Standard Test Procedures Manual

Transcription

1 STP 400 Standard Test Procedures Manual 1. SCOPE 1.1. Description of Test 2. PROCEDURES This method describes the minimum requirements for a contractor s Quality Control Plan that will help to assure that all materials and work submitted to the Department for acceptance will conform to the contract requirements. The Quality Control Plan: a) documents the Contractor s policy for obtaining quality and the assignment of quality control accountability and responsibility; b) has a statistically valid sampling, testing and analysis plan with frequencies, locations and methods; c) details provisions for disposal or rework of non-specification materials or work; d) identifies the laboratory(s) to be used and its credentials; e) identifies the quality control personnel and their qualifications; and f) has provisions for control charts Test Procedure The inspections and tests required to support conformance with the contract will be performed by the Contractor (or his designated agent) and made available to the Department. Standard equipment and qualified personnel will be used by the Contractor to perform the quality control inspection, sampling and testing required by the contract. The Contractor s quality control plan shall include the information as outlined below: Date: Page 1 of 12

2 Production Facility 1. Production Equipment (enter make, type and location). 1.1 Frequency of production equipment inspection, calibration, verification of calibration, and any certification of production facility. (Include documentation). 2. Personnel Responsible for Signing Forms 2.1 Enter name, qualification and telephone number of employee responsible for quality control. 2.2 Enter name and qualification of sampling and testing technician. 2.3 Enter name and telephone number of plant manager or employee responsible for making production facility changes when necessary as a result of QC data. 2.4 Name of employee who is responsible to notifysaskatchewan Highways when finished material is ready for acceptance testing, and how Saskatchewan Highways will be contacted. 3. Enter the type of materials and designs to be used in the contract. 4. List of sources to be used for each material type. 5. Proposed frequency of quality control testing during production operations. The suggested frequency is shown in the attached schedule. 6. How the appropriate Department personnel will be notified before the scheduled work is to begin. 7. How the testing and evaluation will be made available to the Department. 8. How discarded material will be disposed of. 9. What will happen in the event that test data indicates that non-complying material has been incorporated into the work, including when the Department will be notified and when a plan will be submitted, identifying the defective material and its repair and/or removal. For an example of a Quality Control Plan, see attached Appendix A. Page: 2 of 12 Date:

3 Field Operations 1. Personnel 1.1 Enter name, qualification and telephone number of employee directing the field operations. 1.2 Enter name, and qualification, of employee who is responsible for insuring that all items of work will comply with Department specifications. 1.3 Enter name of employee responsible for sampling and testing. 1.4 Name of employee who is responsible to notify Saskatchewan Highways when finished material is ready for acceptance testing and/or surface inspection, and how Saskatchewan Highways will be contacted. 2. Proposed frequency of quality control testing during placement operations. The suggested frequency is shown in the attached schedule. 3. How the appropriate Department personnel will be notified before work is scheduled to begin. 4. How the testing, evaluation and surface inspection will be done and results made available to the Department. 5. How discarded material will be disposed of. 6. What will happen in the event that test data or inspections indicate that non-complying material has been incorporated into the work,including when the Department will notified and when a plan will be submitted, identifying the defective material and its repair and/or removal. For an example of a Quality Control Plan, see attached Appendix A. 3. RESULTS AND CALCULATIONS 3.1. Reporting of Results Reporting of results will be done on the appropriate forms of documentation as identified in Table 1. Date: Page: 3 of 12

4 4. ADDED INFORMATION 4.1. References AASHTO Implementation Manual for Quality Assurance, July, AASHTO Quality Assurance Guide Specifications, July, TABLE 1 SUGGESTED CONTRACTOR S QUALITY CONTROL PLANT AGGREGATE CRUSHING REQUIREMENTS Test or Action Frequency Test Method Method of Documentation Gradation 1 per 500 tonnes STP Aggregate Fractured Faces 1 per 500 tonnes STP Plasticity Index 1 per 500 tonnes STP Lightweight Pieces 1 per 500 tonnes STP Sand Equivalent 1 per 500 tonnes STP FIELD AGGREGATE CRUSHING REQUIREMENTS Test or Action Frequency Test Method Method of Documentation Positive drainage of stockpile site. Once per contract. Layer thickness. Side slopes of stockpile. Continual Inspection Continual Inspection Page: 4 of 12 Date:

5 PLANT AGGREGATE BASE COURSE REQUIREMENTS Test or Action Frequency Test Method Method of Documentation Gradation 1 per 500 tonnes STP MR85 (SHT) Aggregate Fractured Faces 1 per 500 tonnes STP MR85 (SHT) Plasticity Index 1 per 500 tonnes STP MR85 (SHT) Lightweight Pieces 1 per 500 tonnes STP MR85 (SHT) Proctor Density 1 per 2500 tonnes STP MR85 (SHT) Sand Equivalent 1 per 500 tonnes STP MR85 (SHT) FIELD AGGREGATE BASE COURSE Test or Action Frequency Test Method Method of Documentation Density 3 per 500 tonnes STP MR85 Calibration of Nuclear Gauge 1 per year. STP Refer to owner s manual Thickness As required. Surface Defects Continual inspection. Segregation Continual inspection. Distribute Test Data According to contract documents. Date: Page: 5 of 12

6 PLANT ASPHALT CONCRETE Test or Action Frequency Test Method Method of Documentation Marshall Density Air Voids Voids Filled Voids Mineral Aggregate Asphalt Content Aggregate Gradation One asphalt mix sample representing each 3 hours of production or portion thereof be obtained and tested for these properties. STP STP STP STP STP STP MR70 (SHT) MR70 (SHT) MR70 (SHT) MR70 (SHT) MR70 (SHT) MR70 (SHT) Fractured Faces 1 per week. STP MR70 (SHT) Sand Equivalent 1 per week. STP MR70 (SHT) Lightweight Pieces 1 per week. STP MR70 (SHT) Dry Aggregate Temperature Asphalt Storage Temperature Asphalt Mix Temperature at the mixer discharge Stack Emission Temperature 1 per 3 hours of production. 1 per 3 hours of production. 1 per 3 hours of production. 1 per 3 hours of production. MR28 (SHT) MR28 (SHT) MR28 (SHT) MR28 (SHT) Page: 6 of 12 Date:

7 FIELD ASPHALT CONCRETE Test or Action Frequency Test Method Method of Documentation Density Calibration & Nuclear Gauge Smoothness 3 per one paver width wide and 200 m length. STP per year. STP Refer to Owners Manual Final lift of asphalt one paver width wide and 100 m length STP Field Air Voids 1 per 500 tonnes STP Surface Defects Continual inspection Segregation Continual inspection. Penetration of Recovered Asphalt Pavement Application 1 per 500 tonnes. STP STP Application rate checked as needed. Thickness As required. Adding Anti-Strip Agent Distribution of Test Data. Per load of asphalt. According to contract documents. Date: Page: 7 of 12

8 APPENDIX A: EXAMPLES OF QUALITY CONTROL PLANS CONTRACT NO. CONTRACTOR Dear : SUBJECT: QUALITY CONTROL PLAN FOR PRODUCTION FACILITY We are submitting our quality control plan, in accordance with STP 400. This quality control plan is for the production of: Aggregate Crushing / Base Production / Asphalt Mix Production (CIRCLE ONE). 1. PLANT / CRUSHER / PUGMILL (circle one) 1.1 Make of Plant/Crusher/Pugmill Type Location 1.2 Frequency of Inspection Frequency of Calibration Frequency of Verification of Calibration Has Production Facility Been Certified? Yes (Include Documentation) No 2. PERSONNEL RESPONSIBLE FOR OPERATIONS 2.1 The person responsible for the quality control is, of, who can be contacted at, telephone number. 2.2 The sampling and testing technician is and is qualified by. Page: 8 of 12 Date:

9 2.3 The plant manager or employee who is responsible for making production facility changes as a result of Quality Control data is. 2.4 The person responsible to notify Saskatchewan Highways is, when finished material is ready for acceptance testing. This person will contact Saskatchewan Highways by. 3. The types of materials and designs to be used are: a) b) c) d) e) 4. For the types of materials, the sources to be used are: a) Type Source b) Type Source c) Type Source d) Type Source 5. During the production operations we will perform, at a minimum, quality control tests in accordance with the attached schedule. 6. We will notify the appropriate Department personnel at least before the scheduled work is to begin by. (memo, telephone, fax, or other) 7. All testing and evaluations will be completed within hours of sampling Date: Page: 9 of 12

10 and all documentation will be completed and submitted to representing the Department, within hours of sampling. 8. Discarded material will be handled by: 9. When non-complying material has been incorporated into the work, the Department will be notified within hours of the event, and a plan submitted, identifying the defective material and its repair and/or removal according to contract documents, within hours of Department notification. Contractor Contractor s Signature Page: 10 of 12 Date:

11 CONTRACT NO. CONTRACTOR Dear : SUBJECT: QUALITY CONTROL PLAN FOR FIELD OPERATIONS We are submitting our quality control plan, in accordance with STP 400. This quality control plan is for the production of: Aggregate Stockpiling / Base Operations / Asphalt Mix Operations (CIRCLE ONE). 1. PERSONNEL RESPONSIBLE FOR OPERATIONS 1.1 The field operation program is under the direction of, who can be contacted at, telephone number. 1.2 will be responsible for insuring that all items of work will comply with department specifications. 1.3 will be responsible for all sampling and testing. 1.4 The person responsible to notify Saskatchewan Highways is, when finished material is ready for acceptance testing and/or surface inspection. This person will contact Saskatchewan Highways by. 2. During placement operations, we will perform at the minimum, the quality control tests in accordance with the attached schedules. 3. We will notify the Department personnel at least before Date: Page: 11 of 12

12 scheduled work is to begin by. (memo, telephone, fax, or other) 4. All testing and evaluations will be completed within hours of sampling and all documentation will be completed and submitted to, representing the Department, within hours of sampling. 5. Discarded material will be handled by: 6. When non-complying material has been incorporated into the work, the Department will be notified within hours of the event, and a plan submitted, identifying the defective material and its repair and/or removal according to contract documents, within. Contractor Contractor s Signature Page: 12 of 12 Date:

13 APPROVAL SHEET New X Revision Date of Previous Document - - Effective Date: Description of Revision (Reason for Revision): - New test procedure. Review/Implementation Process: - Reviewed by Technical Standards and Policies Branch Other Manuals/Policies Affected: - Nil Follow Up/Training Required: - Nil Comments/Concerns/Implications (Budget/Environment/Stakeholders): Prepared by D. MacLeod Date Prepared and Recommended by D. MacLeod Materials Standards Engineer Date Approval Recommended by R.A. Widger Senior Materials Engineer Date Approval Recommended by A.R. Gerbrandt Dir., Technical Standards & Policies Br. Date Electronic File Updated Update Mailed - - Date: Page: 13 of 12