Pre-Audit Application Form

Transcription

1 Please provide the following information and return responses to AASHTO. Provide all applicable supporting documentation requested. Mill Name: Physical Address: Mailing Address: (if different from above) Proprietary Ownership Company Name: Address: Primary Contact Name: Title: Telephone: ( ) Cell: ( ) Fax: ( ) Management QC Manager: Plant Manager:

2 Table of Contents Section 1: Testing Personnel... 3 Section 2: Standard Specifications... 4 Section 3: Size and Type of Material Produced by the Mill... 5 Section 4: Product Information... 6 Section 5: Reinforcing Steel Bar Identification Markings Section 6: Mill Test Reports (MTR s) Section 7: Quality Management System Section 8: Signature... 18

3 Physical Testing Chemical Testing (melt shop only) AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 1: Testing Personnel Note Please complete the following table naming individuals trained to perform the following functions. If several candidates fulfill each function, please select those who will more often than not work shift one. LMS Sampling Ton Dish Sampling Lab Testing Lab Testing Furnace Supervisor LMS Supervisor Lab. Supervisor QC Sampling QC Sampling QA Sampling QA Sampling QC Testing QA Testing QC Supervisor QC Supervisor QA Supervisor QA Supervisor Name Normal Workdays / Hours

4 Section 2: Standard Specifications Auditor Note - Indicate if current versions of the following AASHTO & ASTM standards are available at the mill. AASHTO* ASTM Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement Standard Specification for Low-Alloy Steel Deformed Bars for Concrete Reinforcement Standard Specification for Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement Standard Test Methods and Definitions for Mechanical Testing of Steel Products Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products M31-07 A A706-09b M A996-09b T A A Standard Practices for Force Verification of Testing Machines T67-08 E4-10 Standard Test Methods for Tension Testing of Metallic Materials T68-05 E8-11 *AASHTO Designations are optional. None *AASHTO Designations are optional

5 Section 3: Size and Type of Material Produced by the Mill Table 1 - Size and Type of Material Produced by the Mill Type: Plain P, Deformed D Form: Straight S, Coil C Rolling Mill Only: Bar Size Melt Shop and Rolling Mill Combination: Specification: A 615 / 615M Please Select All that Apply: Grades 40,000 psi 60,000 psi 75,000 psi 80,000 psi Type Form Type Form Type Form Type Form P D S C P D S C P D S C P D S C Bar Size Specification: A 706 Please Select All that Apply: Grades 60,000 psi 80,000 psi Type Form Type Form P D S C P D S C

6 3 [10] 4 [13] 5 [16] 6 [19] 7 [22] 8 [25] Specification: A 996/ A 996M Please Select All that Apply: Rail Symbol Rail Axle Grades Grades Grades 50,000 psi 60,000 psi 50,000 psi 60,000 psi 40,000 psi 60,000 psi [350 MPa] [420 MPa] [350 MPa] [420 MPa] [280 MPa] [420 MPa] Type Form Type Form Type Form Type Form Type Form Type Form P D S C P D S C P D S C P D S C P D S C P D S C

7 Section 4: Product Information A) General 1) Does the company own mills at other locations? 2) If yes, does each mill have its own unique bar marking? List other locations: B) Billet Information General Billet Information: 1) Does the mill produce billets for the production of rebar? (If NO, proceed to question 2): Indicate the Process used to produce billets: Continuous Casting (transitional billets) Strand Casting (no transitional billets) Other Describe: YES NO How many furnaces does the mill have in operation? (c) What is the capacity of the furnace(s)? (d) Size of the billets produced: Purchased Billet Documentation Requirements: 2) Does the mill purchase billets for the production of rebar? If Yes, please complete items 2 thru 2(f): Does the mill keep copies of all billet certifications on file? How long are billet certifications retained? (c) Do billet certifications include the type of steel (chemistry)? (d) Do billet certifications include the origin of the steel? (e) Do billet certifications include the heat number? (f) How is traceability maintained on billets? Heat No. Other Method Grade Describe:

8 Section 4: Product Information (Continued) C) Bar Information General Bar Information: 1) What is the annual reinforcing bar production capacity? 2) Has the production capacity changed within the last year? If yes, explain: 3) Indicate the rolling process(es) used: Straight line Cross country Jump mill 4) Does the mill have any foreign steel in its inventory? If yes, how is it processed? YES NO How is foreign steel identified? Bar made from in-house produced billets (melt shop + rolling mill): 5) Does product documentation include the following: Chemical test results? Physical test results? (c) Minimum specification requirements? (d) Information concerning Buy America requirements? (e) The heat number?

9 Section 4: Product Information (Continued) D) Bar Information (Continued) Bar made from purchased billets: 1) Does product documentation include the following: The plant that produce the billets? A statement indicating the bar was melted and manufactured in the U.S.A.? (c) The billet certificate? (d) Physical test results? (e) Minimum specification requirements? Bar made from rail or axle steel: 2) Does the mill keep records of all rail and axle steel purchased? 3) How long are records maintained? 4) Does product documentation include the following: Lot number? The origin of the steel? (c) Heat number? YES NO (d) Carbon level? (axle only) (e) Tensile test results? (f) Bend test results? (g) Minimum specification requirements?

10 Section 4: Product Information (Continued) E) General: All Product Documentation 1) What does the mill s product documentation include? (Check all that apply) MTRs Invoices Mill Worksheets YES NO Other Describe: 2) Does the mill keep copies of all product documentation on file? 3) How long is product documentation retained? 4) How does the mill furnish product documentation to the DOT project? With the shipment Mailed after the shipment with an invoice Furnished to a fabricator Other method Describe: F) Rail & Axle Steel Documentation Requirements: 1) Does the mill use rail or axle steel? 2) Does the mill keep records of all rail and axle steel purchased? 3) How long are records for rail and axle steel retained? 4) Do the records include the heat number? 5) Do the records include a carbon estimate? (axle only) 6) Do the records include the origin of the steel? 7) Do the records include a lot number?

11 Section 5: Reinforcing Steel Bar Identification Markings Please provide pictures (hard copy or electronic) that illustrate the reinforcing steel bar identification markings used at this mill Section 6: Mill Test Reports (MTR s) *Please provide a sample MTR representing each type of material produced (M31 / A615; M322 / A996; and / or A706).

12 Section 7: Quality Management System Please attach supporting documentation for each the following requirements: Organization and Staff Does the mill s quality system documentation include: YES NO A) Organization and Organizational Policies 1) Organization chart showing relevant internal organizational components? 2) Quality system policy statement (set by management) and quality objectives? B) Position Descriptions 1) Position descriptions for each technical operational position shown on the mill s organization chart? 2) Do the position descriptions: Identify the position? Describe the duties associated with the position? (c) Describe the required skills, education and experience? (d) Indicate the supervision exercised and received? C) Training 1) Written procedures used to ensure that the mill s personnel are trained to perform chemical and physical tests? What position(s) or employee(s) are responsible for the training program and maintenance of records? Distribution of records to management? D) Competency Evaluations 1) Written procedures used to evaluate staff competency to ensure that each chemical and physical test is performed in accordance with standard procedures? The frequency of evaluations? (c) What position(s) or employee(s) is responsible for evaluating staff competency and maintaining records? Distribution of records to management?

13 Quality Management Does the mill s quality system documentation include: YES NO E) Contract Review 1) A written procedure for processing reinforcing steel orders and the review of contracts for producing reinforcing steel bar? 2) Does the procedure ensure that: The requirements are adequately defined, documented and understood? Records of contract reviews are maintained? (c) The client shall be informed of any deviations from the contract? F) Customer Feedback 1) Written procedures describing the customer feedback system? (c) G) Internal Audits What position(s) or employee(s) are responsible for customer feedback? Methods used to solicit, evaluate and respond to customer feedback? Conditions under which corrective action will be implemented? 1) Written procedures for performing internal audits? (c) What position(s) or employee(s) are responsible for ensuring that internal audits are performed? The frequency, scope and criteria used for performing the audits? Conditions under which corrective action will be implemented? H) Management Reviews 1) Written procedures for performing management reviews? (c) What position(s) or employee(s) are responsible for ensuring that management reviews are performed? The frequency, scope and criteria used for performing the management review(s)? Conditions under which corrective action will be implemented?

14 I) Corrective Action 1) Written procedures describing the actions taken when failures or nonconformities exist in any of the following areas: product, equipment, customer feedback, internal and external audits, and management reviews? What position(s) or employee(s) are responsible for implementing corrective action(s)? Methods used to identify and implement corrective action(s)?

15 Sampling and Testing Does the mill s quality system documentation include: YES NO J) Sampling Plan 1) Written procedures describing sampling for quality control and quality assurance? Number and frequency of samples taken? Sample selection process, including sampling required for retesting? (c) The position(s) or employee(s) responsible for sampling? (d) Required sample preparation? K) Testing Plan 1) Written procedure describing testing for quality control and quality assurance? Number of samples required for testing? Tests required to be performed? (c) The position(s) or employee(s) responsible for testing? (d) How test results are interpreted? (e) The position(s) or employee(s) responsible for approving test results? (f) Criteria and procedures for retesting? L) Retesting Plan 1) Does the mill have written procedures describing their retesting plan? (c) (d) When retesting is performed? Retest sampling requirements? Special retesting conditions? Criteria for acceptance of retest results? (e) Instructions for reporting original test results and retests results?

16 Equipment Standardization and Checking Does the mill s quality system documentation include: YES NO M) Lab Equipment List 1) List(s) giving a general description of physical and chemical test equipment requiring standardization or checks? 2) Does the information for each item listed include: (c) Interval between standardization or checks? Reference to standardization or check procedures? Location of standardization or check records? N) Lab Equipment Plan 1) Written procedures for ensuring that equipment standardizations and checks are performed for all required equipment at specified intervals? Position(s) or employee(s) responsible for standardization and check activities? How to handle equipment which is newly acquired, removed from service, or does not meet accuracy requirements? (c) In-house equipment standardization and check procedures, when they cannot be referenced in applicable standards? (d) Certificates or other documents that establish traceability of in-house equipment or reference standards used for standardization and checks?

17 Product Control and Records Does the mill s quality system documentation include: YES NO O) Recording and Maintaining Product Information and Test Results 1) Written procedures used to produce, check and amend mill test reports (MTRs)? 2) Do the procedures: Identify position(s) or employee(s) responsible for maintaining MTRs? Describe distribution of MTRs? (c) Identify location of MTRs? P) Handling Raw Material for DOT Products 1) A written procedure to ensure that reinforcing bar made for DOT projects does not include any foreign steel? 2) Does the procedure: Identify the responsible position(s) or employee(s)? Indicate how foreign steel is identified, labeled and segregated? Q) Labeling and Storage of Finished Product 1) A written procedure describing how finished product is labeled, packaged and stored? R) Control of Nonconforming Product 1) Written procedures describing the actions to take when product fails to meet specification requirements? What position(s) or employee(s) is responsible for making decisions related to non conforming product? How nonconforming product is identified, labeled and segregated? (c) What is done with the nonconforming product? (d) Who is responsible for taking corrective action?

18 Section 8: Signature Signature: Name: I certify that all responses are truthful and accurate. Date: Title: Mill Name: Location (City, State):