OnlineQC™ Customer Portal User Manual

📑 User Manual Navigation

1. Overview & Architecture 2. Authentication & Multi-Tenant Security 3. Main Navigation & Header Suite 4. Tab 1: Strength Summary & Mix Catalog • 4.3 Requirements for Mix Summary Statuses • 4.4 Moving 45-Test Cohort & Overdesign 5. Tab 2: Strength Analysis & ACI 318 Submittals 6. Tab 3: Low Break Alerts & Root Cause Analysis 7. Tab 4: QA Ingest, PDF OCR & Verification 8. Tab 5: Admin Console & Master Data 9. Engineering Toolbox & Suite Integrations 10. Data Exports, Submittals & FAQs

1. Overview & Technical Capabilities

OnlineQC™ is The Concrete Advantage’s engineering-backed, cloud-synchronized quality control portal developed specifically for ready-mix concrete producers, quality assurance directors, plant managers, and testing engineers. With 39 years of real-world ready-mix QC expertise embedded into its algorithms, OnlineQC protects producers against costly backcharges, automates submittal packages, tracks mix trend deviations, and actively identifies cement optimization opportunities that drive bottom-line savings.

ACI 318

Chapter 26 Compliance

ACI 214R

Statistical Evaluation

45-Test

Moving Average Cohort

256-Bit

Encrypted Isolation

Core Operational Modules:

Live Compressive Strength Tracking: Centralized real-time tracking of early (1–3d), 7-day, 28-day, and 56-day cylinder breaks with historical moving averages.
Automated ACI 318 / ACI 301 Mix Submittal Packages: One-click generation of fully compliant 30-consecutive-test submittal packages with standard deviation, moving averages, and Gaussian bell-curve distributions.
Proactive Low Break Risk Management: Automated dual-rule compliance monitoring per ACI 318-19 Section 26.12.1.1 with root cause correlation (water addition, high air, cold weather curing).
Direct Lab PDF Intake & OCR Verification: Streamlined ingestion of testing lab PDF sheets (Terracon, ECS, PSI, Froehling & Robertson, regional labs) with side-by-side QA verification before committing to active records.
Economic Cement Optimization Engine: Continuously monitors mix overdesign above ACI required average strength (f'cr), pinpointing mixes with >500 psi excess strength where cementitious reduction will yield safe financial and carbon savings.

2. Authentication, Account Management & Multi-Tenant Isolation

OnlineQC utilizes a zero-bleed, multi-tenant customer isolation architecture. Each ready-mix producer accesses a dedicated, encrypted workspace containing only their mix catalog, customer projects, delivery tickets, and cylinder break results.

2.1 Signing In

Navigate to the OnlineQC portal URL in any modern desktop or mobile browser.
Enter your authorized Company Email or Username (e.g., hill@feltonbrothers.com or felton).
Enter your assigned confidential Password.
Optionally check "Remember Me" to securely preserve your active login session on your workstation.
Click "Sign In to OnlineQC Portal →".

🔒 Enterprise Customer Isolation: Producer workspaces are fully isolated. Cowboys Ready Mix cannot access Felton Brothers mix formulations or break records, and vice versa. TCA Certified Quality Certifiers maintain administrative engineering oversight across accounts to perform third-party verification.

3. Main Navigation & Header Suite

+-----------------------------------------------------------------------------------------------------------------------+ | [ THE CONCRETE ADVANTAGE ] [▦ TCA SUITE APPS ▾] Active: [ Felton Brothers ▾ ] ☁️ Cloud Synced 👤 Logged in: Hill | +-----------------------------------------------------------------------------------------------------------------------+ | [ STRENGTH SUMMARY ] [ STRENGTH ANALYSIS ] [ LOW BREAK ALERTS (0) ] [ QA INGEST & ASSIGN (0) ] [ 👑 ADMIN ] | +-----------------------------------------------------------------------------------------------------------------------+

▦ TCA SUITE APPS Menu: Quick-launch access to integrated tools including the ACI 301 Mix Designer, the Concrete Plant Pre-Inspection & DOT Audit, and the TCA Engineering Calculators.
Active Organization Selector: Displays your producer organization name. Users with multi-plant or certifier privileges can switch between regional plant profiles seamlessly.
☁️ Cloud Synced Indicator: Real-time status heartbeat indicating active synchronization with the Supabase PostgreSQL cloud repository.
Red Primary Navigation Bar: Instant single-click switching between the primary operational workspaces without reloading the page.

4. Tab 1: Strength Summary & Mix Catalog (Deep Dive)

The Strength Summary tab is the operational command center of OnlineQC. It delivers a comprehensive overview of every active concrete mix produced, summarizing compressive strength gains, fresh properties, statistical standard deviation, overdesign margins, and compliance statuses.

4.1 Top KPI Summary Cards

Located above the mix catalog, four top-level summary metrics provide immediate quality visibility:

Active Mixes: Total count of commercial mix designs registered and active in your producer database.
Verified Strength Tests: Total cumulative cylinder break reports ingested, verified, and active in the database.
Non-Compliant Mixes: Number of mixes currently exhibiting confirmed cylinder breaks below specified design strength (f'c).
Active Low Break Alerts: Count of uninvestigated or pending low break alerts requiring engineering root cause determination.

4.2 The Mix Catalog Master Table

Column Header	Display Element	Engineering Definition & Calculation Method
Mix No.	Producer Mix ID & Tags	The unique producer product code (e.g., `35NA30`, `45AE30A`). Clicking the code drills into the Mix Details & Ticket Explorer. Displays a green `🌱 Opt` pill when eligible for cement optimization.
Mix Description	Application & Class	Descriptive name and structural application (e.g., 3500 PSI Foundation & Slab Mix, 4500 PSI Commercial Air).
f'c Spec	Specified Strength (psi)	Design specified 28-day compressive strength required by project structural drawings.
28d Tests (N)	Cohort Sample Size	Number of verified 28-day break tests evaluated in the moving cohort (capped at the most recent 45 tests).
Avg Slump	Field Workability (in.)	Average field slump measured at jobsite discharge across the moving 45-test cohort.
Avg Air	Entrained Air (%)	Average field air content measured via pressure meter (ASTM C231) across the moving cohort.
Avg Temp	Fresh Temp (°F)	Average concrete placement temperature measured per ASTM C1064 across the moving cohort.
Avg 7-Day	Early Strength (psi)	Average 7-day compressive strength across tickets in the moving 45-test cohort that have recorded 7-day breaks.
Avg 28-Day	Design Strength (psi)	Arithmetic mean of all 28-day cylinder breaks in the moving 45-test cohort. Displayed in red if below f'c.
Overdesign	Variance vs. ACI f'cr	Difference between actual 28-day average strength and required ACI 318 strength (Avg 28d - f'cr). Highlighted in green with `🌱 >500 psi Opt` badge when exceeding required strength by >500 psi.
Gain (7→28)	Strength Increase (psi)	Actual compressive strength gain from 7 to 28 days (Avg 28d - Avg 7d). Key indicator of pozzolanic hydration and cement reactivity.
Std Dev (Ss)	Sample Std Dev (psi)	Sample standard deviation calculated per ACI 214R across the moving 45-test cohort.
Status	Compliance Badge	The automated quality and compliance status badge evaluating ACI 318 criteria, low breaks, pending tests, and optimization opportunities.

4.3 Requirements & Evaluation Logic for Mix Summary Statuses

Every active mix is evaluated in real time against a rigorous, prioritized compliance hierarchy. OnlineQC inspects test break values, standard deviations, required average overdesign, active alerts, and test maturation schedules to assign one of six distinct statuses:

Status Badge	Priority	Triggering Conditions & Technical Requirements	Operational Action Protocol
🚨 Non-Compliant (X Low Breaks < f'c)	1 (Highest)	Condition: `stats.hasLowBreaks === true` Triggered whenever one or more verified 28-day cylinder strength tests in the moving 45-test cohort fail to reach the specified design strength: Individual Break Test < Specified f'c Example: A 3,500 psi mix has a verified 28-day break of 3,180 psi.	Immediate Producer Action: Open Low Break Alert log to inspect field batch data. Check truck ticket for unauthorized water addition (> batch w/cm). Inspect lab report for cylinder handling or curing flaws (ASTM C31). Coordinate with TCA certifier for engineering review.
⚠️ Below f'cr (Avg < f'cr psi)	2	Condition: `stats.isBelowFcr === true` Triggered when there are zero individual breaks below f'c, but the cohort 28-day arithmetic mean falls below the ACI 318 required average strength (f'cr): Average 28d Strength < Required f'cr The mix meets bare minimum strength on every ticket but lacks adequate statistical safety margin required by ACI 318 Table 26.4.3.1(b).	Preventative QC Action: Batching variability or aggregate moisture shifts are narrowing safety buffer. Review plant scale calibration and aggregate gradation. Consider a minor cementitious trim adjustment (+10–15 lb/yd³) or chemical admixture adjustment.
⚠️ X Active Alerts	3	Condition: `stats.lowBreakCount > 0` Triggered when open, unresolved low break incident reports exist in the low break investigation queue for this mix, but confirmed cylinder breaks have not yet entered the primary moving cohort.	Investigation Action: Navigate to Tab 3 (Low Break Alerts). Complete the root cause diagnostic checklist. Determine whether ticket should be verified or mathematically omitted.
🌱 Potential Optimization	4	Condition: `stats.isPotentialOptimization === true` Triggered when ALL of the following criteria are satisfied: Zero confirmed low breaks below specified f'c. Zero active alerts. Overdesign > +500 psi above required ACI f'cr: (Avg 28d - f'cr) > +500 psi At least 30 verified 28-day test reports: `cohortCount ≥ 30` (required for statistical qualification per ACI 318 before mixture optimization). The entire table row is highlighted in light green, and a green `🌱 Opt` badge is placed on the mix ID.	Cost & Cement Optimization Action: The mix is significantly over-designed, consuming more cementitious material than required by ACI code. Eligible for safe cement reduction (typically 20–40 lb/yd³ savings). Consult TCA mix design director to optimize water-cement ratio and submittal documentation.
⏳ X Pending 28d	5	Condition: `stats.pending7dCount > 0` Triggered when a mix has test records with valid 7-day breaks recorded (avg7d > 0), but the corresponding 28-day cylinder tests have not yet occurred or been entered. Note: Pending tickets are displayed in Mix Details for producer visibility, but are properly excluded from summary moving averages until 28-day break results mature.	Schedule Tracking: Monitor break calendar for upcoming 28-day testing dates. Ensure commercial testing lab delivers 28-day PDF report promptly upon break date.
✓ Compliant	6 (Normal)	Condition: Default compliant state. All 28-day strength tests equal or exceed specified f'c, the 28-day average satisfies ACI required f'cr, there are zero active alerts, and overdesign is within the optimal operating range (+0 to +500 psi above f'cr).	Routine Monitoring: Mix is operating at peak quality compliance and optimal economy. Continue standard batching and testing protocol.

4.4 The 45-Test Moving Average Cohort Methodology

Unlike simplistic systems that lump together years of outdated break data, OnlineQC implements a 45-test moving average cohort. All summary averages—including Slump, Air, Concrete Temperature, 7-Day Strength, 28-Day Strength, 56-Day Strength, Standard Deviation (Ss), and Overdesign—are calculated strictly on up to the most recent 45 consecutive tests of that mix that have verified 28-day results.

Why 45 Tests? Concrete production is subject to seasonal changes, raw material shipments, cement mill variability, and quarry changes. A 45-test moving window satisfies ACI 318 statistical sample requirements (≥ 30 tests) while ensuring that your quality indicators reflect current materials and production conditions rather than obsolete data from previous seasons.

Standard Deviation (Ss) Calculation per ACI 214R:

Sample Standard Deviation Equation:

s_s = √ [ ∑ (X_i - X̄)² / (N - 1) ]

Where X_i is individual 28-day strength test, X̄ is the cohort mean, and N is the cohort sample count.

Required Average Strength (f'cr) per ACI 318-19 Table 26.4.3.1(b):

For Specified Strength f'c ≤ 5,000 psi:

f'_cr = max [ (f'_c + 1.34 × s_s), (f'_c + 2.33 × s_s - 500) ]

For Specified Strength f'c > 5,000 psi:

f'_cr = max [ (f'_c + 1.34 × s_s), (0.90 × f'_c + 2.33 × s_s) ]

4.5 Mix Details & Ticket Explorer

Clicking any mix number in the master table opens the Mix Details & Ticket Explorer:

Mix Specification Header: Displays specified slump, air content range, design f'c, and theoretical unit weight.
Filter Tickets: Filter the ticket list by Active tickets (Included in Summary), Show all tickets, or Show omitted tickets only.
Optional Column Toggles: Show or hide Avg 56 Day breaks and Unit Weight columns.
Export Historical Submittal Sheet: Generates a printable submittal sheet listing all 45 cohort tickets, moving averages, and statistical compliance certifications.
Single-Ticket View: Clicking view on any ticket opens the complete digital break certificate, showing cylinder dimensions, break dates, failure loads, ASTM C39 fracture types (Types 1–6), and lab technician notes.

4.6 Ticket Omission & Quality Audit Trail

When a cylinder break is demonstrably invalid due to documented field errors—such as unauthorized jobsite water addition by a contractor, dropped cylinders, cold weather jobsite storage curing violations (ASTM C31), or testing machine calibration failure—producers can initiate a ticket omission request.

Click "Flag / Omit Ticket" on the ticket view modal.
Select the formal justification category (e.g., Jobsite Water Addition > Allowable, Cylinder Handling/Curing Damage, Third-Party Lab Procedure Violation).
Enter supporting field notes and lab report cross-references.
Upon sign-off by a TCA Quality Certifier, the ticket is omitted from statistical standard deviation and average calculations while remaining permanently preserved in the audit log for complete regulatory transparency.

5. Tab 2: Strength Analysis & ACI 318 Submittal Engine

The Strength Analysis tab provides advanced multi-dimensional statistical filtering and engineering modeling adhering to ACI 318-19 Section 26.4.3 and ACI 214R.

5.1 Multi-Dimensional Filter Engine

Isolate and analyze specific performance variables across your production history:

Mix Selection Checkboxes: Analyze a single mix or multi-select similar mixes to evaluate aggregate performance.
Project Directory Checkboxes: Filter breaks strictly for a specific commercial project (e.g., Microsoft LYH10 Data Center) or evaluate all projects combined.
Date Range Selectors: Evaluate seasonal performance (e.g., Summer mix vs. Winter mix adjustments).
Fresh Property Slump & Air Sliders: Filter out out-of-spec batches to evaluate baseline design performance.

5.2 ACI 214 Statistical Evaluation Panel

The calculation engine computes comprehensive quality control metrics instantly:

Metric	Formula / Origin	ACI 214 Quality Standard Interpretation
Coefficient of Variation (V)	V = (s_s / X̄) × 100%	< 10.0%: Excellent plant control. 10.0% – 12.0%: Very Good plant control. 12.0% – 15.0%: Good (Normal) plant control. 15.0% – 18.0%: Fair plant control. > 18.0%: Poor control — batching review required.
Required Strength (f'cr)	ACI 318 Table 26.4.3.1(b)	Minimum target average compressive strength required to ensure ≤ 1 in 100 chance of low breaks.
Overdesign Margin	X̄ - f'_cr	Actual safety margin in PSI. Values > 500 psi indicate opportunity for cementitious reduction.

5.3 Interactive Charts & Visualizations

Strength vs. Age Progression Curve: Compares early 1-day, 3-day, 7-day, 28-day, and 56-day progression curves against the specified design strength line.
Moving Average of 3 Consecutive Tests: Trendline tracking consecutive 3-test moving averages directly against the f'c compliance threshold per ACI 318.
Gaussian Strength Distribution Bell Curve: Statistical histogram displaying normal distribution bell-curve fitted over individual strength test frequencies, showing standard deviation lines and specified f'c cutoffs.

5.4 Saved Submittal Query Presets

Save frequently required contractor or DOT submittal parameters:

Set your desired mix, project, and date filters.
Click "💾 Save Analysis Query".
Name the query (e.g., 35NA30 - Microsoft LYH10 Foundation Submittal).
The query snapshot is saved to your organization profile. Click the preset name at any time to instantly reload those exact filters.

6. Tab 3: Low Break Alerts & Root Cause Diagnostic Engine

OnlineQC continuously audits every cylinder break against ACI 318-19 Section 26.12.1.1 concrete acceptance criteria:

ACI 318 Acceptance Standard 1 (Individual Test Criterion):

No individual strength test (average of two 6x12" or three 4x8" cylinders) falls below f'c by more than 500 psi (when f'c ≤ 5,000 psi) or by more than 0.10 f'c (when f'c > 5,000 psi).

ACI 318 Acceptance Standard 2 (Moving Average Criterion):

Every arithmetic average of any three consecutive strength tests equals or exceeds specified f'c.

6.1 Automated Root Cause Diagnostics

When a cylinder break falls below specified strength, OnlineQC's diagnostic engine analyzes fresh concrete properties from the batch ticket to determine the primary contributing factor:

Water-Cement Ratio Shift / Slump Anomaly: Flags field slump > 5.5" or recorded jobsite water additions exceeding allowable mix design water.
Air Entrainment Exceedance: Flags fresh air content > 6.5%. (Rule of thumb: each 1% excess air reduces compressive strength by approximately 5%).
Low Temperature Placement / Curing: Flags batch or placement temperatures < 50°F indicative of delayed hydration or improper ASTM C31 initial field curing box maintenance.
Testing Laboratory Anomaly: Flags Type 5 (shear) or Type 6 (columnar) cylinder breaks often caused by unlevel cylinder capping, unplaned ends, or eccentric machine loading.

7. Tab 4: QA Ingest, Lab PDF OCR & Verification Queue

OnlineQC simplifies test report ingestion by allowing producers to submit commercial testing lab PDF break sheets directly into an automated verification queue.

[ PDF Lab Report Upload ] → [ Automated OCR Data Extraction ] → [ Side-by-Side Review Lightbox ] → [ 1-Click Database Approval ]

7.1 Submitting Test Reports (Ingestion Protocols)

OnlineQC supports three fast, flexible methods for producers to transmit compressive strength break sheets:

Method A: Loose PDF Reports: Drag & drop individual PDF files. Recommended batch size: 20 to 25 reports (under 35 MB) for instantaneous cloud sync.
Method B: Select Entire Folder: Click "📁 Select Folder of Reports" to upload an entire daily project directory without manually clicking each file.
Method C: Compressed .ZIP Archive: For large project backlogs or quarterly submittals (50 to 300+ reports), right-click your desktop folder → Compress to ZIP and drop the single .zip file.

📄 Dedicated Printable Ingestion Guide Available:
For step-by-step Windows 10/11 right-click zipping instructions, scanner orientation rules, and transfer speed tables, open the official OnlineQC Ingestion Quick Guide & SOP (Printable / PDF) →

Click "📤 SEND TEST REPORTS TO TCA" (or open the QA review dropzone).
Drop your PDFs, entire folder, or .zip archive into the upload box.
Wait for the Green Checkmark: Always keep your browser tab open until the progress bar reaches 100% and displays "✅ Ingestion Complete" before navigating away.

7.2 Side-by-Side QA Review Lightbox

TCA Certifiers and designated producer QC managers review reports using a split-screen lightbox:

Left Pane: High-resolution PDF document viewer displaying original laboratory seals and break sheets.
Right Pane: Extracted editable data form containing batch date, ticket number, cylinder dimensions, break loads, calculated PSI, and fresh properties.
Approval: Click "✅ Approve & Push to Live Database" to commit the verified tests to your active database in one click.

8. Tab 5: Admin Console & Master Data Management

Accessible to users with administrative credentials, the Admin Console provides management of organization master data:

Mix Catalog Management: Register new master mix designs, configure specified f'c, target slump, design air, target unit weight, and maximum water-cement ratio.
Customer Project Directory: Add master construction projects, specify general contractors, and assign authorized mix designs.
User Accounts & Access Roles: Manage user accounts, role permissions (customer, admin, certifier), and email aliases.
Cloud Database Backup & Synchronization: Monitor real-time synchronization with the Supabase PostgreSQL cloud backend. OnlineQC implements non-destructive union merging so data is permanently protected against accidental resets.

9. Engineering Toolbox & Suite Integrations

Through the ▦ TCA SUITE APPS dropdown in the top header, producers have instant access to specialized engineering modules:

9.1 ACI 301 Mix Designer Integration

Launch directly into the full-featured ACI 301 Mix Designer web application. The Mix Designer features volumetric absolute volume mix proportioning, 3-point water-cement ratio curve modeling per ACI 301-20 Section 4.2.3, aggregate sieve analysis, and submittal sheet generation scoped to your customer account.

9.2 Concrete Plant Pre-Inspection & DOT Audit Checklist

A comprehensive 12-point inspection module compliant with NRMCA and State DOT plant certification protocols:

Scales & Calibration Tolerances: Cementitious scale (±1%), Aggregate scale (±2%), Water meter (±1%), Admixture dispensers (±3%).
Moisture Probes: Daily microwave calibration verification of aggregate moisture sensors.
Mixer Uniformity: ASTM C94 mixer blade wear inspection and slump uniformity across load.
DOT Compliance Scorecard: Computes real-time percentage compliance score and generates an audit certification certificate.

9.3 Interactive Engineering Calculators (3 Modules)

Plastic Shrinkage Evaporation Rate (ACI 305.1 Nomograph):
Computes predicted evaporation rate E (lb/ft²/hr) from concrete temperature, air temperature, relative humidity, and wind speed using the official ACI 305.1 formula:

E = 5 × [ (T_c + 18)^2.5 - r × (T_a + 18)^2.5 ] × (V + 4) × 10^-6

Flags cracking risk (Safe: <0.10, Moderate: 0.10–0.20, Severe: >0.20 lb/ft²/hr) and outputs required curing precautions.
Water-Soluble / Total Chlorides Calculator (ACI 318 Table 19.3.2.1):
Evaluates chloride ion contributions from cement, mixing water, fine aggregates, coarse aggregates, and admixtures against ACI maximum limits for prestressed concrete (0.06%), reinforced concrete in wet service (0.15%), and dry service (1.00%).
Concrete Temperature Energy Balance Prediction:
Calculates predicted freshly mixed concrete temperature based on thermal specific heat balance of coarse aggregate, fine aggregate, cement, fly ash/slag, mixing water, and added batch ice.

10. Data Exports, Submittals & FAQs

10.1 Reporting & Export Formats

Formal ACI Submittal PDF: Generates official producer submittal packages with company letterhead, moving averages, standard deviation charts, and individual cylinder break listings.
CSV Data Export: Export raw ticket break data for seamless import into Command Alkon, Sysdyne, Marcotte, Jonel, or Microsoft Excel.
Individual Break Certificates: Print single-ticket ASTM C39 test certificates with fracture type diagrams and technician sign-offs.

10.2 Frequently Asked Questions (FAQ)

Q: How does OnlineQC calculate standard deviation if I have fewer than 30 tests?
A: In accordance with ACI 318 Table 26.4.3.1(a), if fewer than 30 tests are available (between 15 and 29 consecutive tests), the sample standard deviation is multiplied by an ACI modification factor (1.16 for 15 tests, 1.08 for 20 tests, 1.03 for 25 tests, 1.00 for 30+ tests). OnlineQC handles this adjustment automatically in the Strength Analysis module.

Q: How do I know if a mix qualifies for cement optimization?
A: Check the Mix Summary status badge. When a mix achieves the 🌱 Potential Optimization badge (with a green 🌱 Opt pill on the mix code and green row highlighting), its 28-day average strength exceeds the ACI required average strength (f'cr) by more than 500 psi with zero low breaks and at least 30 verified 28-day test reports. This ensures complete statistical confidence per ACI 318 before cement reduction is submitted.

Q: What happens if a contractor adds water on the jobsite?
A: Record the contractor water addition in the ticket details. If the resulting break fails to meet specified f'c, flag the ticket for omission under the "Jobsite Water Addition > Allowable" justification. Once approved by the TCA certifier, the ticket is omitted from the moving 45-test standard deviation calculations to protect your plant compliance record.

Q: Is our data backed up to the cloud?
A: Yes. All data is continuously synchronized with the central Supabase PostgreSQL cloud repository with multi-tier union merge protection to prevent accidental loss or overwrite.

The Concrete Advantage (TCA) • Technical Support: support@theconcreteadvantage.com

Compliant with ACI 318-19 • ACI 214R-11 • ACI 301-20 • ASTM C94