Mill: Name: Physical Address: Mailing Address: SAME AS ABOVE (if different from above) Primary Contact Name: Title: Telephone: Cell: Email: Management QC Manager: Plant Manager: Auditor Contact Name: Telephone: Address: Email: Other Attendee Contact Name: Title: Organization: Telephone: Email: DOT Official Contact Name: Title: Organization: Telephone: Email:
AASHTO s National Transportation Product Evaluation Program () Audit Summary Evaluation Program for Steel Mills Producing Rebar Summary Report For Plant City, State Introduction The National Transportation Product Evaluation Program () is program under the sponsorship of the American Association of State Highway and Transportation Officials (AASHTO). The Evaluation Program for Steel Mills Producing Rebar provides a comprehensive review of the production and testing of rebar 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, 2016. 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 this report for the list the plant personnel approved to perform quality control tests. Rebar Identification Markings and Bundle Tags (Section 2) Please refer to Section 2 of this report for pictures and/or diagrams of rebar identification markings and bundle tags. Rebar Size and Type Produced by Mill (Section 3) This mill produces ASTM A615 and A706 rebar (both straight and coiled, having bar numbers 3 through 11) along with coiled rod for wire. See Section 4 of this report for the types of rebar produced at this facility. Page 2 of 26 Number: REBAR-2019-01-000
AASHTO s National Transportation Product Evaluation Program () Audit Summary Standard Specifications (Section 4) The standards are maintained electronically by the QC Manager. Production Information (Section 5) This mill has 1 furnace with a scrap capacity of 110 tons and a heat yield of 92 tons. The furnace was not in operation during the on-site audit. The mill produces 5.12 square billets. After casting, the billets are stored indoors with the last billet of a heat tagged on top and every 5th billet tagged on the end. Gaps are placed between different heats. Billets are charged into the reheat furnace and tracked by piece count along with a gap between the heats. The end of the heat is relayed throughout the rolling mill when the last billet of the heat is sent from the furnace to the rollers. This mill has 1 rolling mill (straight line). For straight deformed bar, #3 bar is split during the rolling process. For #4, #5, and #6 bar, two billets (one after the other) are run and go through two parallel sets of rollers. Number 7 bar and up, as well as all coiled deformed bar, are run single strand. Rod is diverted 90 degree through another set of rollers and then through the rod block. All personnel interviewed during the audit were very knowledgeable with both their personal job responsibilities as well as what their co-workers are doing in the surrounding areas. Quality Control Testing (Section 6) Three samples are then taken from the caster stream: C1 is taken fifteen minutes after the heat is opened, C2 approximately fifteen minutes after that (the middle of the heat), and C3 is taken fifteen minutes before the end of the heat. The last sample, C3, is reported as the final chemistry on the MTR. The mill typically performs 15 bend tests and 2 tensile tests (reports first result) on all heats. Heats are tracked through an SAP system. It is used to maintain and track the inventory for the mill. All certificates, finished goods inventory, and test reports are tracked through this program. Completed heats are tracked through an SAP system to generate the Mill Test Reports. It is used to maintain the inventory for the mill. All certificates, finished goods inventory, and test reports are tracked through this program. Physical Analysis (Section 7) The following physical tests were performed satisfactorily by NAME. The equipment for each test was in good condition: o Rebar Deformation Measurements o Unit Weight o Bend Test o Elongation Number: REBAR-2019-01-000 Page 3 of 26
AASHTO s National Transportation Product Evaluation Program () Audit Summary o Yield Strength o Tensile Strength The bend test is performed using a hydraulic ram (in a vertical plane) testing rig with a verified pins. Reinforcement bars are tested to one of the following specifications; ASTM A615, A706, A955 or A1035. Quality Management System (QMS) Reviews (Section 8) Complete training and competency evaluation records were presented and reviewed for NAME during the on-site audit. The most recent internal audit/management review was completed on DATE, 2016. These records were reviewed by the Auditor. Corrective actions from the previous audit were reviewed and found to be implemented as described. Equipment Calibration, Standardization & Checking (Section 9) Tension test devices, extensometers, and chemical analysis devices are calibrated/serviced every six months. In addition, balances, elongation punches, elongation measuring devices, and deformation measuring devices are verified internally every month. Standard blocks and shims are done every three years. This exceeds the AASHTO R18 minimum of an annual calibration. Calibration records for all testing equipment were current and complete. Records of Specimens Tested During Audit (Section 10) Please refer to Section 10 of this report for the list of heats, grades and sizes of rebar tested. Number: REBAR-2019-01-000 Page 4 of 26
AASHTO s National Transportation Product Evaluation Program () Table of Contents Table of Contents Section 1: Testing Personnel... 6 Section 2: Rebar Identification Markings and Bundle Tags... 7 Section 3: Size and Type of Material Produced by the Mill... 9 Section 4: Standard Specifications... 11 Section 5: Product Information... 12 Section 6: Quality Control Testing... 14 Section 7: Physical Analysis... 15 Section 8: Quality Management System (QMS) Review... 20 Section 9: Equipment Calibration, Standardization & Checking... 22 Section 10: Records of Specimens Tested During Audit... 23 Section 11: Report Signature... 24 Section 12: Attachments... 25 Number: REBAR-2019-01-000 Page 5 of 26
AASHTO s National Transportation Product Evaluation Program () Section 1 Testing Personnel Section 1: Testing Personnel Physical Testing Title/Responsibility QC Sampling QC Testing QC Supervisor Comments: None Name Number: REBAR-2019-01-000 Page 6 of 26
AASHTO s National Transportation Product Evaluation Program () Section 2 Rebar Identification Section 2: Rebar Identification Markings: Rebar Markings: Number: REBAR-2019-01-000 Page 7 of 26
AASHTO s National Transportation Product Evaluation Program () Section 2 Rebar Identification Rebar Bundle Tag: Number: REBAR-2019-01-000 Page 8 of 26
AASHTO s National Transportation Product Evaluation Program () Section 3 Size and Type Produced Section 3: Size and Type of Material Produced by the Mill Bar Size 3 4 5 6 7 8 9 10 11 14 18 20 Table 1 Size and Type (English Units) Type: Plain P, Deformed D Form: Straight S, Coil C Specification: ASTM A615 Please Select All that Apply: Grades 40,000 psi 60,000 psi 75,000 psi 80,000 psi 100,000 psi 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 Bar Size 3 4 5 6 7 8 9 10 11 14 18 Specification: ASTM A706 Please Select All that Apply: Grades 60,000 psi 80,000 psi Type Form Type Form P D S C P D S C XM28 Grade 60 Grade 75 316LN Grade 60 Grade 75 Number: REBAR-2019-01-000 Specification: ASTM A955 Please Select All that Apply: Grades 2205 Grade 60 Grade 75 2304 Grade 60 Grade 75 Page 9 of 26
AASHTO s National Transportation Product Evaluation Program () Section 3 Size and Type Produced Bar Size 3 4 5 6 7 8 9 10 11 14 18 20 Grade 80 Grade 100 Grade 80 Grade 100 Grade 80 Grade 100 Grade 80 Grade 100 Type Form Type Form Type Form Type Form P D S C P D S C P D S C P D S C Specification: ASTM A1035 Please Select All that Apply: Type 1035 CL Type 1035CM Type 1035 CS Grades Grades Grades 100,000 psi 120,000 psi 100,000 psi 120,000 psi 100,000 psi 120,000 psi Bar Size 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 3 4 5 6 7 8 9 10 11 14 18 20 Number: REBAR-2019-01-000 Page 10 of 26
AASHTO s National Transportation Product Evaluation Program () Section 4 Standard Specifications Section 4: Standard Specifications Indicate if current versions of the Primary ASTM standards are available and the version of the Secondary specifications presented by the manufacturing facility. Primary 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 Deformed and Plain Stainless Steel Bars for Concrete Reinforcement Standard Specification for Deformed and Plain, Low-Carbon, Chromium, Steel Bars for Concrete Reinforcement Standard Test Methods and Definitions for Mechanical Testing of Steel Products Qualification of Highway Product Manufacturers Through the Use of Audits Committee Work Plan For Evaluation of Reinforcing Steel Manufacturers ASTM A615-18 A706-16 A995-18b A1035-16b A370-17a SP01-18 RS-2018 Secondary (current version not required) Current Version Version Presented Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products A751-14a A751-14a Standard Practices for Force Verification of Testing Machines E4-16 E4-16 Standard Practices for the Verification and Classification of Extensometer Systems E83-16 E83-16 Comments: The standards are maintained electronically by the QC Manager. Number: REBAR-2019-01-000 Page 11 of 26
AASHTO s National Transportation Product Evaluation Program () Section 5 Product Information Section 5: Product Information A) Facility Information 1) Does the company own mills at other locations? How many are audited locations? B) Billet None Information General Billet Production Information 1) Does the mill produce billets for the production of rebar? (If No, proceed to Question 2) a. How many furnaces does the mill have in operation? b. What is the capacity/yield of each furnace? c. Size(s) of the billets produced? Describe traceability of billets from casting through storage: Purchased Billet Information 2) Does the mill purchase billets for the production of rebar? (If No, proceed to Part C) a. Does the mill keep copies of all billet certifications on file? b. How long are billet certifications retained? c. Do billet certifications include the steel manufacturer, heat number and steel (chemistry)? d. Does the mill have any foreign steel in its inventory? e. How are foreign billets identified? Billet Traceability Requirements 3) How does the mill maintain the traceability of billets after storage through the production of rebar? Comments: Yes No Number: REBAR-2019-01-000 Page 12 of 26
AASHTO s National Transportation Product Evaluation Program () Section 5 Product Information C) Bar Manufacturing Information General Bar Information 1) Indicate the rolling process(es) used to produce bar: Comments: Straight Line Cross Country Jump Mill 2) Indicate the finished bar product produced by this mill: Straight Bar Coiled Bar Both Comments: Comments: None D) General: Product Identification/Documentation 1) What does the mill s product documentation for shipment include? (Check all that apply): MTRs Invoices Mill Worksheets Other Method, Please Describe: 2) Does the Mill Test Report contain: 1) The Heat Number? 2) Chemical Test Results? 3) Physical Test Results? 4) Specification the product was produced to meet? 5) A statement indicating that the bar was melted and manufactured in the U.S.A.? 3) Does the mill keep copies of all product documentation on file? 4) How long is product documentation retained? Comments: Yes No Number: REBAR-2019-01-000 Page 13 of 26
AASHTO s National Transportation Product Evaluation Program () Section 6 Quality Control Testing Section 6: Quality Control Testing A) Chemistry Testing 1) What equipment is used in the chemical analysis? Spectrometer 2) Is the equipment verified once a day or once a shift? 3) Describe the process for determining the final chemistry: Comments: 4) Describe the process carried out if chemistry failures are determined: B) Physical Testing Comments: 1) Please indicate the sampling and testing process for rebar: (minimum is 1test per heat for all physical tests) The mill sample 4 bars per heat. One sample is quenched and used for dimensional checks, one is used for tensile, one for bend, and one backup bar. 2) If more than one tensile test is performed per heat, which value is used on the MTR? 3) Describe the process carried out if physical test results indicate a failure: (Note: At least two specimens should be retested and both need to meet the requirements of the specification) 4) Describe the process carried out to put the heat on hold if retest failures occur: C) Transfer of Test Results to MTR 1) How does the manufacturer transfer chemical and physical results to the MTR? Number: REBAR-2019-01-000 Page 14 of 26
AASHTO s National Transportation Product Evaluation Program () Section 7 Physical Analysis Section 7: Physical Analysis Deformation Measurement A) Apparatus Deformation Measurement For Deformed Bar Yes No 1) Tape measure or other measuring device? 2) Caliper or other depth measuring device? B) Procedure Determination of Average Deformation Spacing 1) Spacing determined by measuring the length of a minimum of ten spaces and dividing that length by the number of spaces included in the measurement? 2) Measurement begins from a point at the beginning of the first space to the corresponding point on a deformation after the last included space? 3) Spacing measurements not made over a bar area containing bar markings? Determination of Average Deformation Height 1) Height determined by averaging at least two typical deformations? 2) How is it being done? 3) Height determinations based on three measurements per deformation, one at the center on the overall length and two at quarter points? 4) Rejection based on measurements of ten or more adjacent deformations on each side of the bar measured? Comments: None Number: REBAR-2019-01-000 Page 15 of 26
AASHTO s National Transportation Product Evaluation Program () Section 7 Physical Analysis Unit Weight A) Apparatus Deformed Bar Unit Weight For Plain & Deformed Bar Yes No 1) Balance or scale of sufficient capacity? 2) Balance or scale with sufficient readability? Plain Bar 3) Caliper or other measuring device, readable and accurate to at least 0.001 in? B) Procedure Deformed Bar 1) Evaluated on the basis of the measured weight of the test specimen being at least 94% of the nominal weight? 2) Mass per unit length determined and reported to the nearest 0.001 lb/ft? Plain Bar 1) Computed on the basis of permissible variation in diameter? Comments: None Number: REBAR-2019-01-000 Page 16 of 26
AASHTO s National Transportation Product Evaluation Program () Section 7 Physical Analysis Bend Test A) Apparatus Bend Test For Plain & Deformed Bar Yes No 1) Is a bend test jig of a suitable design available and operational? 2) What type of bend test jig is used? Modified Production Machine Three Point (Vertical) Load Three Point (Horizontal) Load Other (Describe): 3) Are the bend test jig s pin and supports free to rotate? 4) Will the bend test jig bend a bar through 180 (unless noted otherwise)? 5) Are pins of the required sizes used and in good condition? 6) Is the distance between the fixed points correct? Comments: None B) Procedure 1) Is the test specimen a full section of the bar as rolled and of sufficient length to ensure free bending? 2) Is coiled material straightened before test? 3) Is the test specimen at least 60 F and placed in the bending jig with longitudinal ribs at a right angle to the plane of bending? 4) Are the mill marks placed so they do not end up in the outer radius of the bend? 5) Is the proper pin being used for the size and grade of bar tested? 6) Is the force applied continuously and uniformly throughout the bending operation? 7) Is the specimen free to move at all points of contact? 8) Is the specimen wrapped closely around the pin? 9) Is the specimen bent to the prescribed bend prior to spring-back? Comments: None The distance between the fixed points shall conform to the following equation: C = 2r + 3d ± d/2 Where: C = Distance between the points, r = radius of the pin, d = diameter of the bar A615 bars 14 [43] and 18 [57] shall only be bent to 90 Number: REBAR-2019-01-000 Page 17 of 26
AASHTO s National Transportation Product Evaluation Program () Section 7 Physical Analysis Tension Test Apparatus Tension Test Plain and Deformed Bar Yes No A) Loading System 1) Is the Load Testing Machine maintained in good operating condition? 2) Are specimens loaded axially? 3) Is the Load Testing Machine of sufficient capacity to test all bar (sizes) produced by mill? Comments: None B) Gripping Devices (Wedge Type) 1) Liners/shims available in pairs and in various thicknesses? 2) Liners/shims have flat, parallel faces? 3) Are the faces of the grips serrated and in good physical condition? 4) Grips aligned to hold specimen at approximately the centerline of head of testing machine? Comments: None C) Elongation Measuring Equipment 1) Direct Method: a. Calipers or other measuring device (dividers, etc.), readable and accurate to 0.01 in? b. Center punch (single or two point), scribe, or marking pen? 2) Direct Readout Device - Automatically calculates the change in length for 8 inch gauge length, accurate to 1% elongation? Comments: None D) Yield Point / Strength Determination Equipment 1) Drop of Beam or Halt of Gauge - Note 1 The equipment required is a loading machine with measurements accurate to 1% of the applied load? 2) Auto-Graphic - Able to accurately display bend of knee? 3) Offset Method (0.2% Offset): a. Extensometer Class B2? b. Strain range of 0.05 to 1.0 %? Comments: None Number: REBAR-2019-01-000 Page 18 of 26
AASHTO s National Transportation Product Evaluation Program () Section 7 Physical Analysis Tension Test Procedure Tension Test Plain and Deformed Bar Yes No E) Tensile Test Procedure 1) Is the test specimen full size (not reduced diameter)? 2) Is coiled material straightened according to the in-house procedure prior to testing? 3) Total test specimen length at least: the gage length, + two bar diameters between each gage mark and the grips, + the length of material required to fill the grips completely with some protruding beyond the grips? 4) Is an 8 inch gage length used to determine elongation? 5) Are gage marks clearly indicated on the specimen with light punch marks and not located on transverse deformations? 6) Is the gage length measured to the nearest 0.01 in? 7) Is the cross sectional area used in calculations the nominal bar area? 8) Does the test specimen protrude from the upper and lower grips? 9) Is most of the serrated face of the grip in contact with the specimen? 10) Are grips fully supported within the head of the testing machine and shimmed so that no more than ½ in. of the grip protrudes from the head of the machine? 11) Is the specimen placed approximately at the centerline of the head of the testing machine? 12) Is a convenient rate of loading used up to ½ the specified yield strength or ¼ the specified tensile strength, whichever is smaller? 13) Rate of loading between 10,000 psi/min. and 100,000 psi/min. to the yield point? 14) Yield point determined using: Drop of Beam/Halt of Gauge Auto-Graphic Extensometer Comments: None 15) Is the criteria for a valid test a break that occurs within the middle half of the gage length? 16) How are breaks outside the gage length handled? Describe: Invalid test 17) Tensile strength - maximum load divided by the original cross-sectional area - reported to the nearest psi? 18) Yield Strength reported to the nearest psi? 19) Elongation - change in gage length divided by original length reported to the nearest percent? Comments: None Number: REBAR-2019-01-000 Page 19 of 26
AASHTO s National Transportation Product Evaluation Program () Section 8 QMS Review Section 8: Quality Management System (QMS) Review Audit of Training and Competency Evaluation records Auditor Note The auditor shall select two random names from Section 1 to verify training and competency evaluation records are complete. Name: NAME Name: NAME 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: a. List the date(s) of the review and identification of the reviewer? b. Indicate that all relevant competency evaluations have been completed? Comments: Training and competency records for NAME and NAME were reviewed and found to be complete. C) Internal Audits 1) Was a current internal audit presented? 2) Are internal audits performed at least annually? 3) Do internal audits cover all processes that affect product quality (melt shop, rolling mill, 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, 2019 and the most recent management review was completed on DATE. Copies of these were presented to the auditor and reviewed. Number: REBAR-2019-01-000 Page 20 of 26
AASHTO s National Transportation Product Evaluation Program () Section 8 QMS Review E) 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: Yes No 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 Yes No Section Deviation and Corrective Action Response Comments: No correction actions noted on the previous report. Number: REBAR-2019-01-000 Page 21 of 26
AASHTO s National Transportation Product Evaluation Program () Section 9 Equipment Records Section 9: Equipment Calibration, Standardization & Checking QC Testing Equipment Auditor Note Use the following table to perform the record audit of quality control testing equipment calibration, standardization, checks. *Adequate documentation on each record includes: (1) Model & Serial No., (2) Name of worker, (3) ID of equipment used for calibration, (4) Date of calibration, (5) Detailed calibration results, and (6) Reference to calibration procedure used. ITEM Frequency SP01 Universal Testing Machine calibrate every 12 Mos. Extensometer calibrate every 12 Mos. 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. Chemical Analysis Device PM every 12 Mos. Bending Pins verify every 12 Mos. Elongation Punching Device verify prior to use Comments: OA PERFORMING ENTITY IN CALIBRATION VERIFICATION STANDARDIZE 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: REBAR-2019-01-000 Page 22 of 26
AASHTO s National Transportation Product Evaluation Program () Section 10 Records of Specimens Tested During Audit Section 10: Records of Specimens Tested During Audit Insert Manufacturing Test Information Spreadsheet here CORRECTIVE ACTION: Number: REBAR-2019-01-000 Page 23 of 26
AASHTO s National Transportation Product Evaluation Program () Section 11 Report Signature Section 11: Report Signature The Preceding Report has been reviewed and assured to be accurate by the Lead Auditor. Auditor Name: Signature: Number: REBAR-2019-01-000 Page 24 of 26
AASHTO s National Transportation Product Evaluation Program () Section 12 Attachments Section 12: Attachments Meeting Attendance Sheet: Number: REBAR-2019-01-000 Page 25 of 26
AASHTO s National Transportation Product Evaluation Program () Section 12 Attachments Mill Test Reports for Samples Tested During Audit: Number: REBAR-2019-01-000 Page 26 of 26