designing the rest of the structure. This may include excavation and dewatering requirements, soil preparation and amendments, the type and size of foundations needed, the choice of structural materials, and structural design. Soil testing ensures the project will be sound and successful before the foundation is laid. Without this testing, builders and engineers would not be aware of the quality of the sub-surface and materials and whether they will meet the project’s requirements. Other types of field testing include:

Soil and Aggregate Sampling and Testing

• Compaction and density
• Bearing ratio
• Permeability testing

Concrete sampling and testing

• Air entrainment testing
• Slump testing
• Temperatures
• Unit weight

On-site inspections are necessary to ensure compliance with the requirements of the project documents and the building code. For example, an inspector can review rebar, structural steel, and the bolts and welding holding these materials together. Site inspection ensures any deficiencies are detected and corrected before these materials are covered and concealed. Depending on code requirements and the type of inspection required, third-party certified professionals or professional engineers perform this work.

There are many other tests available to perform before, during, or after construction to assist in the conformity of the project with building codes and owner requirements. For example, a floor moisture analysis and floor flatness test defines the safety and longevity of a concrete slab foundation. Floor moisture analysis detects any wetness within the concrete slab, eliminating future issues with installed floor finishes. Floor flatness testing measures how levelled the concrete slab is and detects undulations across the top surface.

Laboratory testing

Lab testing involves collecting material samples at a construction site and taking them back to an off-site location or lab for review and analysis. Lab testing might be confused with product testing, which is also done in a lab and involves reviewing, testing, and reporting on the performance of product samples from bring up such as doors, windows, curtain walls, and roofing products. The performance of products pre-tested in a lab does not necessarily guarantee how well they will perform in the field, especially if the construction materials supporting the finished products have not been completely tested and inspected.

Lab examination on material samples, such as soil, asphalt, aggregate, concrete, and masonry provide a reliable and detailed analysis of the materials, ensuring the on-site materials function as intended. Lab tests can also be performed if the field-testing results are inconclusive or if a more detailed analysis is needed. Other examples of lab testing include:

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Soil testing

• Moisture content
• Specific gravity test
• Dry density test
• Atterberg limits test
• Sieve analysis
• Modified or standard proctor
• Bearing ratios
• Chloride or sulfide testing
• pH testing
• Permeability testing

 Asphalt testing

• Mix evaluation
• Stability
• Flow
• Bulk specific gravity
• Extraction

Masonry/Concrete testing

• Flex strength testing
• Compression strength testing
• Unit weight, tensile testing
• Absorption
• Efflorescence testing
• Mix design
• Structural masonry testing

Whether performed in the field or laboratory, the key takeaway is that applicable testing performed at appropriate intervals during construction provides an important complement to pre-testing, and a final assurance of the quality and performance of the critical materials and assemblies that make a sound project. Both types of testing in tandem with regular inspections to monitor the progress are ways to perform quality checks on the project.

 Regulatory requirements

Construction material testing is a regulatory requirement for most large-scale building projects. Specific codes and regulations applicable to building materials vary from state to state, but there are common oversight organizations, including the American Society for Testing and Materials (ASTM) International, United States Army Corps of Engineers (USACE), Federal Aviation Administration (FAA), and the American Association of State Highway and Transportation Officials (AASHTO). To gain approval for a project, contractors work with licensed and accredited construction material testing professionals before breaking ground.

Ensuring the use of the right materials

Building codes, location, and the land being built upon can impact the quality of materials. To reiterate, product testing is completed on finished products prior to being shipped to a construction site. Material testing is done on the construction materials on-site, then tested and inspected periodically throughout
the process for both quality control (QC) and quality assurance (QA).

Highlight risks

By testing materials in the field, starting with the foundations, project managers can be immediately notified of any problems, allowing them to take corrective action with limited cost impacts and schedule delays.

If material testing and inspections are not performed, unseen deficiencies may result in failures long after construction is completed, leading to litigation and other serious consequences. Potential problems include non-compliance with building codes, mold, rust which could lead to material deterioration, and moisture, which could cause serious structural failures.

Avoid costly mistakes

Think of material testing and inspections during the construction process as an “ounce of prevention.” The efficacy of periodic testing throughout the building process and the upfront costs are small compared to the potential cost of failures. Such precautions will save the time and expense of redoing any work, avoid litigation, and worst-case scenario, building malfunction or collapse.

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Increase safety

Think of material testing and inspections as extensions of safety gear. Just like helmets, goggles, vests, and so on, these tests are designed for protection. While the results may not seem immediate, ensuring the materials are structurally safe by testing and inspecting throughout increases the structure’s overall safety and integrity.

Asking the right questions

Frequently, manufacturers and owners request a specific test, believing it is all they needed to determine whether the product will succeed in its intended use. A quality testing lab should always challenge this assumption and ask questions such as: What are the company’s goals with the product? What market do they want to be in and why? How will the presented product perform in a particular market? What is the longevity of this product? The product approval process is likely different from what was originally envisioned.

Architects and general contractors are buying performance, not a product. The testing lab’s job is to assure the product will perform as promoted. By taking the long view, a manufacturer can save time and money as well and offer a certified product which can compete effectively in the desired construction material’s marketplace.

Component complexity simplified

Many of today’s new products are made from several components working together to achieve a singular performance goal. For instance, in a window, the glass may come from Europe, the aluminum from China, and the locking mechanisms from South America. Since all these products must first meet their own set of performance requirements, it is unreasonable to expect the window manufacturer to coordinate and oversee the testing of the components to comply with the performance objectives of the window as a whole assembly. Testing reports for each component will need to comply and reconcile as international regulations may vary. Such complicated details are better left
to the materials testing experts rather than the product manufacturer.

A sophisticated testing facility can coordinate these details into one testing plan which meets the objectives, eliminating the product manufacturer from the effort to “trace and chase” paperwork to sell their windows.

Wrangling the big idea

Product manufacturers are excellent at creating new and innovative solutions. However, for the whole product to align with each component’s capability,
it is critical to share the design with the component team. They are the experts in their own products, and they may offer solutions to avoid unforeseen problems. Ask them whether part A will work with part B, as there can be multiple points of failure.

Many manufacturers feel it is not their problem or responsibility to oversee components if their “part” works. However, most component manufacturers would be happy to provide their advice free of charge, which could save time
and money. Inviting them to the testing lab can be helpful as they are valuable resources and not just vendors.

Component compatibility

Component incompatibility is often the main problem when it comes to testing. Even after the advance work and partnering with the component team, no one knows how the product will perform until it is tested, because a single test is worth a thousand opinions. Testing exposes the weaknesses in the system, and a quality lab can pinpoint those weak spots and give ideas on a remedy.

If possible, test “beyond the code” of the minimum required standard. By exploring the outer limits of the product standards, manufacturers can sometimes elevate their products into new markets or meet previously unforeseen performance requirements. It is important to remember, tests are a great barometer of how a product will perform, but field testing is the final frontier. In conclusion, product testing above the required standard reduces the risk of failures in the field.

 Lessons worth continuing

Indoor air quality (IAQ) is now more important than ever. Occupant health and controlling the transmission of aerosolized particles are some of the new challenges building owners now face. Buildings now have to be healthier spaces, and manufacturers should be prepared to address new standards and expectations. Building enclosures, mechanical systems, and interior materials all have an impact on IAQ. Building enclosure assemblies should be designed to prevent moisture issues and air infiltration, and site inspections and testing should be performed to ensure proper installation. Building enclosure failures can result in mold issues, a serious health threat, and damage the structure and interior finishes as well. Mechanical systems should be designed for optimized ventilation and improved filtration to dilute and remove air pollutants that impact respiratory health. Selection of interior materials, such as sealants, adhesives, paints, insulation, flooring, composite wood, etc., all which have been independently tested against low-emitting material standards prevent the introduction of indoor pollutants.

Conducting post-construction IAQ testing provides assurance that potentially harmful materials were not installed. Rating systems, including Leadership in Energy and Environmental Design (LEED) and WELL, have established industry-leading indoor health and wellness standards for materials and completed buildings, and rely on testing to demonstrate compliance.

Building owners are relying on air quality testing to diagnose problems and to validate the efficacy of interventions to improve the IAQ. They are also using testing to confirm tried and true strategies, such as increased ventilation and high efficiency filtration are providing the desired and required results. More exotic interventions are frequently not necessary.

 Sustainability is now the norm

Creating a more sustainable environment for future generations is top of mind for everyone, including manufacturers. Material transparency and the use of sustainable, healthier, eco-friendly, and low embodied carbon products is a growing trend.

Material testing companies should ask questions such as: What is the product’s life cycle? Can it be recycled? Does it improve the energy efficiency of the building? What is its embodied carbon? How can it get to the market quickly with less shipping costs or impact on the environment?

LEED, the Living Building Challenge, and other sustainable building ratings have defined sustainable performance standards for materials. Successful products will be carefully measured by their contributions to a more sustainable built environment, making testing and material transparency reporting necessary.

The future of testing

Manufacturers, architects, engineers, contractors, and other building professionals can benefit from using testing as a basis for good design. As the built environment becomes increasingly complex, using the expertise of a high-quality, third-party testing facility can help ensure materials are safe and products will perform as expected. IAQ, safety, designing beyond the code, and sustainability trends are here to stay, and professionals in the industry should keep these concepts at the top of their design checklist.

Author

Heather Stahl-Figueroa is the regional operational sales manager for Intertek. Intertek provides engineers and subject matter experts worldwide, flexible services, fast turnaround times, innovative testing solutions, and global approvals. Prior to this position, Stahl-Figueroa was the lab manager of Intertek’s Farmingdale New York Product Testing Laboratory. She has been with Intertek since 2016, and has provided support in sales, marketing, and management roles for more than five years. Her background includes fenestration product testing, as well as geotechnical services for concrete, asphalt, and soils.

Source URL: https://www.constructionspecifier.com/achieving-project-success-through-product-and-material-testing/

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