AASHTO s National Transportation Product Evaluation Program (NTPEP) Evaluation of *Insert Plant Name and Location* Contact Information Mill: Physical Address: Mailing Address: (if different from above) Proprietary Ownership Company Physical Address: Primary Contact Title: Telephone: Email: Fax: Management QC Manager: Plant Manager: Auditor Contact Telephone: Address: Email: Number Page 1 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Evaluation of *Insert Plant Name and Location* Contact Information DOT Official Contact Title / Organization: Telephone: Address: Email: DOT Official Contact Title / Organization: Telephone: Address: Email: DOT Official Contact Title / Organization: Telephone: ( ) Address: Other Attendee Contact Title / Organization: Telephone: ( ) Address: Number Page 2 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Evaluation of *Insert Plant Name and Location* Audit Summary Evaluation Program for Steel Mills Producing Rebar Summary Report For Mid-American Steel- Madill, Oklahoma Introduction The National Transportation Product Evaluation Program (NTPEP) is program under the sponsorship of the American Association of State Highway and Transportation Officials (AASHTO). The NTPEP 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. The desktop review was performed by Katheryn Malusky (AASHTO) and the on-site audit was conducted by Lead Auditor Evan Rothblatt (AASHTO). The Illinois Department of Transportation was represented by Ed Hughes (Metals & Products Coordinator) and Ray Rowden (Testing & Field Coordinator). Gerdau Ameristeel was represented by Arlan Piepho (Vice President and General Manager), Lisa Churnetski (Metallurgist Service Manager), during the on-site audit which was conducted on Tuesday, December 1, 2009. The evaluation findings follow. Deviations from program requirements are noted in red. Testing Personnel (Section 1) The following personnel were approved to run quality control testing at the plant: Standard Specifications (Section 3) REBAR Size and Type Produced by Mill (Section 4) This plant produces ASTM A615 rebar having bar numbers 4 through 11 and ASTM A706 rebar having bar numbers 9 through 11. See Section 4 of the full audit report for the Number Page 3 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Evaluation of *Insert Plant Name and Location* Audit Summary type of rebar this mill produces. Production Information (Section 5) Physical Analysis (Section 8) Quality Management System (QMS) Requirements (Section 9) Equipment Calibration, Standardization & Checking (Section 10) Records of Specimens Tested During Audit (Section 11) Number Page 4 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Table of Contents Table of Contents Section 1: Testing Personnel... 6 Section 2: Reinforcing Steel Bar Identification Markings... 7 Section 3: Standard Specifications... 8 Section 4: REBAR Size and Type Produced by Mill... 9 Section 5: Product Information... 11 Section 6: Audit Mill Test Reports (MTRs)... 14 Section 7: Chemical Analysis (melt shop only)... 15 Section 8: Physical Analysis... 16 Section 9: Quality Management System Requirements... 21 Section 10: Equipment Calibration, Standardization & Checking... 29 Section 11: Records of Specimens Tested During Audit... 30 Section 12: Personnel Involved in the Audit... 34 Section 13: Report Signature... 35 Section 14: Miscellaneous Documentation... 35 Section 15: Annexes... 35 Number Page 5 of 42
Physical Testing Chemical Testing (melt shop only) AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 1 Personnel Section 1: Testing Personnel Auditor Note Complete the following table from the information provided in the pre-audit documentation. Title/Responsibility Name Normal Workdays / Hours 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 Number Page 6 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 2 Markings Section 2: Reinforcing Steel Bar Identification Markings *Insert Electronic format illustration. Number Page 7 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 3 Specifications Section 3: 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 A615-12 A706-09b M322-07 A996-09b T244-10 A370-12 A751-11 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. Number Page 8 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 4 Size & Type Produced Section 4: REBAR Size and Type Produced by Mill Auditor Note Complete the following section using information acquired by the pre-audit documentation. Bar Size 3 4 5 6 7 8 9 10 11 14 18 Table 1 Size and Type (English Units) Type: Plain P, Deformed D Form: Straight S, Coil C 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 3 4 5 6 7 8 9 10 11 14 18 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 Number Page 9 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 4 Size & Type Produced Bar Size 3 4 5 6 7 8 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 Type Form Type Form Type Form Type Form Type For m 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 Number Page 10 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 5 Product Information Section 5: Product Information Auditor Note Complete the following section using information acquired by the pre-audit documentation. 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) a. Indicate the process used to produce billets: Continuous Ingot Strand Batch Other, Describe: b. How many furnaces does the mill have in operation? c. What is the capacity of the furnace(s)? d. Size(s) of the billets produced? Purchased Billet Documentation Requirements 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 type of steel (chemistry)? d. Do billet certifications include the origin of steel? e. Do billet certifications include the heat number? f. Traceability maintained on billets by: Heat No. Grade Other Method, Describe: Yes No Number Page 11 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 5 Product Information C) Bar Information General Bar Information 1) What is the annual reinforcing bar production? 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? a. How is foreign steel identified as foreign? Bar made from In-house produced billets (melt shop + rolling mill) 5) Does product documentation include the following: a. Chemical Test Results? b. Physical Test Results? c. Minimum Specification Requirements? N/A d. A statement indicating that the bar was melted and manufactured in the U.S.A.? e. The Heat Number? Bar made from purchased billets 6) Does product documentation include the following: N/A a. The plant that produced the billets? b. Information concerning Buy America : Statement listing mill, city, and state of billet producer Statement showing that bar manufacture occurred at your facility c. The billet certificate? d. Physical Test Results? e. Minimum Specification Requirements? Yes No Number Page 12 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 5 Product Information D) Rail & Axle Steel Documentation Requirements 1) Does the mill use rail or axle steel? (If No, proceed to Section E) 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: a. Lot Number? b. Origin of the steel? c. Heat Number? d. Carbon Level? (axle only) e. Tensile Test Results? f. Bend Test Results? g. Minimum Specification Requirements? h. Information concerning Buy America : Statement showing that bar manufacture occurred at your facility? F) General: All Product Documentation 1) What does the mill s product documentation include? (Check all that apply) MTRs Invoices Mill Worksheets Other Method, Please 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: Yes No Number Page 13 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 6 MTRs Section 6: Audit Mill Test Reports (MTRs) Number Page 14 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 7 Chem. Analysis Section 7: Chemical Analysis (melt shop only) A) Apparatus 1) How is the chemical analysis determined? Describe: 2) Is the calibration verified once a day or once a shift? 3) For M31/A615 Steel Are percentages of carbon, manganese, phosphorus, and sulfur determined? (If No, proceed to Question 4.) a. When during the production process are the percentages determined? Describe Percentages Determined: 4) For M322/A706 Steel Are percentages of carbon, manganese, phosphorus, sulfur, silicon, copper, nickel, chromium, molybdenum, and vanadium determined? (If No, proceed to Part B.) a. When during the production process are the percentages determined? B) Procedure Describe Percentages Determined: 1) Is the specified in-house procedure followed? N/A Yes No Number Page 15 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 8 Physical Analysis Section 8: Physical Analysis Deformation Measurement REBAR Deformation Measurement AASHTO: M31, M322; sec. 7.0 ASTM: A615, A706, A996; sec. 8.0 A) Apparatus 1) Caliper or other measuring device, readable and accurate to at least 0.001in. (0.02 mm)? Equipment Not Checked During Audit B) Procedure Determination of Average Spacing 1) Spacing determined by averaging the space of a minimum of 10 spaces? 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 Height 4) Height determined by averaging at least two typical deformations? 5) Height determinations based on three measurements per deformation, one at the center on the overall length and two at quarter points? 6) Rejection based on measurements of ten or more adjacent deformations on each side of the bar measured? Not Demonstrated During Audit Yes No Number Page 16 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 8 Physical Analysis Unit Weight A) Apparatus Deformed Bar Unit Weight AASHTO: M31, M322; sec. 11.0 ASTM: A615, A996; sec. 11.0 A706 sec. 10.0 1) Balance or scale of sufficient capacity? (Annex Table A 2.1) 2) Balance or scale with sufficient readability? (Annex Table A 2.1) Plain Bar 3) Caliper or other measuring device, readable and accurate to at least 0.001 in. (0.02 mm)? Equipment Not Checked During Audit B) Procedure Deformed Bar 1) Specimen length at least 20 times the largest cross-sectional dimension? 2) Mass determined to the nearest 0.5% or less? 3) Mass per unit length determined and reported to the nearest 0.001 lb/ft (0.001 kg/m)? Plain Bar 4) Diameter determined to nearest 0.001 in. (0.02 mm)? Not Demonstrated During Audit Yes No Number Page 17 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 8 Physical Analysis Bend Test A) Apparatus Bend Test AASHTO: M31, M322; sec. 10.0 ASTM: A615, A996; sec. 10.0 A706 sec. 9.2 1) Is a bend test jig of a suitable design available? 2) Is the bend test jig in good condition? 3) How is the force applied to the bend test jig? Describe: 4) Is the force applied continuously and uniformly throughout the bending operation? 5) Are the bend test jig s pin and supports free to rotate? 6) Will the bend test jig bend a bar through 180? 7) Are pins of all required sizes available and in good condition? (See Annex A 3.1) 8) Is the distance between the fixed points correct? (Annex Table A 3.2) (Note 1) Equipment Not Checked During Audit 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) For retesting the specimen shall not exhibit the following imperfections: Laps, Seams, Scabs, Slivers, Cooling or Casting Cracks, or Mill / Guide Markings 4) For retesting is the test specimen test at, at least, 60 F and placed in the bending jig with longitudinal ribs at a right angle to the plane of bending? 5) Is the proper pin being used for the size and grade of bar tested? (Note 2) 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) Are the pin and supports free to rotate as the force is applied? (Note 3) 9) Is the specimen wrapped closely around the pin? 10) Is the specimen bent a full 180? (Note 4) Not Demonstrated During Audit Note 1 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 Note 2 Smaller pins than the spec calls for are permitted. However, the results are final. There is no retest mandated because the original test is not considered invalid. Note 3 M31/A615 and M322/A996 allow for other, more severe, methods of bending. These include, small pins being used, using a setup of having fixed pin and fixed supports. If a fixed pin and rotating supports setup is used, then retests must be conducted using the same setup. Note 4 M31/A615 bars 14 [43] and 18 [57] shall only be bent to 90. Yes No Number Page 18 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 8 Physical Analysis Tension Test Apparatus A) Loading System ASTM A 370 sec. 7.0; E 4 1) Hydraulic or Mechanical? 2) Maintained in good operating condition? 3) Specimen loaded axially? Tension Test Apparatus Yes No 4) Of sufficient capacity to test all bar (sizes) produced by mill? 5) Provides measurements within 1% accuracy? Equipment Not Checked During Audit B) Gripping Devices (Wedge Type) ASTM A 370 sec. 5.2; E8 sec. 5.2 1) Liners available in pairs and in various thicknesses? 2) Liners 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? Equipment Not Checked During Audit C) Elongation Measuring Equipment ASTM E 8 sec. 5.4) 1) Direct Method: a. Calipers or other measuring device (dividers, etc.), readable and accurate to 0.01 in (0.2 mm)? 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? Equipment Not Checked During Audit D) Yield Point / Strength Determination Equipment (ASTM A370 sec. 13.0) 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) Total Extension Under Load Method: a. Extensometer Class C or better? b. Class C Extensometer verified from at least 0.05% strain onward? c. Resolution of 0.0005 in. /in. (mm/mm) (E83 Table 1)? d. Fixed error of ±0.001 in. /in. (mm/mm) (E83 Table 1)? Equipment Not Checked During Audit Number Page 19 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 8 Physical Analysis Tension Test Procedure Tension Test Procedure AASHTO T 68 sec. 7.0, ASTM E 8 sec. 7.0 Yes No E) Tensile Test Procedure 1) Is the test specimen full size (not reduced diameter)? 2) Is coiled material carefully straightened 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 (0.2 mm)? Not Demonstrated During Audit 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 an autographic diagram or extensometer? 15) Yield point determined by halt in the gage of the testing machine? 16) After yield behavior is observed, is the strain rate set between 0.05 and 0.5 in./in./min until the specimen breaks? (0.4 and 4 in./min)? Not Demonstrated During Audit 17) Is the criteria for a valid test a break that occurs within the middle half of the gage length? 18) Tensile strength - maximum load divided by the original cross-sectional area - reported to the nearest psi (MPa)? 19) Yield Strength reported to the nearest psi (MPa)? 20) Elongation - change in gage length divided by original length reported to the nearest percent? Not Demonstrated During Audit Number Page 20 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 9 QMS Requirements Section 9: Quality Management System (QMS) Requirements Organization and Staff Organization and Staff Yes No A) Organization and Organizational Policies 1) Does the mill have an organization chart showing relevant internal organizational components? 2) Does the mill have a quality policy statement (set by management) and quality objectives? B) Position Descriptions 1) Does the mill have position descriptions for each technical operational position shown on the mill s organization chart? 2) Do the position descriptions: a. Identify the position? b. Describe the duties associated with the position? c. Describe the required skills, education and experience? d. Indicate the supervision exercised and received? Number Page 21 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 9 QMS Requirements Training and Competency Evaluations Training and Competency Evaluations Yes No A) Training 1) Does the mill have written procedures used to ensure that the mill s personnel are trained to perform chemical (melt shop only) and physical tests? 2) Do the procedures: a. Indicate what position(s) or employee(s) are responsible for the training program and maintenance of records? b. Indicate the distribution of records to management? 3) Does the mill follow their procedures? B) Competency Evaluations 1) Does the mill have written procedures used to evaluate staff competency to ensure that each chemical (melt shop only) and physical test is performed in accordance with standard procedures? 2) Do the procedures: a. Indicate the frequency of evaluations? b. Indicate what position(s) or employee(s) are responsible for the training program and maintenance of records? c. Indicate the distribution of records to management? 3) Does the mill follow their procedures? Number Page 22 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 9 QMS Requirements Quality Management Quality Management Yes No A) Contract Review 1) Does the mill have written procedures for processing reinforcing steel orders and reviewing contracts for reinforcing steel bar? 2) Do the procedures: a. Ensure that the requirements are adequately defined, documented and understood? b. Indicate that records of contract reviews are maintained? c. Ensure that the client shall be informed of any deviations from the contract? 3) Does the mill follow their procedures? B) Customer Feedback 1) Does the mill have written procedures describing their customer feedback system? 2) Do the procedures: a. Indicate what position(s) or employee(s) are responsible for customer feedback? b. Identify the methods used to solicit, evaluate and respond to customer feedback? c. Identify conditions under which corrective action will be implemented? 3) Does the mill follow their procedures? C) Internal Audits 1) Does the mill have written procedures for performing internal audits? 2) Do the procedures: a. Indicate what position(s) or employee(s) are responsible for ensuring that internal audits are performed? b. Indicate the frequency, scope and criteria used for performing the audits? c. Identify conditions under which corrective action will be implemented? 3) Does the mill follow their procedures? Number Page 23 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 9 QMS Requirements Quality Management (cont d) Quality Management (Continued) Yes No D) Management Reviews 1) Does the mill have written procedures for performing management reviews? 2) Do the procedures: a. Indicate what position(s) or employee(s) are responsible for ensuring that management reviews are being performed? b. Indicate the frequency, scope and criteria used for performing the reviews? c. Identify conditions under which corrective action will be implemented? 3) Does the mill follow their procedures? E) Corrective Action 1) Does the mill have 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? 2) Do the procedures: a. Indicate what position(s) or employee(s) are responsible for implementing corrective action(s)? b. Indicate the methods used to identify and implement corrective action? 3) Does the mill follow their procedures? Number Page 24 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 9 QMS Requirements Sampling and Testing Sample and Testing Yes No A) Sampling Plan 1) Does the mill have written procedures for describing sampling for quality control and quality assurance? 2) Do the procedures: a. Meet the minimum specification requirements? (See Annex A4) b. Indicate the number and frequency of samples taken? c. Indicate sample selection process, including sampling required for retesting? d. Identify the position(s) or employee(s) responsible for sampling? e. Indicate the required sample preparation? 3) Does the mill follow their procedures? B) Testing Plan 1) Does the mill have written procedures for describing testing for quality control and quality assurance? 2) Do the procedures: a. Meet the minimum specification requirements? (See Annex A4) b. Indicate the number of samples taken? c. Indicate the test required to be performed? d. Identify the position(s) or employee(s) responsible for testing? e. Indicate how test results are interpreted? f. Identify the position(s) or employee(s) responsible for approving test results? 3) Does the mill follow their procedures? C) Retesting Plan 1) Does the mill have written procedures describing their retesting plan? 2) Do the procedures: a. Meet the minimum specification requirements? (See Annex A5) b. Indicate when retesting is performed? c. Identify the retest sampling requirements? d. Indicate special retesting conditions? e. Indicate criteria for acceptance of retest results? f. Instructions for reporting original test results and retest results? 3) Does the mill follow their procedures? Number Page 25 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 9 QMS Requirements Equipment Standardization and Checking Equipment Standardization and Checking Yes No A) Equipment List 1) Does the mill have listings giving a general description of physical and chemical test equipment requiring standardization or checks? 2) Do the listings include all of the equipment requiring calibration, standardization or checks? (See Section 10) 3) Does the information for each item listed: a. Identify the interval between standardizations or checks? b. Reference the standardization or check procedures? c. Identify the location of standardization or check records? 4) Does the mill follow their procedures? B) Equipment Plan 1) Does the mill have written procedures for ensuring that equipment standardizations and checks are performed for all required equipment at specified intervals? 2) Do the procedures: a. Indicate the position(s) or employee(s) responsible for standardization and check activities? b. Indicate how to handle equipment which is newly acquired, removed from service, or does not meet accuracy requirements? c. Identify the in-house equipment standardization and check procedures, when they cannot be referenced in applicable standards? d. Include certificates or other documents that establish traceability of in-house equipment or reference standards used for standardization and checks? 3) Does the mill follow their procedures? Number Page 26 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 9 QMS Requirements Product Control and Records Product Control and Records Yes No A) Recording and Maintaining Product Information and Mill Test Reports 1) Does the mill have written procedures used to produce, check and amend mill test reports (MTRs)? 2) Do the procedures: a. Meet minimum specification requirements? b. Indicate what information shall be included on an MTR? c. Identify the location of MTRs? 3) Does the mill follow their procedures? B) Handling Raw Material for DOT Products 1) Does the mill have written procedures to ensure that reinforcing bar made for DOT projects does not include any foreign steel? 2) Do the procedures: a. Indicate the position(s) or employee(s) responsible for ensuring the exclusion of foreign steel to DOT projects? b. Indicate how the foreign steel is identified, labeled and segregated? 3) Does the mill follow their procedures? C) Product Markings 1) Does the mill have written procedures describing how finished product is marked? 2) Do the procedures meet minimum specification requirements? (See Annex A6) 3) Does the mill follow their procedures? Number Page 27 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 9 QMS Requirements Product Control and Records (cont d) Product Control and Records (Continued) Yes No D) Labeling and Storage of Finished Product 1) Does the mill have written procedures describing how finished product is marked? 2) Do the procedures meet minimum specification requirements? (See Annex A6) 3) Does the mill follow their procedures? E) Control of Nonconforming Product 1) Does the mill have written procedures describing the actions taken when product fails to meet specification requirements? 2) Do the procedures: a. Indicate the position(s) or employee(s) responsible for making decisions related to nonconforming product? b. Indicate how nonconforming product is identified, labeled and segregated? c. Identify what is done with the nonconforming product? d. Indicate the position(s) or employee(s) responsible for taking corrective action? 3) Does the mill follow their procedures? Number Page 28 of 42
Plant spec. interval req. Int.? C/V current? C/V Per-formed in spec. int.? In QM or ref. to loc.? C/V equip. listed Model & Serial No. Name of Worker ID of C/V equip. used Date Work done Detailed results Reference to procedure used AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 10 Equipment Records Section 10: Equipment Calibration, Standardization & Checking Section 10: Equipment Calibration, Standardization & Checking Cal/Verify (C/V) Written Procedure Do the records contain the following? ITEM Tension Test Machine (calibrate at least every 12 Months, 1% accuracy) T67E4 and E8/T68 Tension Test Grips (check physical condition every 12 months) T68/E8 Chemical Analysis Device (calibrate every 12 months, 0.0005% accuracy) (A751/A706) Balances, Scales and Weights (calibrate every 12 months, 0.5% accuracy) (PP45) Extensometer (calibrate every 12 months, 0.01% accuracy) (E83) Elongation Punching Device (check every 12 months) (T244/A370) Elongation Measuring Device (calibrate every 12 months, 0.1% accuracy) (T244/A370) Deformation Measuring Device (standardize every 12 months, 0.1% accuracy) (A615/A706/A996) Bending Pins (check dimensions and physical conditions at least annually) (A615/A706/A996) Number Page 29 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 11 Audit Testing Section 11: Records of Specimens Tested During Audit Specimen No. Heat No. Spec. Size Grade Deformed or Plain Straight or Coiled Pass Results Fail 1 D P S C 2 D P S C 3 D P S C 4 D P S C 5 D P S C 6 D P S C 7 D P S C 8 D P S C 9 D P S C 10 D P S C 11 D P S C 12 D P S C Number Page 30 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 11 Audit Testing A 615 Bar - Results of On-site Testing Specimen No. Bar Tested Size: 3[10] 4[13] 5[16] 6[19] 7[22] 8[25] 9[29] 10[32] 11[36] 14[43] 18[57] Bar Tested Grade: 40[280] 60[420] 75[520] 80[550] Type: Deformed Plain Form: Str. Coil Bar Tested from : Heat Number Specimen Length? Test Property Reported Result Specification Requirement Chemical Analysis, % Carbon, Manganese, Phosphorus, Sulfur Deformed Bar Weight, lb/ft (4 sign. fig.) C Mn P S The phosphorus content shall not exceed 0.06%. At least 94% of the weight per unit length in Annex Table A1.1. Plain Bar Weight Equivalent, in. (0.001 in. [0.02 mm]) Def. Spacing, 0.001 in.[0.02 mm] Def. Height, 0.001 in. [0.02 mm] Def. Gap, 0.001 in. [0.02 mm] Yield Strength, psi Tensile Strength, psi Elongation, nearest % Bend Test Pass Fail Date Tested: Tested by: Permitted Variation in thickness from Annex A2. Shall not exceed the 7/10 the nominal diameter (Table A1.1). Shall meet the minimum values in Table A1.1. Shall not exceed the 12.5% of the nominal perimeter (Table A1.1). Grade 40 [280] at least 40,000 psi [280 MPa] Grade 60 [420] at least 60,000 psi [420 MPa] Grade 75 [520] at least 75,000 psi [520 MPa] Grade 80 [550] at least 80,000 psi [550 MPa] Grade 40 [280] at least 60,000 psi [420 MPa] Grade 60 [420] at least 90,000 psi [620 MPa] Grade 75 [520] at least 100,000 psi [690 MPa] Grade 80 [550] at least 105,000 psi [725 MPa] Shall meet the minimum percent in A615, Table 2 Bent 180 for bars: 3-11 Bent 90 for bars: 14, 18 No cracking on the outside radius. Number Page 31 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 11 Audit Testing A 706 Bar - Results of On-site Testing Number Specimen No. Bar Tested Size: 3[10] 4[13] 5[16] 6[19] 7[22] 8[25] 9[29] 10[32] 11[36] 14[43] 18[57] Bar Tested Grade: 60[420] 80[550] Type: Deformed Plain Form: Str. Coil Bar Tested from : Heat Number Specimen Length? Test Property Reported Result Specification Requirement Chemical Analysis, % Carbon, Manganese, Phosphorus, Sulfur Carbon Equivalent (C.E.),% Deformed Bar Weight, lb/ft [kg/m] Plain Bar Weight Equivalent, in. or mm Def. Spacing, 0.001 in.[0.02 mm] Def. Height, 0.001 in. [0.02 mm] Def. Gap, 0.001 in. [0.02 mm] Yield Strength, psi Tensile Strength, psi Elongation, nearest % C Mn P S Si Cu Ni Cr Mo V Maximum Amount: Carbon (C) 0.30%, Manganese (Mn) 1.50%, Phosphorus (P) 0.035%, Sulfur (S) 0.045%, Silicon (Si) 0.50% Shall not exceed 0.55% Other Elements: Copper (Cu) Nickel (Ni) Chromium (Cr) Molybdenum (Mo) Vanadium (V) At least 94% of the weight per unit length in Annex Table A1.1. (4 sign. fig.) Permitted Variation in thickness from Annex A2. (4 sign. fig.) Shall not exceed the values in A706, Table 1. Shall meet the minimum values in A706, Table 1. Shall not exceed the values in A706, Table 1. Grade 60 [420] at least 60,000 psi [420 MPa] but less than 78,000 psi [540 MPa] Grade 80 [550] at least 80,000 psi [550 MPa] but less than 98,000 psi [540 MPa] Grade 60 [420] at least 80,000 psi [550 MPa] & 1.25 Times the Yield Strength Grade 80 [550] at least 100,000 psi [550 MPa] & 1.25 Times the Yield Strength Bars 3, 4, 5, & 6 at least 14% Bars 7, 8, 9, 10 & 11 at least 12% Bars 14 & 18 at least 10 % Bend Test Pass Fail No cracking on the outside radius. Date Tested: Tested by: Carbon Equivalency C.E. = % C % Mn % Cu % Ni % Cr % Mo % V 0 Page 32 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 11 Audit Testing A 996 Bar - Results of On-site Testing Bar Tested Size: 3[10] 4[13] 5[16] 6[19] 7[22] 8[25] Bar Tested Grade: 40[280] 50[350] 60[420] Bar Tested from : Lot Number Specimen No. Steel Type: Rail Sym Rail Axle Type: Deformed Plain Form: Str. Coil Specimen Length? Test Property Reported Result Specification Requirement Carbon Range, % Weight, lb/ft[kg/m] (4 sign. fig.) Def. Spacing, 0.001 in. [0.02 mm] Def. Height, 0.001 in. [0.02 mm] At least 94% of the weight per unit length in Annex Table A1.1. Shall not exceed the values in A996, Table 1. Shall meet the minimum values in A996, Table 1. Def. Gap, 0.001 in. [0.02 mm] Shall not exceed the values in A996, Table 1. Yield Strength, psi Tensile Strength, psi Grade 40[280] at least 40,000 psi [280 MPa] Grade 50[350] at least 50,000 psi [350 MPa] Grade 60[420] at least 60,000 psi [420 MPa] Grade 40[280] at least 70,000 psi [280 MPa] Grade 50[350] at least 80,000 psi [350 MPa] Grade 60[420] at least 90,000 psi [420 MPa] Elongation, nearest % Shall meet the minimum percent in A996, Table 2 Bend Test Pass, Fail No cracking on the outside radius. Date Tested: Tested by: Number Page 33 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 12 Evaluation of *Insert Plant Name and Insert Location* Personnel Involved With Audit Section 12: Personnel Involved with Audit Section 12: Personnel Involved in the Audit Position: Position: Position: Position: Position: Position: Position: Position: Position: Personnel Involved in the Close-out Meeting: Position: Position: Position: Position: Position: Position: Position: Position: Number Page 34 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 13 Report Signature Section 13: Report Signature The Preceding Report has been reviewed and assured to be accurate by the Lead Auditor. Manufacturing Auditor Signature: Number Page 35 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 14 Miscellaneous Documentation Section 14: Miscellaneous Documents Note The Management Review and Internal Audit gathered during the audit are attached. Number Page 36 of 42
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 15 Annexes Section 15: Annexes ANNEX A1 Bar Requirements from A615, A996, A706* Table A1.1 Deformed Bar Designation Numbers, Nominal Weights [Masses], Nominal Dimensions and Deformation Requirements Bar Designation Number Nominal Weight [Mass] Diameter Cross- Sectional Area Perimeter Maximum Average Spacing Minimum Average Height Maximum Gap (Chord of 12.5% of Nominal Perimeter) (lb/ft) [kg/m] (in.) [mm] (in. 2 ) [mm 2 ] (in.) [mm] (in.) [mm] (in.) [mm] 3 [10] 0.376 [0.560] 0.375 [9.5] 0.11 [71] 1.178 [29.9] 0.262 [6.7] 0.015 [0.38] 0.143 [3.6] 4 [13] 0.668 [0.994] 0.500 [12.7] 0.20 [129] 1.571 [39.9] 0.350 [8.9] 0.020 [0.51] 0.191 [4.9] 5 [16] 1.043 [1.552] 0.625 [15.9] 0.31 [199] 1.963 [49.9] 0.437 [11.1] 0.028 [0.71] 0.239 [6.1] 6 [19] 1.502 [2.235] 0.750 [19.1] 0.44 [284] 2.356 [59.8] 0.525 [13.3] 0.038 [0.97] 0.286 [7.3] 7 [22] 2.044 [3.042] 0.875 [22.2] 0.60 [387] 2.749 [69.8] 0.612 [15.5] 0.044 [1.12] 0.334 [8.5] 8 [25] 2.670 [3.973] 1.000 [25.4] 0.79 [510] 3.142 [79.8] 0.700 [17.8] 0.050 [1.27] 0.383 [9.7] 9 [29] 3.400 [5.060] 1.128 [28.7] 1.00 [645] 3.544 [90.0] 0.790 [20.1] 0.056 [1.42] 0.431 [10.9] 10 [32] 4.303 [6.404] 1.270 [32.3] 1.27 [819] 3.990 [101.3] 0.889 [22.6] 0.064 [1.63] 0.487 [12.4] 11 [36] 5.313 [7.907] 1.410 [35.8] 1.56 [1006] 4.430 [112.5] 0.987 [25.1] 0.071 [1.80] 0.540 [13.7] 14 [43] 7.65 [11.38] 1.693 [43.0] 2.25 [1452] 5.32 [135.1] 1.185 [30.1] 0.085 [2.16] 0.648 [16.5] 18 [57] 13.60 [20.24] 2.257 [57.3] 4.00 [2581] 7.09 [180.1] 1.58 [40.1] 0.102 [2.59] 0.864 [21.9] *A996 Excludes Bars 9-18. ANNEX A2 Unit Weight: Specimen Size and Balance Requirements for Deformed Bars Permissible Variation in Thickness for Plain Bars Table A2.1 Unit Weight Specimen Size & Balance Requirements Bar Size Min. Specimen Length (in.) Min. Capacity (lb) Min. Capacity (kg) Req. Readability (lb) Req. Readability (g) No. 3 [10] 8 0.24 0.1 0.001 0.5 No. 4 [13] 10 0.56 0.3 0.003 1 No. 5 [16] 13 1.09 0.5 0.005 2 No. 6 [19] 15 1.88 0.9 0.009 4 No. 7 [22] 18 2.98 1.4 0.015 7 No. 8 [25] 20 4.45 2.0 0.022 10 No. 9 [29] 23 6.39 2.9 0.032 14 No. 10 [32] 25 9.11 4.1 0.046 21 No. 11 [36] 28 12.49 5.7 0.062 28 No. 14 [43] 34 21.59 9.8 0.108 49 No. 18 [57] 45 51.16 23.2 0.256 116 Number Page A1
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 15 Annexes Table A2.2 Permissible Variation in Thicknesses Bar Size Measurement Variation Results No. 3 [10] 0.375 ±0.006 0.369 0.381 in. No. 4 [13] 0.500 ±0.007 0.493 0.507 in. No. 5 [16] 0.625 ±0.007 0.617 0.633 in. No. 6 [19] 0.750 ±0.008 0.742 0.758 in. No. 7 [22] 0.875 ±0.007 0.866 0.884 in. No. 8 [25] 1.000 ±0.009 0.991 1.009 in. No. 9 [29] 1.125 ±0.010 1.115 1.135 in. No. 10 [32] 1.250 ±0.011 1.239 1.261 in. No. 11 [36] 1.375 ±0.012 1.363 1.387 in. No. 14 [43] 1.75 ±1/64 in. 1.734 1.766 in. No. 18 [57] 2.25 +1/32 in. 2.250 2.281 in. ANNEX A3 Bend Test Pin Requirements Bend Test Pin Separation Requirements Table A3.1 Bend Test Pins Required Diameter, inch [mm] M31 (A615) A706 M322 (A996) Bar Size Grade 40 Grade 60 Grade 75 & 80 Grade 60 Grade 80 Rail Symbol Grades 50/60 Rail Grades 50/60 Axle Grades 40/60 No. 3 [10] 1.31 [33.3] 1.31 [33.3] --- 1.13 [28.5] 1.31 [33.3] 2.25 [57.0] 1.31 [33.3] 1.31 [33.3] No. 4 [13] 1.75 [44.5] 1.75 [44.5] --- 1.50 [38.1] 1.75 [44.5] 3.00 [76.2] 1.75 [44.5] 1.75 [44.5] No. 5 [16] 2.19 [55.7] 2.19 [55.7] --- 1.88 [47.7] 2.19 [55.7] 3.75 [95.4] 2.19 [55.7] 2.19 [55.7] No. 6 [19] 3.75 [95.5] 3.75 [95.5] 3.75 [95.5] 3.00 [76.4] 3.75 [95.5] 4.50 [114.6] 3.75 [95.5] 3.75 [95.5] No. 7 [22] --- 4.38 [111.0] 4.38 [111.0] 3.50 [88.8] 4.38 [111.0] 5.25 [133.2] 4.38 [111.0] 4.38 [111.0] No. 8 [25] --- 5.00 [127.0] 5.00 [127.0] 4.00 [101.6] 5.00 [127.0] 6.00 [152.4] 5.00 [127.0] 5.00 [127.0] No. 9 [29] --- 7.90 [200.9] 7.90 [200.9] 6.77 172.2] 7.90 [200.9] --- --- --- No. 10 [32] --- 8.89 [226.1] 8.89 [226.1] 7.62 193.8] 8.89 [226.1] --- --- --- No. 11 [36] --- 9.87 [250.6] 9.87 [250.6] 8.46 [214.8] 9.87 [250.6] --- --- --- No. 14 [43] --- 15.24 [387.0] 15.24 [387.0] 13.54 [344.0] 15.24 [387.0] --- --- --- No. 18 [57] --- 20.31 [515.7] 20.31 [515.7] 18.06 [458.4] 20.31 [515.7] --- --- --- Number Page A2
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 15 Annexes Bar Designation No. Table A3.2 Bend Test Pins Required Separation, inch [mm] A 615 A706 A 996 Grade 40 Grade 60 Grade 75 Grade 60 Type Rail Type R Type A Symbol Distance Distance Distance Distance Distance Distance Distance 3 [10] 2.444 2.444 2.256 3.384 2.444 2.444 4 [13] 3.250 3.250 3.000 4.500 3.250 3.250 5 [16] 4.063 4.063 3.750 5.625 4.063 4.063 6 [19] 6.000 6.000 3.750 5.250 6.750 6.000 6.000 7 [22] 7.000 4.375 6.125 7.875 7.000 7.000 8 [25] 8.000 5.000 7.000 9.00 8.000 8.000 9 [29] 11.280 7.896 10.152 10 [32] 12.700 8.890 11.430 11 [36] 14.100 9.870 12.690 14 [43] 20.316 15.237 18.623 18 [57] 27.084 20.313 24.827 ANNEX A4 Sampling and Testing Requirements Table A4.1 A615 - Sampling and Testing Requirements for Each Heat Bar Size Minimum Requirement Chemical: ----- Percent - Carbon, Manganese, Phosphorus, & Sulfur Physical: 3 to 11 One tension test and one bend test for the largest size rolled Dimensional Properties: If bar sizes differ by 3 or more 14 18 For Each Size Rolled One tension test (including tensile strength, yield strength and elongation) and one bend test for both the largest and smallest size rolled One tension test (including tensile strength, yield strength and elongation) and one bend test One tension test (including tensile strength, yield strength and elongation) and one bend test Bar mass and Deformation - spacing, height and gap Number Page A3
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 15 Annexes Table A4.2 A706 - Sampling and Testing Requirements for Each Heat Bar Size Chemical: ----- Physical: Dimensional Properties: For Each Size Rolled For Each Size Rolled Minimum Requirement Percent - Carbon, Manganese, Phosphorus, Sulfur, Silicon, copper, nickel, chromium, molybdenum, & vanadium One tension test (including tensile strength, yield strength and elongation) and one bend test Bar mass and Deformation - spacing, height and gap Table A4.3 A996 - Sampling and Testing Requirements for Each Lot of 10 tons or Less Bar Size Chemical: Each Axle Percent Carbon Minimum Requirement One tension test (including tensile strength, yield strength and Physical: All Sizes elongation) and one bend test Dimensional All Sizes Bar mass and Deformation - spacing, height and gap Properties: Note: A lot of bars means, all of the bars of one bar number and pattern of deformations contained in an individual shipping order. Number Page A4
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 15 Annexes Tension Specimen Bend Test Specimen Weight Test Invalid Test Criteria ANNEX A5 Retesting Criteria Table A5.1 Retesting Criteria A615, A706 & A996 Valid Test & Specimen Fails, but is within: 2000 psi of required tensile strength, or 1000 psi of required yield strength, or 2 percent of required elongation Valid Test & Specimen Fails Valid Test & Specimen Fails 1) The elongation of a tension test specimen is less than that specified and any part of the fracture is outside the middle half of the gage length. 2) Failure of the test equipment or improper specimen preparation. 3) Flaws in the test specimen. Action Required Retest two random specimens for each original tension specimen from a lot. Both must pass. Retest two random specimens from the same lot at an air temperature 60 F with the test specimen placed in the bending jig with longitudinal ribs at a right angle to the plane of bending. Both must pass. All contact points must be free to rotate. OR Retest two random specimens using smaller pins than required, however the results of the retest shall be final and no further retesting is allowed. Retest two random specimens from the same lot. Both must pass. The original results shall be discarded and the test shall be repeated on a new specimen from the same lot. Note: A lot of bars means, all of the bars of one bar number and pattern of deformations contained in an individual shipping order. Number Page A5
AASHTO s National Transportation Product Evaluation Program (NTPEP) Section 15 Annexes ANNEX A6 Reinforcing Bar Identification A1. Producing Mill - The top letter or symbol identifies the producing mill. A2. Bar Size - The next marking tells the bar size according to a system of metrically calculated sizes. A3. Steel Type - The third marking symbol designates the manufacturing material usually either "S" for billet steel (A615) or "W" for low-alloy steel (A706). Markings also include: I for Rail (A616), IR for Rail meeting supplemental requirement S1, (A616), and A for Axle (A617). A4. Minimum Yield - There may be a grade marking (4 or 5, for 420 or 520) or the grade may be designated by the addition of one line (420) or two lines (520) that run the length of the bar. Nothing is required for Grade 40 (280 MPa) steel or for A706 steel since it only comes in Grade 60. Note Bars may be marked with R and A to connote Rail or Axle Steel meeting requirements of A996. Figure A6.1 ANNEX 7 Product Labeling Storage (See ASTM A700) Labels on bundles or coils of rebar must include at least the following information: Heat Number, Size, Grade, No. of pieces, Length of pieces Number Page A6