Address: 2500 Northwinds Parkway, Suite 500 Alpharetta, GA 30009

Transcription

1 for Geosynthetic Reinforcement Plant Name: Tensar Corporation LLC Physical Address: 1210 Citizens Pkwy Morrow, GA Mailing Address: same (if different from above) Proprietary Ownership Company Name: Tensar International Physical Address: 2500 Northwinds Parkway, Suite 500 Alpharetta, GA Primary Contact Name: Willie Liew Title: Application Technology Mgr Telephone: Fax: Management QC Manager: David Hall Plant Manager: Bill Shelton Auditor Contact Name: Willie Liew Telephone: Address: 2500 Northwinds Parkway, Suite 500 Alpharetta, GA Page 1 of 16

2 for Geosynthetic Reinforcement DOT Official Contact Name: Title / Organization: Telephone: Address: DOT Official Contact Name: Title / Organization: Telephone: Address: DOT Official Contact Name: Title / Organization: Telephone: Address: Other Attendee Contact Name: Joel Sprague Title / Organization: TRI/Environmental, Inc. Telephone: Address: 3101 Augusta St. Greenville, SC jsprague@tri-env.com Page 2 of 16

3 Evaluation Program for Geosynthetic Reinforcement Summary Report For UX MSE / HS Product Line Introduction The National Transportation Product Evaluation Program (NTPEP) is a program under the sponsorship of the American Association of State Highway and Transportation Officials (AASHTO). The NTPEP Evaluation Program for Geosynthetic Reinforcement audit report provides a comprehensive review of the consistency of the product line, allowing products representative of the line to be tested and the results of that testing applied to the remaining products in the line not subjected to the full suite of tests, in accordance with AASHTO PP The evaluation includes a desktop review of the facility s quality manual and an on-site review of the facility s processes and their quality management system documentation. The desktop review and the on-site review were conducted jointly by auditor Joel Sprague. Geosynthetic manufacturer Tensar was represented by Willie Liew and Bill Shelton, during the on-site audit which was completed on April 27, The evaluation findings follow. Deviations from program requirements are noted in red. The audit was conducted to evaluate the UX MSE / HS product line, including UX1100, UX1400, UX1500, UX1600, UX1700. Raw materials used include HDPE and Carbon Black. Raw materials, including COA s and QC/QA test results, were traceable to the finished product and found to be consistent throughout the specified product line. The manufacturing process from raw material to finished product was found to be consistent for all production lines used to produce products for this product line (UX MSE / HS). The QC/QA processes used by the manufacturer, including raw material specification requirements used by the manufacturer to procure and evaluate raw materials used in the product line, and quality control for the finished geogrid products, appear adequate to maintain consistency of the as-manufactured products. Therefore, the manufacturer was found to be compliant with regard to the definition of a geosynthetic reinforcement product line in the NTPEP work plan and AASHTO PP66-10, for the product line as specified herein. Page 3 of 16

4 Table of Contents Section 1: Geosynthetic Reinforcement Product Line Summary and Production Line Overview.. 5 Section 2: Product Raw Materials Information... 6 Section 3: QMS QC/QA Requirements... 6 Section 4: Sample Reports for Resin and Geosynthetic Testing Section 5: Manufacturing Process Control Section 6: Records Retention and Traceability Section 7: Geosynthetic Reinforcement Identification Markings Section 8: Report Signature Section 9: Sampling Page 4 of 16

5 Section 1: Geosynthetic Reinforcement Product Line Summary and Production Line Overview Product Line Product Designation UX MSE / HS UX1100MSE UX1100HS UX MSE / HS UX1400MSE UX1400HS UX MSE / HS UX1500MSE UX1500HS UX MSE / HS UX1600MSE UX1600HS UX MSE / HS UX1700MSE UX1700HS NOTE: A UXMSE product having excess bow or skew is reclassified as UXHS. This is unrelated to physical properties. Tensar uniaxial products MSE have a bow and skew maximum tolerance of 12 mm and 20 mm, respectively. Above these tolerances, the product is designated HS. The HS bow and skew tolerances are a maximum of 24mm and 45mm, respectively. a) Manufacturing Plants Used to Produce Product Line: Does the company own plants at other locations that produce, or help to produce, one or more of the products within the product line under consideration? YES NO If yes, does each plant have its own unique geosynthetic marking? YES NO List other locations: Plant Name Physical Address Mailing Address City, State, Country Auditor Note: Obtain information to identify the production lines used to produce products for the product line under consideration, and describe any differences between production lines that produce products for the same product line as defined in the NTPEP REGEO work plan. If more than one production line used to produce a geosynthetic reinforcement product (e.g., a different production line may be used to produce the yarn that is used to manufacture the final product), identify each production line used and what part of the product manufacturing process is conducted on each production line. b) Production Line Details: Manufacturing Plant Morrow, GA Production Line Identification/Description Morrow MDO (machine direction orientor) Note: 3 extrusion stations and 3 press (punch) stations can supply the single MDO. Products Manufactured on the Production Line All Page 5 of 16

6 Section 2: Product Raw Materials Information YES NO N/A 1) Identify raw materials received at the plant to form the products in the product line: Resin describe resin used: HDPE Additives identify type of additives: Carbon Black (with extra anti-oxidant) Coatings identify type of coatings: Fibers Describe fibers used: Yarns identify types: 2) Describe Raw Material Lot definition and Numbering System: Resin: Rail Car (4 compartments) numbering by resin manufacturer Additives: Gaylord Boxes (typically lbs) numbering by resin manufacturer Coatings: Fibers: Yarns: 3) Are Certificates of Analysis furnished by the raw materials Manufacturers for each lot? Resin: HDPE Additives: Carbon Black Coatings: Fibers: Yarns: 4) Is regrind (reworked material) used as a source of resin for the products produced? If the answer to Question #4 is yes, what % of the product source is regrind? 35% If the answer to Question #4 is yes, how is the quality of the final product maintained with consideration to the possibility that some losses in the raw material properties due to the regrind process could occur? Extra antioxidant is incorporated through the carbon black additive. The melt flow index is tested on each extruded roll of UX sheet. The regrind melt flow index for UX sheet is spot checked at the pelletizers. 5) Are post-consumer recycled materials used as a resin source for the raw materials used in the final products or to otherwise form the final products? If the answer to Question #5 is yes, how are these products segregated from the products that meet AASHTO PP66-10 and the NTPEP work plan? Comments: Section 3: QMS QC/QA Requirements A) QMS Manual Information QMS Manual Identification: Date of Revision of Approved QMS: Facility has this manual available? Comments: The QC-QA Manual on Manufacture of Tensar Geogrid Jan. 9, 2012 (updated annually) yes Page 6 of 16

7 B) Manufacturer QC/QA for Raw Materials YES NO N/A 1) Does the manufacturer have property specifications for raw materials used in their geosynthetic reinforcement products: a) For resin? b) For fibers? c) For Yarns? d) For coatings? e) Other: Carbon Black 2) Identify properties used in the manufacturer s raw materials specifications: a) For resin: a. Melt index b. Carbon black content c. Other : Melt Point d. Are lot specific values for all these properties included in the COA? If not, which ones are not included? b) For fibers: a. Denier b. Tenacity c. Tensile strength d. Molecular weight e. CEG f. Other g. Are lot specific values for all these properties included in the COA? If not, which ones are not included? c) For yarns: a. Denier b. Tenacity c. Tensile strength d. Molecular weight e. CEG f. Other g. Are lot specific values for all these properties included in the COA? If not, which ones are not included? d) For coatings: a. Brookfield viscosity b. Density c. Gel temperature d. Durometer (Shore A) Initial e. Other: f. Are lot specific values for all these properties included in the COA? If not, which ones are not included? Page 7 of 16

8 B) Manufacturer QC/QA for Raw Materials YES NO N/A e) For other raw materials (e.g., additives such as carbon black, antioxidants, coloring, etc.): Carbon Black a. Properties used: Pigment and Melt b. Are lot specific values for all these properties included in the COA? If not, which ones are not included? 3) Do the manufacturer s raw material specifications meet AASHTO PP66-10 requirements? 4) Manufacturer raw material QC/QA approach used: a) Visual check of raw material supplier Certificate of Analysis (COA) in comparison to geosynthetic manufacturer raw material specifications b) QC/QA tests conducted by manufacturer or contracted outside lab 5) Do the raw material QC/QA procedures as described in the QMS: a) Specify the QC/QA process and procedures for the raw materials? b) The timing and frequency of random sampling, and sample size, considering lot size? c) Require raw materials QC/QA testing prior to using them in production? If the answer to 5(c) is no, how is final product identified/traced that contains raw material(s) that did not meet specification requirements? Summarize the raw materials QC/QA program, including sampling frequency relative to raw materials lot size/definition, sample size, when/where the material is sampled, QC/QA tests conducted on each raw material type, and corrective action taken when the QC/QA tests fail to meet one or more geosynthetic manufacturer raw material(s) property specifications: a) When/where sampling of raw materials is conducted: HDPE at railcar before unloading; Carbon Black at loading dock before use. b) Raw materials sampling frequency and size: HDPE small sample from every compartment; Carbon Black small sample from a random box from each shipment. c) QC/QA tests conducted on (if not applicable, insert N/A ): 1) Resin: Melt Index & Melt Point 2) Fibers: N/A 3) Yarns: N/A 4) Coatings: N/A 5) Other raw materials (e.g., additives such as carbon black, antioxidants, coloring, etc.): Carbon Black: Pigment Concentration & Melt Point d) Corrective action taken when QC/QA test results don t meet geotextile manufacturer property specifications (usually, these are the same as the supplier s specifications): Resin entire car rejected; Carbon Black entire shipment rejected. e) Other raw materials evaluation activities done by the geosynthetic manufacturer: N/A Page 8 of 16

9 Auditor Note Verify that the QMS manual contains the information/requirements identified in the table below. C) Quality Control Inspection and Testing (geosynthetic Product) YES NO N/A 1) Does the QMS include procedures for the inspection and testing of geosynthetics during and at the completion of the production of the geosynthetic products? 2) Do the procedures in the QMS: a) Require visual inspections of the final product? b) Specify the QC/QA process and procedures c) Describe a method for random sampling? The roll selected for QC sampling is chosen from the 10 th to 15 th rolls of a lot. d) Describe the timing and frequency of geosynthetic random sampling, and sample size, considering lot size? 3m per lot sample e) Specify the lot numbering system for the geosynthetic products? The first number in the lot designation is the particular extrusion sheetline, whether L1, L2, or L3. The subsequent number is the running consecutive reel number from the time of started up of that particular sheet line. Provide the definition of a lot used for the geosynthetic products: One extruded reel is considered a lot. For Tensar uniaxial products 1400, 1500, 1600, and 1700, the reel size can vary from 12,000 lbs to 20,000 lbs, representing an average of 90 to 125 finished rolls. 3) Does the QMS include an example of a quality control test report form? 4) Does the QMS document procedures and measurements used to verify the consistency of the manufacturing process (e.g., processing temperatures, fiber and rib forming processes, etc.) and condition of the manufacturing equipment? 5) Does the QMS describe quality control procedures for the coating used (PET geosynthetics only) and how it is applied to the polyester yarns/ribs to form the final product, considering both application rate and quality of the coating? 6) Does the QMS establish traceability from the final geosynthetic product back to the resin lot used? Roll to Reel & Reel to Resin 7) Are the documents that establish traceability of the final geosynthetic product maintained along with the inventory? Comments : Segregation for HS downgrade is done by production at doffing station if skew or bow (as defined in QC manual) is out of limits. Every 5 th roll (or more frequent) is inspected. D) Statistical Analysis of Test Results YES NO N/A 1) Does the QMS include a document describing the statistical process control plan? SPC is done continuously online. Computers at end of lines. 2) Does the plan include methods such as control charts to monitor production facility quality control test results to identify trends and make production adjustments as necessary? Charts maintained on computers. Page 9 of 16

10 Corrective action taken when QC/QA test results don t meet product property specifications (include how failing sample is related to specific rolls of product produced and action taken with those particular rolls): Nonconformance process is detailed in QMS. Product staged and cannot go into inventory until QC data is entered. Nonconformance is issued and product quarantined if QC data is out of spec. Can do extra testing to segregate bad product. Downgrade or regrind determined by mgt. E) QC/QA Testing Plan and Procedures Test Name Testing Performed by: In House Outside lab Test Interval Tests for Raw Materials: RESIN- Melt Index (ASTM D1238) X 4 per lot RESIN- Melt Point X 4 per lot ADDITIVE - Carbon black content (Pigment X 1 per lot No Testing Performed or N/A Concentration via ASTM D 4218)) ADDITIVE Melt Point X 1 per lot - Denier N/A - Tenacity N/A - Tensile strength N/A - Molecular weight N/A - Carboxyl end group content N/A - Brookfield viscosity (coatings only) N/A Geosynthetic Tests: - Mass per Unit Weight (ASTM D 5261) X 1 per lot - Single rib tensile strength (ASTM D6337) X - MD 1 per lot - Wide width tensile strength (ASTM D4595 or ASTM D6337) - Aperture size and rib width (hand measure) - Junction strength ASTM D 7737 X - MD 1 per lot - Weight / Length (tape measure / scale) X 1 per lot - CMD Brittleness (45 deg bend test) X 1 per lot 1 Names, addresses, and contact information for outside laboratory facility(ies) used: None Tensile test includes 2%, 5%, and ultimate; bow and skew, width, MD aperture measurements are work-inprocess (i.e. on-line) checks made approximately every 5 rolls, and every lot. Other testing done on production products that is not lot specific: Page 10 of 16

11 Section 4: Sample Reports for Raw Materials and Geosynthetic Testing Auditor Note Maintain example hard copies of the test records, certificates of analysis, and reports gathered during the audit. Sample Test Reports: Please provide sample reports representing quality control testing in accordance with WSDOT T925/AASHTO PP66-10 Specification: Raw materials Melt Index, molecular weight, carboxyl end group content, tensile strength, denier, Brookfield viscosity, etc. Geosynthetic Mass/unit weight, aperture/rib width, single rib tensile strength, wide width tensile strength, junction strength, etc. Test reports for raw materials and final geogrid products available to state DOT personnel upon request. Auditor reviewed test reports for geogrid samples obtained at the manufacturing facility in Morrow, GA, including test reports for the raw materials used in the specific product samples obtained. Test results were consistent with expectations. Page 11 of 16

12 Section 5: Manufacturing Process Control Note: If not applicable, enter N/A in box. A) Process from resin to fiber/yarn/rib Control of additives (amount and distribution) and how measured: % by weight; carbon black tested in QC Consistency of fiber forming/drawing process, including processing environment, and how measured: Continuous recording of process conditions. Can be used to assess finished product variability or non-conformity. Consistency of yarn weaving process: N/A B) Process from fiber/yarn/rib to final product Consistency of product weaving process, geogrid junction forming process, or geogrid formation process: See above. On line measurement of thickness during extrusion and apertures during punching and drawing. For PET geogrids, consistency of coating process, including processing environment, coating rate, and final weight per unit area or thickness of coating, including how measured for each aspect of process: N/A Page 12 of 16

13 Section 6: Records Retention and Traceability 1) Does the QMS include a process for storing quality control test reports for raw materials and the finished geosynthetic products, as well as raw material COA s? 2) Does the plant follow their procedures for the following: a) Test results and product traceability (storing and locating test reports)? b) Resolving non-conforming test results? 3) Does the QMS establish traceability from the final geotextile product back to the raw material lot used? 4) Are the documents that establish traceability of the final geosynthetic product maintained along with the inventory? 5) Regarding the raw materials supplier COA and manufacturer QC/QA data/test results: a) Are they traceable to the final geosynthetic products produced? b) Was auditor able to verify traceability on site? YES NO N/A Indicate method used by manufacturer to maintain traceability (e.g., raw material lot number included in final product identification, computer database maintained by manufacturer quality staff): Resin lot # included on COA, resin QC report, and reel product sheet. Reel production sheet includes Reel (and finished product) lot # as does the Grid production sheet, grid QC report. For Auditor indicate products evaluated for traceability: All sampled rolls used for evaluating traceability. Also, used recent reel record. 6) Regarding manufacturer QC/QA data/test results for geosynthetic product: a) Are they traceable to the final geosynthetic products produced? b) Was auditor able to verify traceability on site? Indicate method used by manufacturer to maintain traceability (e.g., finished product lot number included in final product identification, computer database maintained by manufacturer quality staff, etc.): Each roll has a sequential roll number and an associated lot number. The lot number is based on the sequential reel number. Each reel production record has resin and additive lot numbers that can be traced. For Auditor indicate products evaluated for traceability: Each sampled roll plus random reel and associated resin. Comments: Page 13 of 16

14 Section 7: Geosynthetic Reinforcement Identification Markings Auditor Note - Insert a picture(s) of the plant s unique geosynthetic identification markings. Refer to the plant s pre-audit documentation or previous audit report. Page 14 of 16

15 Section 8: Report Signature The Preceding Report has been reviewed and assured to be accurate by the Lead Auditor. Auditor Name: C. Joel Sprague Signature: Auditor Name: Signature: Auditor Name: Signature: Section 9: Sampling The sampling report form follows on the next page(s). Page 15 of 16

16 IN-PLANT SAMPLING REPORT NTPEP Program: REGEO NTPEP Number: (20 )-0 Manufacturer Name: Tensar Page _1_ of _1_ Type of Facility where Sampling Conducted: _X Manufacturing (production line); Describe: Geogrids are manufactured at this plant. _X Warehouse (storage of finished product): Describe: Connected to manufacturing facility. Location of Facility where Sampling Conducted: Morrow, GA Location within Production Line/Process where Sampling Conducted: Taken from Inventory, Palletized, and Verified on Loading Dock Date Material(s) Sampled: April 27, 2012 Manufacturer Representative(s) Present: Willie Liew, Bill Shelton Pre-arrangements Made with Manufacturer to Sample: Surprise inspection X Advance warning given (14 days) with specific sampling appt. date Material(s) Sampled and Description: Uniaxial Geogrids - Extruded, Drawn, HDPE (product designation if finished product, or description if sampling unfinished product, e.g., fiber, greige good, coating, etc., for Product) Sample 1 (finished product) - UX1100MSE Sample 2 (finished product) - UX1400MSE Sample 3 (finished product) - UX1500MSE Sample 4 (finished product) - UX1600MSE Sample 5 (finished product) - UX1700MSE Roll No. 109 Lot No Roll No. 140 Lot No Roll No. 111 Lot No Roll No. 56 Lot No Roll No. 36 Lot No Sampling Event Notes: (plant condition, roll storage/inventory, traceability of raw materials to products, sampling issues, etc.) Sample rolls preselected by auditor. Rolls "picked", palletized, and wrapped for shipping to lab prior to arrival. Shipment preparation verified by auditor. Sample Shipment Preparation Observations: (sample identification approach, sample placement in the shipping container, who did shipment preparation, how shipped, etc.) See above. Sampler Name and Affiliation: (please print): C. Joel Sprague 4/27/2012 TRI/Environmental, Inc. Signature Date Send copy of sampling report to NTPEP Geosynthetics TC Chairperson (Tony Allen, WSDOT, allent@wsdot.wa.gov) Also include copy of sampling report with samples. Page 16 of 16