NTPEP. Plant Name: Physical Address: Mailing Address: Same (if different from above) Primary Contact Name: Title: Telephone:

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1 Plant Name: Physical Address: Mailing Address: Same (if different from above) Primary Contact Name: Title: Telephone: Management QC Manager: Plant Manager: Auditor Contact Name: Telephone: Address: Other Attendee Contact Name: Title: Organization: Telephone: DOT Official Contact Name: Title: Organization: Telephone:

2 AASHTO s National Transportation Product Evaluation Program () Report Summary Evaluation Program for Plastic Pipe Facilities Producing PVC Pipe Summary Report For PLANT City, ST Introduction The National Transportation Product Evaluation Program () is a program under the sponsorship of the American Association of State Highway and Transportation Officials (AASHTO). The evaluation program for manufacturers of plastic pipe (PVC) provides a comprehensive review of the production and testing of pipe and of the quality management system. The evaluation starts with a desktop review of the facility s quality manual and concludes with an on-site review of the facility s processes and their quality management system documentation. An on-site audit of the PLANT facility, located in City, State, was conducted by Lead Auditor NAME (AASHTO) on DAY, MONTH, DATE, NAME was accompanied by Name (Auditor). PLANT was represented by NAME (Position). The STATE DOT was represented by NAME (Position). Deviations from program requirements noted in red will require a corrective action report along with supporting evidence for the corrective action to obtain compliance. Deviations from program requirements noted in italics will not require a corrective action report and supporting evidence; however, they will be reevaluated during the next year s audit and may be subject to further investigation by state transportation agencies. These deviations are also known as Observations. Testing Personnel (Section 1) Please refer to Section 1 of the report for the list of personnel approved to perform quality control tests. Pipe Identification Markings (Section 2) Please refer to Section 2 of the report for the pipe identification markings used at this facility. Plastic Pipe Size and Type Produced (Section 3) This plant produces AASHTO M 304 pipe with diameter sizes ranging from 15 inches 36 inches. See Section 3 of the report for the sizes produced. Quality Control Testing (Section 4) Please refer to Section 4 of the report for quality control testing frequencies performed on manufactured pipe. CTR Laboratories, Inc. located in Orange, CA performs third-party testing for this facility. Number: THP X Page 2 of 35

3 AASHTO s National Transportation Product Evaluation Program () Report Summary Standard Specifications (Section 5) The plant had current versions of all applicable AASHTO and ASTM standards. These standards were located on/in???. Quality Management System Records Review (Section 6) Paper Training Records were well organized and are located in the QA Manager s office. Training records were reviewed for NAME and contained the required information. This Plant follows ASTM D3212 and produces watertight pipe. Testing is performed at their Springfield location. Manufacturing Walkthrough (Section 7) The plant operates several pipe lines four of which are AASHTO pipe: o Line 6 producing 6, 8 & 12 inch diameters o Line 8 producing 24, 30 & 36 inch diameters o Line 9 producing 12, 15 & 18 inch diameters, and o Line 10 producing 24, 30 & 36 inch diameters. The Plant operates 3 shifts 7am-3pm, 3pm-11pm and 11pm-7am and was/was not producing AASHTO pipe at the time of the audit. Compound lot identification numbers are by railcar number of a particular formulation. The facility utilizes three (3) different compounds: 18A-71 (for 6-18 diameter pipe), 30A-32 (for diameter pipe), and 36A39 (for 36 diameter pipe). This facility receives all compound formulations from their Springfield, IL location with an Inter Plant Material Certification from their Springfield location (where all compounding takes place). The certification certifies the railcar of PVC compound as meeting the required cell class and no test values are shown. The plant maintains traceability of the compound lots used to produce a lot of pipe as follows: o For any particular PVC Pipe Identification Marking the plant knows which formulation was used (due to the diameter) and knows the time when it was produced (PVC Pipe Identification Marking). o The plant calculates the weight of compound equal to the amount of pipe produced from that particular compound and links it back to the compounds in the silo at the time of production. Railcars deliver preapproved compound powder (formulation) from their Springfield location. Compound is off-loaded into silos which are designated by formulation. These silos feed the production lines with compound. Cell classification for the compound is performed by a Third- Party Laboratory - CRT Laboratories, Inc., Orange, CA. Reworked material used in AASHTO pipe at a maximum amount of 15% (reground mixture of any scrap is then used only in the making of 24, 30, and 36 inch diameter pipe). Comparison/Record Samples (Section 8) A 30 inch diameter M 304 sample was selected from the storage yard and was cut into test specimen. The pipe specimens and a sample of the compound used to produce the 30-inch pipe were sent testing. to TRI for Number: THP X Page 3 of 35

4 AASHTO s National Transportation Product Evaluation Program () Report Summary Plastic pipe was well organized by size throughout the entire stockyard. The correct information was labeled clearly on each piece of pipe examined. This Plant obtains injection molded fittings from their Springfield plant. All fabricated fittings come from Harco. All fittings that were viewed had the proper ASTM marks for ASTM pipe. Three samples of M 304 pipe (18, 30 and 36 inch diameter) were selected to review the test reports and COA s. All of the records contained the proper information. The manufacturer s lab quality results were paper documents and allowed traceability to be reviewed. No additional test reports and COA s were reviewed for pipe produced during other random weeks throughout the year, since the yard sampled pipe was from a sufficient range of dates. Quality Control Testing Evaluation (Section 9) The following quality tests were demonstrated by NAME and the equipment for each test was in adequate condition: o Wall Thickness o Inside Diameter o Length of Pipe o Pipe Stiffness o Pipe Flattening o Impact Resistance (TUP) o Heat Inversion o Acetone Immersion Wall thickness is performed as unit weight/hour and two destructive test per shift) to verify wall thickness. For the Inside Diameter (ID) measurement, this plant utilizes a Go-No Go ring gage for each diameter. The Impact Resistance (TUP) machine was very impressive and performed the test correctly. This plant has the TUP weights verified every year by an Outside Calibration Agency. This plant drops the TUP weight from a height that delivers 220 ft-lbf for all sizes. If the specimen fails, they re-test to 140 ft-lbf. If it passes, the pipe is designated for other uses. If not, it is recycled. This exceeds ASTM D2444 maximum requirement of 120 ft-lbf. Number: THP X Page 4 of 35

5 AASHTO s National Transportation Product Evaluation Program () Table of Contents Table of Contents Section 1: Testing Personnel... 6 Section 2: Corrugated Pipe Identification Markings... Error! Bookmark not defined. Section 3: Sizes of Pipe Produced... 9 Section 4: Quality Control Testing... Error! Bookmark not defined. Section 5: Standard Specifications Section 6: Quality Management System Records Review Section 7: Manufacturing Walkthrough Section 8: Comparison/Record Samples Section 9: Quality Control Testing Evaluation Section 10: Report Signature Section 11: Miscellaneous Documents Number: THP X Page 5 of 35

6 AASHTO s National Transportation Product Evaluation Program () Section 1 Personnel Section 1: Testing Personnel Identification of the personnel approved to run quality control testing at the plant Compound Testing: Testing performed on compound. Production Testing: Line checks and testing performed during production which may include workmanship, unit weight, pipe diameter, pipe length, wall thickness, etc. Lab Testing: Lab testing on conditioned pipe including, but not limited to, stiffness/flattening, brittleness, and any other test performed in the lab. Compound Name Testing Production Testing Lab Testing Number: THP X Page 6 of 35

7 AASHTO s National Transportation Product Evaluation Program () Section 2 Markings Section 2: Corrugated Pipe Identification Markings Insert a picture(s) and/or diagram(s) of the plant s unique pipe identification markings. Number: THP X Page 7 of 35

8 AASHTO s National Transportation Product Evaluation Program () Section 3 Sizes of Pipe Section 3: Sizes of Pipe Produced Specification M 304: Indicate all applicable pipe produced at this location: Size inches [mm] St 4 [100] 5 [125] 6 [150] 7 [175] 8 [200] 9 [225] 10 [250] 12 [300] 15 [375] 18 [450] 21 [525] 24 [600] 27 [673] 30 [750] 36 [900] 42 [1050] 48 [1200] Number: THP X Page 8 of 35

9 AASHTO s National Transportation Product Evaluation Program () Section 4 Quality Control Testing Section 4: Quality Control Testing Matrix of Quality Control Tests, Facilities, and Intervals Please indicate for the QC tests shown below if your facility conducts the test in-house or indicate the name of the outside facility used (second or third Party). Additionally, indicate the frequency of record testing. Please indicate contact information for second/third party facilities below. Quality Control Test Compound Tests: Tensile Strength and Modulus of Elasticity Impact Resistance (Izod) Deflection Temperature Pipe Tests: Wall Thickness Inside Diameter Perforation Locations and Dimensions Pipe Stiffness Pipe Flattening Impact Resistance (TUP) Acetone Immersion Heat Reversion Soiltightness Watertightness Minimum Frequency Once per year per formulation Once per year per formulation Once per year per formulation One per shift per line One per shift per line One per shift per line One per day per line One per day per line One per day per line One per line per year One per line per year One per year In-house/ M 304 Outside Facility Frequency One per year Names, addresses, and contact information for second and/or third-party facilities used: Comments: None Number: THP X Page 9 of 35

10 AASHTO s National Transportation Product Evaluation Program () Section 5 Standard Specifications Section 5: Standard Specifications Auditor Note - Indicate if current versions of the following AASHTO & ASTM standards are available at the plant. Primary AASHTO ASTM M (2015) Poly (Vinyl Chloride) (PVC) Profile Wall Drain Pipe and Fittings Based on Controlled Inside Diameter Committee Work Plan for Evaluation of Profile Wall Polyvinyl Chloride Drainage Pipe Manufacturers Standard Practice for Qualification of Highway Product Manufacturers Through the Use of Audits Secondary PVC-17 SP01-18 Standard Terminology Relating to Plastics D Standard Terminology for Abbreviated Terms Relating to Plastic D Standard Specification for Rigid Poly (Vinyl Chloride) (PVC) Compounds and Chlorinated Ploy (Vinyl Chloride) (CPVC) D Compounds Standard Test Method for Determining Dimensions of Thermoplastic Pipe and Fittings D Standard Test Method for Adequacy of Fusion of Extruded Poly (Vinyl Chloride) (PVC) Pipe and Molded Fittings by Acetone Immersion D Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading D Test Method for Determination of Impact Resistance of Thermoplastic Pipe and Fittings by Means of a TUP (Falling Weight) Standard Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals Standard Terminology Relating to Plastic Piping Systems Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe Standard Practice for Estimating the Quality of Extruded Poly (Vinyl D (10) D (13) F412-17a F Chloride) (PVC) Pipe by the Heat Reversion Technique Comments: Standards are maintained on the corporate drive by the Quality?? Number: THP X Page 10 of 35

11 AASHTO s National Transportation Product Evaluation Program () Section 6 QMS Review Section 6: Quality Management System Records Review Audit of Training and Competency Evaluation records Auditor Note The auditor shall select at least two random names from to verify training and competency evaluation records are complete. Training and Competency Evaluations Yes No A) Training 1) Does the manufacturing facility maintain records to ensure that the facility s personnel are trained to perform physical tests initially? 2) Do the training records for the individual(s) listed above: a. List the date(s) of training and identification of the trainer? b. Indicate that all relevant training has been completed? B) Competency Review 1) Does the manufacturing facility perform competency checks to evaluate staff competency on at least an annual basis? 2) Do the competency evaluation records for the individual(s) listed above: Comments: a. List the date(s) of the review and identification of the reviewer? b. Indicate that all relevant competency evaluations have been completed? Training and competency records for NAME were reviewed and found to be complete. Number: THP X Page 11 of 35

12 AASHTO s National Transportation Product Evaluation Program () Section 6 QMS Review C) Internal Audits 1) Was a current internal audit presented? Quality Management Yes No 2) Are internal audits performed at least annually? 3) Do internal audits cover all processes that affect product quality (production, quality testing, training, shipping, etc)? 4) Do internal audits determine if quality system processes are being followed? D) Management Reviews 1) Was a current management review presented? 2) Are management reviews performed at least annually? 3) Do management reviews determine the effectiveness of quality system processes? Comments: The most recent internal audit was completed on DATE, 2016 and the most recent management review was completed on DATE. Copies of these were presented to the auditor and reviewed. E) Pipe Testing Report Requirements 1) Do test reports include identification of the plant, date of production, shift, line, and lot designation? 2) Does the lot designation trace to the resin lot test results? 3) Are test results recorded properly using forms contained in the plant s QM? 4) Is there evidence to indicate that the plant intends to retain copies of test reports for a minimum of 5 years? 5) Please describe the test reporting system: None Comments: None Number: THP X Page 12 of 35

13 AASHTO s National Transportation Product Evaluation Program () Section 6 QMS Review F) Review of a Recent Resolution of Non-Conforming Product or Test Results 1) Does the manufacturing facility document each instance for resolving nonconforming product or test results? 2) Does the documentation clearly identify the deficiencies? 3) Does the documentation require that product produced subsequent to the deficiency will be quarantined pending an investigation of the failure? 4) Does the investigation include: a) Obtaining and testing check samples? b) If check sample meets requirements, reasons for original failure documented? c) After reasons are documented, is the quarantined material released? d) If check sample fails requirements, corrective action taken? G) Review of Previous Corrective Actions Have all deviations noted in the last report been corrected? Section Deviation and Corrective Action Response Yes No Comments: None Number: THP X Page 13 of 35

14 AASHTO s National Transportation Product Evaluation Program () Section 6 QMS Review H) QC Testing Equipment Record Checks ITEM Frequency SP01 OA PERFORMING ENTITY IN CALIBRATION VERIFICATION STANDARDIZE COMMENTS Parallel Plate Test Machine calibrate every 12 Mos. Ultrasonic Gauge/Transducer calibrate every 12 Mos. verify prior to use Balances and Scales verify prior to use Standard Weights verify every 60 Mos. Calipers and Micrometers verify prior to use Standard Gage Blocks verify every 60 Mos. Melt Index Heater standardize prior to use Muffle Furnace standardize prior to use Temperature Measuring Device standardize prior to use Comments: OA - denotes performed by an outside agency IN denotes performed internally All equipment calibration/verification records were current, well organized and contained the required Work Plan details. Number: THP X Page 14 of 35

15 AASHTO s National Transportation Product Evaluation Program () Section 7 Manufacturing Process Walkthrough Section 7: Manufacturing Process Walkthrough A) Plant Walkthrough Manufacturing line 1) How many manufacturing lines produce AASHTO pipe? 2) Identification of each line and size range of pipe produced: B) Compound Information 1) How is compound received at the plant? by Railcar by Truckload with Hopper by Truckload of Boxes by Other Method: If Other Method, Please Describe: 2) Please Describe your Lot Numbering System: Please identify and describe what blends your facility uses: C) Additional Compound Testing and Control Information General Requirements 1) Are Lot Numbers defined as a railcars or truckloads (hopper truckloads or truckloads of boxes) of compound? 2) Are the lot numbers carried through to the finished product? 3) Are compound quality control tests completed prior to using compounds in production? 4) Is compound testing completed prior to production runs? 5) Are Certificates of Analysis furnished by Manufacturers for each lot of compound? 6) Do Certificates of Analysis (Compound) includes the following lot specific data: a. Melt Index? b. Density? YES NO Number: THP X Page 15 of 35

16 AASHTO s National Transportation Product Evaluation Program () Section 8 Comparison/Record Samples Section 8: Comparison/Record Samples A) Comparison Sample Selection Product Trade Name: None Sample 1 Sample 2 Sample 3 Sample 4 Spec: M304-Yard Spec: Spec: Spec: Size: inch Size: Size: Size: Is a compound sample available for testing? Yes No Yes No Yes No Yes No Comparison sample testing is requested for: Pipe only Pipe only Compound and Pipe Compound and Pipe Pipe only Compound and Pipe Pipe only Compound and Pipe B) Raw Materials Are compound lot test results available? Yes No Yes No Yes No Yes No C) Finished Product Tests Are production facility test reports are available for the same lot of pipe? Yes No Yes No Yes No Yes No Compound Lot # Compound Lot # Compound Lot # Compound Lot # Pipe Lot # Pipe Lot # Pipe Lot # Pipe Lot # Compound Manufacturer(s): Compound Manufacturer(s): D) Comparison Sample Markings Verifications Compound Manufacturer(s): Compound Manufacturer(s): 1) Do pipe markings: Yes No a) exist along the pipe at intervals not exceeding 4.9 ft [1.5 m]? b) include the Manufacturer s name or trademark? c) include nominal size? Comments: d) include the specification designation? e) identify the plant designation code? f) identify the date of manufacture or an appropriate code? None Number: THP X YES NO Page 16 of 35

17 AASHTO s National Transportation Product Evaluation Program () Section 8 Comparison/Record Samples E) Visual Inspection of Pipe in the Yard Comments: Pipe Inspections 1) The auditor shall inspect exterior and interior walls to ensure that: a. free from delamination? b. free from blowouts? c. free of foreign inclusion and visible defects? d. the ends are cut squarely and do not affect joining? 2) The auditor shall inspect non-aashto pipe to ensure that it is not marked M304? 3) The auditor shall inspect to ensure that damaged pipe has been marked according to the manufacturer s Quality Manual? Comments: Fittings and Couplings Inspections 1) The auditor shall inspect exterior and interior walls to ensure that: a. free of foreign inclusion and visible defects? b. the ends are cut squarely and do not affect joining? 2) The auditor shall inspect fittings and couplings to ensure the markings include: a. Manufacturer Name or Trademark? b. Specification? None Number: THP X Page 17 of 35

18 AASHTO s National Transportation Product Evaluation Program () Section 8 Comparison/Record Samples M 304 Record Samples F) M 304 Record Sample Information and Record Audit M 304 Yard Sample 1 M 304 Yard Sample 2 M 304 Yard Sample 3 Size: inch Size: inch Size: inch Shift/Lot: Shift/Lot: Shift/Lot: Manuf. Date: Manuf. Date: Manuf. Date: Plant: Plant: Plant: Compound Lot #: Compound Lot #: Compound Lot #: Records available, records indicate tests are performed at required frequency and results meet spec. requirements for: Quality Control Test COMPOUND TESTS Tensile Strength and Modulus of Elasticity Impact Resistance (Izod) Deflection Temperature PIPE TESTS Wall Thickness Inside Diameter Perforation Locations and Dimensions Pipe Stiffness Pipe Flattening Heat Reversion Impact Resistance (Tup) Acetone Immersion Soiltightness Watertightness Specified Interval once per year per formulation once per year per formulation once per year per formulation one per hour per line one per hour per line one per hour per line one per hour per line one per hour per line one per year one per day per line one per year once per year once per year Sample 1 Sample 2 Sample 3 YES NO YES NO YES NO Number: THP X Page 18 of 35

19 AASHTO s National Transportation Product Evaluation Program () Section 8 Comparison/Record Samples H) Additional Test Record Audit In addition to a review of the test records for the M 304 yard samples selected, test records are reviewed for AASHTO pipe produced on up to three additional weeks throughout the year since the previous audit. Auditor Note: If any tests have not been performed, collect all pertinent testing documentation for that lot of pipe. Records available, records indicate tests are performed at required frequency and results meet spec. requirements for: Date Produced Comments: Line/ Lot Size Additional Test Records Reviewed Compound Lot # Line Compound Lot Size # Week 1 All Tests Performed Line Size Compound Lot # YES NO No additional test reports and COA s were reviewed for pipe produced during other random weeks throughout the year, since the yard sampled pipe was from a sufficient range of dates. Number: THP X Page 19 of 35

20 AASHTO s National Transportation Product Evaluation Program () Section 9 Quality Control Testing Evaluation Section 9: Quality Control Testing Evaluation A) Quality Control Plant: General Requirements 1) Is there an assigned QC Manager responsible for assuring all sampling and testing is done correctly? Name: 2) Is this the same person identified in the QMS? 3) Is the plant s test equipment adequately housed to allow proper operation of all required test equipment in accordance with the applicable test procedures? 4) Is all test facility equipment in proper working order? 5) Is there documentation which indicates that required maintenance has been performed? 6) Are test results recorded properly using forms contained in the plant s QM? 7) Is there evidence to indicate that the plant intends to retain copies of test reports for a minimum of 5 years? Yes No Number: THP X Page 20 of 35

21 AASHTO s National Transportation Product Evaluation Program () Section 9 Quality Control Testing Evaluation Acetone Immersion Adequacy of Fusion of Extruded Poly Pipe and Molded Fittings by Acetone Immersion A) Apparatus (ASTM D2152) 1) A container which is either individual, sealable for each specimen or one large, airtight container capable of holding several specimens without touching one another? 2) Precision hydrometer, graduated in thousandths, with a minimum range of to g/ml? 3) A cylinder large enough to immerse the hydrometer? 4) A thermometer with ASTM 12C total immersion, range from 20 C to 102 C accurate to 0.2 C, or equivalent? 5) American Chemical Society Reagent Grade, having a maximum density of g/ml at 25 C. B) Procedures (ASTM D2152) 1) Test conducted at Standard Laboratory Atmosphere of 23 ± 2 C? 2) Sufficient dried acetone placed into the container to ensure complete immersion of the specimen? 3) Allowing specimen to stand immersed in sealed container for 20 min without being agitating? 4) Inspection for signs of attack? Heat Reversion Estimating the Quality of Extruded Poly (Vinyl Chloride) (PVC) Pipe by the Heat Reversion Technique A) Apparatus (ASTM F1057) 1) A thermostatically controlled Air Oven capable of operating at C ( F)? 2) Air temperature with the oven (that is, the test temperature) is monitored within 3 in. from the outer edge of the test specimen; make assurances that the temperature does not contact the test specimen? Yes Yes No No Number: THP X Page 21 of 35

22 AASHTO s National Transportation Product Evaluation Program () Section 9 Quality Control Testing Evaluation B) Procedures (ASTM D2152) 1) Specimens of pipe 150 mm (6 in.) long or longer with ends cut square so that they stand perpendicular on end when placed in the oven? 2) Staves cut from pipes whose size prevents insertion of full round specimens in the oven and prepared so that their lengths parallel to the pipe axis are 150 mm (6 in.) or longer? 3) Examination of the specimens and noting any unusual features such as discoloration, inclusions, or pinholes in the cut edge? 4) Specimens placed in the oven so that hot air can flow freely between? 5) Recording the time when the air in the oven directly adjacent to the test specimen recovers to 180 C (356 F). Recovery must occur within 15 min or less. 6) Specimens removed after an additional 30 min of exposure within the test temperature tolerance of C? 7) Examination of the specimens within 3 min after removal from the oven? Wall Thickness Micrometer Wall Thickness Yes No A) Apparatus (ASTM D2122) 1) A cylindrical or ball anvil tubing micrometer readable to ± in. (± 0.02 mm)? B) Procedure (ASTM D2122) 1) Pipes cut cleanly and burrs removed? 2) Specimens conditioned and tested at: a F ± 3.6 F (23 C ± 2 C)? b. 50% ± 5% relative humidity? 3) Conditioned for not less than 24 hr (where required, in accordance with D618)? 4) A minimum of eight measurements taken at closely spaced intervals and averaged? Number: THP X Page 22 of 35

23 AASHTO s National Transportation Product Evaluation Program () Section 9 Quality Control Testing Evaluation Wall Thickness Ultrasonic Gauge Wall Thickness via Alternative Apparatus Yes No A) Apparatus (D2122) (Work Plan Approved Alternate Procedure) 1) Device Used? Ultrasonic Laser Electronic Nuclear 3) Has the apparatus used been validated in accordance with D2122? 4) Is each gauge and transducer identified? Gauge S/N: Transducer S/N: B) Procedure for Wall Thickness via Ultrasonic gauge 1) Two sets (8 measurements/set) of liner thickness readings taken per shift? 2) One of the sets taken with a micrometer in accordance with D2122? 4) Each set of measurements comprised of at least eight readings? 5) Are the numbers from each reading recorded? 6) Does the record indicate whether a micrometer or ultrasonic gauge was used? Inside Diameter Inside Diameter Yes No A) Apparatus (ASTM D 2122 Sec. 8.0) 1) Internal micrometer telescoping gauge or metal rule accurate to 1 mm (1/32 in.)? OR 2) Tapered plug gage, having a taper ratio of 1:100 and accurate to ± 1% of its taper and ± in. (± 0.02 mm) of its diameter and a 45 by 1/8 in (3 mm) face bevel located on the entrance of the end of the gage? B) Procedure (ASTM D 2122 Sec. 8.2) 1) A minimum of three measurements taken, to determine the average diameter? OR 2) A plug gage inserted into the pipe, causing round out but no expansion used to determine the inside diameter? Number: THP X Page 23 of 35

24 AASHTO s National Transportation Product Evaluation Program () Section 9 Quality Control Testing Evaluation Length of Pipe A) Apparatus (ASTM D2122) Number: THP X Length of Pipe Yes No 1) Steel tape or rule with marked graduations of ¼ or less (240 x 0.01 x 0.1) accurate to ± 6 mm in 3 m? Comments: None B) Procedure (ASTM D2122) Comments: 1) Pipe stress free and at rest on a flat surface and in a straight line? None Pipe Stiffness Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading A) Apparatus (ASTM D2412) 1) A properly calibrated compression testing machine of the constant-rate-ofcrosshead movement type meeting the requirements of Test Method D695? 2) Applying of the load to the specimen through two parallel steel bearing plates? 3) The condition of plate with flat, smooth, and clean? 4) The plate length that equal or exceed the specimen length? 5) The plate width that more than the pipe contact width at maximum pipe deflection plus 6.0 in.? 6) Measurement of the change in inside diameter, or deformation parallel to the direction of loading, with a suitable deformation indicator meeting the requirements of Test Method D695? 7) Measurement of the changes in diameter during loading by continuously recording plate travel or by periodically computing it? B) Procedures (ASTM D2412) 1) Determination of the length of each specimen to the nearest 1/32 in. or better by making and averaging at least four equally spaced measurements around the perimeter? 2) Measurement of the wall thickness of each specimen in accordance with Test Method D2122 with minimum eight measurements equally spaced around one end and calculation of the average wall thickness? 3) Determination whether a line of minimum wall thickness exists along the length of the specimen? 4) Determination of the average outside diameter to the nearest 0.01 in. (0.2 mm) using a circumferential wrap tape or by averaging the maximum and minimum Yes No Page 24 of 35

25 AASHTO s National Transportation Product Evaluation Program () Section 9 Quality Control Testing Evaluation outside diameters as measured with a micrometer or caliper? 5) Calculation of the average pipe inside diameter for OD-controlled pipe? 6) Calculation of the average pipe inside diameter for ID-controlled pipe? 7) Location of the pipe section with its longitudinal axis parallel to the bearing plates with laterally center position in the testing machine? 8) Placement of the first and successive specimen followed by the orientation of minimum wall thickness? 9) Crosshead speed the faster of: 0.5 in. per minute, or 2 percent of the nominal inside diameter per minute. 10) Recording of the load-deflection measurements continuously or intermittently with reference to the relative movement of the bearing plates? 11) Note of the load and deflection at the first evidence of each of the following significant events when and if they occur: line cracking or crazing, wall cracking, wall delamination, rupture? 12) Record of type and position of each event with respect to the corresponding load and deflection? 13) Performed on three (3) test specimens three specimens, each with a length equal to one pipe diameter (but not less than 300 mm (12 in.) nor greater than 900 mm (36 in.)) and determine the average pipe stiffness. Impact Resistance Determination of the Impact Resistance of Thermoplastic Pipe and Fittings Yes No A) Apparatus (ASTM D2444) 1) The mass of the tup to be 6, 12, 20, or 30 lb? 2) The sufficient length of the drop tube to provide for a free* fall of at least 10 ft. (*falls freely - does not chatter down the tube)? 3) Means provided (1) to hold the tup at steps of 2 in. (50.8 mm) for a distance of 2 to 10 ft (610 mm to 3.0 m) above the specimen holder, (2) to release the tup in a reproducible manner, (3) to allow the tup to fall freely, and (4) to catch the tup on the first rebound? 4) Pipe specimen held with: V-block holder, for Tups A and C, with the minimum length of the specimen being tested and having a 90-deg included angle? The side supports with sufficient depth to support the specimen in the V and not on the top edges of the V-block? Flat-plate holder, for Tup B, with approximate size of 8by 12 by 1 in.? The groove with about 0.12 in. in depth with the edges rounded to a radius of about 0.06 in.? Number: THP X Page 25 of 35

26 AASHTO s National Transportation Product Evaluation Program () Section 9 Quality Control Testing Evaluation Comments: 5) Test specimen equal in length to the nominal outside diameter but not less than 6 in. (152 mm) in length with burrs removed? None B) Procedures (ASTM D2444) Comments: 1) Impaction of one of the specimens using required energy? 2) Failure in the test specimens determined as shattering or any crack or split created by the impact and that can be seen by the naked eye? None Number: THP X Page 26 of 35

27 AASHTO s National Transportation Product Evaluation Program () Section 10 Report Signature Section 10: Report Signature The Preceding Report has been reviewed and assured to be accurate by the Lead Auditor. Auditor Name: Signature: Number: THP X Page 27 of 35

28 AASHTO s National Transportation Product Evaluation Program () Section 11 Miscellaneous Documents Section 11: Miscellaneous Documents Attendance Sheet: Number: THP X Page 28 of 35

29 AASHTO s National Transportation Product Evaluation Program () Section 11 Miscellaneous Documents Certificates of Analysis: Number: THP X Page 29 of 35

30 AASHTO s National Transportation Product Evaluation Program () Section 11 Miscellaneous Documents Number: THP X Page 30 of 35

31 AASHTO s National Transportation Product Evaluation Program () Section 11 Miscellaneous Documents Number: THP X Page 31 of 35

32 AASHTO s National Transportation Product Evaluation Program () Section 11 Miscellaneous Documents Number: THP X Page 32 of 35

33 AASHTO s National Transportation Product Evaluation Program () Section 11 Miscellaneous Documents Stiffness Test Results: Number: THP X Page 33 of 35

34 AASHTO s National Transportation Product Evaluation Program () Section 11 Miscellaneous Documents Number: THP X Page 34 of 35

35 AASHTO s National Transportation Product Evaluation Program () Section 11 Miscellaneous Documents Example of certification received with purchased pipe gaskets (Typical): Number: THP X Page 35 of 35