• Quality Assurance, Quality Control, Boston Valley Terra Cotta, Factory

QA/QC

Boston Valley Terra Cotta is committed to producing the highest quality terra cotta product in the country. We have put a quality assurance program in place that ensures every block leaving our facility will meet our assured standards. The program is in place all the way from clay batching, through extrusion into drying and firing and finally sizing and shipping. Product is checked for conformance to dimensional tolerances after it is dried and after it is fired. Straightness of the panels is checked on a laser controlled tolerance inspection machine which automatically rejects non-conforming panels for recycling. After firing panels are also checked for color range conformance using a photospectrometer. Boston Valley also performs consistent periodic material testing to ensure our clay bodies continue to perform in the industry property testing expected of ceramic materials. Our recipes consistently outperform the industry standards.

TRACKING

Our bar coded tracking system tool provides a unified method for monitoring project status, from material supply award through final shipment and project close out.

Throughout each stage of the manufacturing process, Boston Valley incorporates our custom designed tracking system. This system assigns a unique identifier to each sample received from the building and associates it with replacement units shown on the shop, setting, section and detail drawings generated by our skilled design and drafting departments. Our bar-coded tracking system tool provides production schedule accountability, product delivery updates for contractors to coordinate equipment and labor need at the project site, and a unified method for monitoring project status from material supply award through final shipment and project close out.

From individual blocks to our expansive manufacturing facility in Orchard Park, New York, Boston Valley Terra Cotta employs the latest technology, quality control services and innovative tools to ensure product quality, consistency and production schedule accuracy. We understand that our clients have demanding schedules and utilize those tools available to us to make their work at the project site easier.

Quality Assurance, Quality Control, Tracking, Boston Valley Terra Cotta, Factory, St. Bart's Dome
Quality Assurance, Quality Control, Layout, Fit, Boston Valley Terra Cotta, Factory

LAYOUT & FIT

Prior to being packed and shipped, units manufactured at Boston Valley are checked for conformance with industry standard dimensional tolerances and against the approved color control sample. For large restoration and new construction projects, or when requested by the client, Boston Valley will also perform a layout and dry-fit of the terra cotta units to ensure alignment of the blocks in the assembly according to the approved setting drawing. This last step in our quality control process confirms to the client that the units can be installed when they arrive at the job site. Clients are welcome to visit the facility to inspect the layout and dry-fit; additionally they could consider hiring a third-party company to perform inspection.

LAYOUT & FIT

Prior to being packed and shipped, units manufactured at Boston Valley are checked for conformance with industry standard dimensional tolerances and against the approved color control sample. For large restoration and new construction projects, or when requested by the client, Boston Valley will also perform a layout and dry-fit of the terra cotta units to ensure alignment of the blocks in the assembly according to the approved setting drawing. This last step in our quality control process confirms to the client that the units can be installed when they arrive at the job site. Clients are welcome to visit the facility to inspect the layout and dry-fit; additionally they could consider hiring a third-party company to perform inspection.

Quality Assurance, Quality Control, Layout, Fit, Boston Valley Terra Cotta, Factory

SHIPPING

The last stop for products before they leave our facility is the shipping department. Here, blocks that have been sized and inspected are packaged into wooden crates. Product is packaged and shipped according to the priority sequencing that was established at the beginning of the project. Each unit number is recorded into a log with the date and crate number indicated, and the contents of every crate are photo documented prior to being shipped. The client will receive a shipping report that provides the project name, date, shipment number, crate number, block style and unit number.

Quality Assurance, Quality Control, Shipping, Boston Valley Terra Cotta, Factory

SHIPPING

The last stop for products before they leave our facility is the shipping department. Here, blocks that have been sized and inspected are packaged into wooden crates. Product is packaged and shipped according to the priority sequencing that was established at the beginning of the project. Each unit number is recorded into a log with the date and crate number indicated, and the contents of every crate are photo documented prior to being shipped. The client will receive a shipping report that provides the project name, date, shipment number, crate number, block style and unit number.

Quality Assurance, Quality Control, Shipping, Boston Valley Terra Cotta, Factory
Quality Assurance, Quality Control, Installation, Boston Valley Terra Cotta, Factory

INSTALLATION

Although we do not provide installation services ourselves, we can connect you with a company from our network of experience and trusted installers. These companies have undergone classroom training and on-site factory training on full-sized building mockups to teach the proper and most efficient methods of Terraclad installation.

INSTALLATION

Although we do not provide installation services ourselves, we can connect you with a company from our network of experience and trusted installers. These companies have undergone classroom training and on-site factory training on full-sized building mockups to teach the proper and most efficient methods of Terraclad installation.

Quality Assurance, Quality Control, Installation, Boston Valley Terra Cotta, Factory