AASHTO’s National Transportation Product Evaluation Program (NTPEP) Contact Welded Wire Reinforcement Information
Audit Report
Facility: Name: Physical Address:
Mailing Address: (if different from above)
Primary Contact Name: Title: Telephone: Cell: Email:
Management QC Manager: Plant Manager:
Auditor Contact Name: Telephone: Address:
Email:
PLANT - City, ST Page 1 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
REV 1/26/2016 AASHTO’s National Transportation Product Evaluation Program (NTPEP) Contact Welded Wire Reinforcement Information
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DOT Official Contact Name: Title / Organization: Telephone: Address:
Email:
PLANT - City, ST Page 2 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
REV 1/26/2016 AASHTO’s National Transportation Product Evaluation Program (NTPEP) Table of Welded Wire Reinforcement Contents
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Evaluation Program for Manufacturers of Welded Wire Reinforcement - WWR
Summary Report For PLANT - City, State
Introduction The National Transportation Product Evaluation Program (NTPEP) is program under the sponsor ship of the American Association of State Highway and Transportation Officials (AASHTO). Th e NTPEP Evaluation Program for Manufacturers of Reinforcing Steel for Concrete (Welded Wire Reinforcement-WWR) provides a comprehensive review of the production and testing of WWR a nd of the quality management system. The evaluation starts with a desktop review of the manufa cturing facility’s quality manual and concludes with an on-site review of the facility’s processes a nd their quality management system documentation.
The on-site audit was conducted on Day, Month Date, 2016 by Lead Auditor Robert Sarcinella (AASHTO). PLANT was represented by NAME (Position). Also in attendance was NAME, Titl e (State DOT).
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 fr om program requirements noted in italics will not require a corrective action report and supporti ng 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 Obser vations.
PLANT - City, ST Page 3 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Testing Personnel (Section 1)
Standard Specifications (Section 3)
Size and Type of Material Produced by the Manufacturer (Section 4)
Production Information (Section 5)
Physical Analysis (Section 6)
Quality Management System (QMS) Review (Section 7)
Equipment Calibration, Standardization & Checking (Section 8)
Records of Specimens Tested During Audit (Section 9)
PLANT - City, ST Page 4 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Table of Contents
Section 1: Testing Personnel...... 8 Section 2: Welded Wire Reinforcement Information...... 9 Section 3: Standard Specifications...... 11 Section 4: Size and Type of Material Produced by the Manufacturing Facility...... 12 Section 5: Production Information...... 13 Section 6: Physical Analysis...... 27 Section 7: Quality Management System (QMS) Review...... 36 Section 8: Equipment Calibration & Standardization/Verification...... 38 Section 9: Record of Testing Performed During the Audit...... 39 Section 10: Report Signature...... 42 Section 11: Attachments...... 43
PLANT - City, ST Page 5 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 1: Testing Personnel
Title/Responsibility Name l
a QC Sampling c i s
y QC Testing h P
g QC Supervisor n i t s e T Comments: None
PLANT - City, ST Page 6 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
REV 1/26/2016 AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 2 Welded Wire Reinforcement Markings
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Section 2: Welded Wire Reinforcement Identification
Product:
Tags:
PLANT - City, ST Page 7 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 3: 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 ASTM Standard Specification for Steel Wire and Welded Wire A1064-16b Reinforcement, Plain and Deformed, for Concrete Standard Specification for Zinc-Coated (Galvanized) Carbon A641 - N/A Steel Wire 09a(2014) Standard Test Methods and Definitions for Mechanical A370-15 Testing of Steel Products Secondary Version Presented Standard Practices for Force Verification of Testing Machines E4-16 Standard Practices for the Verification and Classification of E83-11 Extensometer Systems Comments:
PLANT - City, ST Page 8 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
REV 1/26/2016 AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 4 Welded Wire Reinforcement Size & Type Produced
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Section 4: Size and Type of Material Produced by the Manufacturing Facility
A) Wire and WWR Production Type
Wire: Type: Plain Deformed
WWR: Type: Plain Deformed
Style: Rolls Sheets Other
If other, please list: B) Typical Material Produced
Product Information:
PLANT - City, ST Page 9 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 5: Production Information
YES NO A) Facility Information 1) Does the manufacturing facility own facilities in other locations? List other locations: B) Rod Information Rod Documentation Process: 1) How does the manufacturing Facility maintain documentation for the rod used in the production of WWR? (a) Does the manufacturing facility retain copies of all rod certifications on file? (b) How long are rod certifications retained? 2) How is traceability maintained on rod after the Manufacturing Facility receives them? Describe: Verification of a randomly selected Domestic Rod Certification (Does the rod certificate show): (a) The chemical test results? (b) The plant that produce the rod? (c) A statement indicating the rod was melted and manufactured in the U.S.A? (d) Any physical test results?
Foreign Rod Usage and Traceability: 1) Does the manufacturing facility have foreign rod in its inventory? If yes, how is foreign steel identified throughout the WWR manufacturing process? Comments: None C) Wire Manufacturing Information General Wire Information: 1) Indicate the process(es) used to produce wire:
Drawn Rolled Both
2) Indicate the number of lines of deformations for deformed wire:
3) Describe each of the wire production lines: PLANT - City, ST Page 10 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Traceability of domestic wire manufacture:
1) How does the manufacturing facility maintain identity of the wire throughout the wire manufacturing process?
PLANT - City, ST Page 11 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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D) Welded Wire Reinforcement (WWR) Manufacturing Information General WWR Information: 1) Wire Feed: Spools Straight & Cut Bundles Carriers
2) Transverse Wire: Single Throw Double Throw
3) Describe the WWR production lines:
Traceability of domestic WWR fabrication:
1) How does the manufacturing facility maintain identity of the WWR during the fabrication process?
Comments: None
PLANT - City, ST Page 12 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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YES NO E) General: Product Identification/Documentation 1) The tag affixed to each roll/bundle of WWR includes the following information:
2) What does the manufacturing facility’s product documentation include? (Check all that apply) Certifications Invoices Process Worksheets Other Describe: 3) Does the manufacturing facility keep copies of all product documentation on file? 4) How long is product documentation retained? 5) How does the manufacturer furnish product documentation for a DOT project? With the shipment Mailed after the shipment with an invoice Furnished to a fabricator Other method Describe: Comments:
PLANT - City, ST Page 13 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 6: Physical Analysis
• Reduction in Area Reduction in Area – Plain Wire Specimens Yes No A) Apparatus (ASTM A1064) 1) Caliper or other measuring device, readable and accurate to at least 0.001in.? Comments: None B) Procedure (ASTM A1064) 1) Following the tension test, is the reduced diameter of the test specimen determined using a micrometer or caliper and reported? 2) Is the reduction of area determined from the difference between the test specimens’ reduced area and the original cross section area expressed as a percentage of the original cross section area and reported to the nearest percent? Comments:
• Wire Roundness Roundness – Plain Wire Specimens Yes No A) Apparatus (ASTM A1064) 1) Caliper or other measuring device, readable and accurate to at least 0.001in.? Comments: None B) Procedure (ASTM A1064) 1) Are the maximum/minimum diameters of the test specimen determined to the nearest 0.001 in. using a micrometer or caliper and reported? Comments:
• Wire Diameter Diameter – For Plain Wire Specimens Yes No A) Apparatus (ASTM A1064) 1) Caliper or other measuring device, readable and accurate to at least 0.001in.? Comments: None B) Procedure (ASTM A1064) 1) The diameter of the test specimen determined to the nearest 0.001 in. using a micrometer or caliper and reported? Comments: • Unit Weight Unit Weight – Deformed Wire Specimens Yes No A) Apparatus (ASTM A1064) 1) Balance or scale with sufficient readability? 2) Wire sample of sufficient length for accurate calculation? Comments: None
PLANT - City, ST Page 14 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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B) Procedure (ASTM A1064) 1) Where is the specimen obtained that is used for Unit Weight calculation? 2) Mass per unit length determined and reported to the nearest 0.001 lb/ft? 3) Unit Weight verified within +6% of nominal weight? Comments:
• Deformation Measurement Deformation Measurement – Deformed Wire Specimens Yes No A) Apparatus 1) Tape measure or other measuring device? 2) Caliper or other depth measuring device? Comments: None B) Procedure • Determination of Average Spacing 1) Average spacing determined by dividing a measured length (10 inches min.) of the wire specimen by the number of individual deformations in any one row of deformations? 2) Spacing measurements not made over area containing any identification markings? • Determination of Average Height 3) Height determined by averaging at least two typical deformations from each line of deformations? 4) Height determinations based on measurements at the center of indentions or raised ribs? 5) Is the minimum average height of the center of typical deformations based on the nominal wire diameters? Comments:
PLANT - City, ST Page 15 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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• WWR Dimensions Plain or Deformed WWR Yes No A) Apparatus (ASTM A1064) 1) Steel tape or rule readable and accurate to 0.1 in. or less? Comments: None B) Procedure (ASTM A1064) WWR Width: 1) Center to center distance between the outside longitudinal wires determined and reported? WWR Length: 2) Overall length of the longitudinal wires in flat sheets determined and reported? Transverse Wire Overhang: 3) Length of the transverse wire that extends beyond the centerline of each longitudinal edge wire determined and reported? Wire Spacing: 4) Center to center distance between wires in the WWR mat determined and reported? Comments:
PLANT - City, ST Page 16 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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• Bend Test Apparatus Bend Test – Plain & Deformed Wire and WWR Yes No A) Apparatus (ASTM A1064) 1) Is a bend test jig of a suitable design available and operational? 2) How is the force applied to the bend test jig? Describe: 3) Will the bend test jig bend a wire through 180° (for smooth) or 90° (for deformed) after rebound? 4) Are bending pins of required sizes available and in good condition? Comments:
• Bend Test Procedure Bend Test Yes No B) Procedure (ASTM A1064) 1) Are bend test specimens obtained from the finished wire? 2) Is one bend test made, prior to WWR fabrication, from each 10 tons or less of each size of wire or fraction thereof in a lot, or a total of seven samples, whichever is less? (A lot shall consist of all coils of a single size produced at the same time) 3) Are these coiled test specimens straightened before test? 4) Are test specimens obtained by cutting from the finished welded wire reinforcement a full width section, of sufficient length to perform the bend test? 5) Is one bend test made for each 75,000 ft2 of WWR or remaining fraction thereof? 6) Are test specimens taken from between the welds? 7) For plain wire test specimens, is the proper pin diameter used? For wire W7 [MW45] and smaller: 1d (d= the nominal wire diameter) For wire larger than W7 [MW45] : 2d (d= the nominal wire diameter) 8) Are plain wire test specimens bent at room temperature (50-100 degrees Fahrenheit) through 180°? 9) For deformed wire test specimens, is the proper pin diameter used? For wire D6 [MD39] and smaller: 2d (d= the nominal wire diameter) For wire larger than D6 [MD39] : 4d (d= the nominal wire diameter) 10) Are deformed wire test specimens bent at room temperature (50-100 degrees Fahrenheit) through 90°? 11) Is the test specimen wrapped closely around the pin? 12) Is the test specimen inspected for cracking on the outside of the bent portion? 13) If a test specimen fails the bend test is the material accepted only if two additional test specimens taken from the same sheet or roll pass the bend test? Comments: None
PLANT - City, ST Page 17 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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• Tension Test Apparatus Tension Test – Plain & Deformed Wire and WWR Yes No A) Apparatus (ASTM A1064, A370) Loading System – ASTM A 370: 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 wire (sizes) produced by plant? Gripping Devices (Wedge Type) – ASTM A 370: 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? Yield Strength Determination Equipment (ASTM A370): Does the manufacturing facility perform the Yield test? If “YES”, check which method is used: 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? Auto-Graphic - Able to accurately display “bend of knee”? Total Extension Under Load Method: a. Extensometer Class B-1? b. Resolution of 0.00005 in. /in.? Offset Method (0.2% Offset): c. Extensometer Class B-1? d. Resolution of 0.00005 in. /in.? Reduction of Area Equipment (ASTM A370): 1) A device for measuring the mean diameter of the reduced specimen to the same accuracy as the original dimensions? Comments:
PLANT - City, ST Page 18 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
REV 1/26/2016 AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 6 Welded Wire Reinforcement Physical Analysis
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• Tension Test Procedure Tension Test – Plain & Deformed Wire and WWR Yes No B) Procedure (ASTM A1064, A370) Number of Tests: 1) For WWR, is one tension test made for each 75,000 ft2 or remaining fraction thereof? 2) Is one tension and one bend test made from each 10 tons or less of each size of wire or fraction thereof in a lot, or a total of seven samples, whichever is less? (A lot shall consist of all coils of a single size produced at the same time) Test Specimens: 1) Are test specimens obtained by cutting wire from either across or between the welds of finished welded wire reinforcement? 2) Are no less than 50% of test specimens taken from across the welds? 3) For test specimens taken from across the welds, is the welded intersection located approximately at the center of the wire specimen, and, does the wire forming the welded intersection extend approximately 1 inch beyond each side of the intersection. Test Procedure: 1) Is the test specimen full size (not reduced diameter)? 2) Total test specimen length at least: the gage length, + two wire diameters between each gage mark and the grips, + the length of material required to fill the grips completely with some protruding beyond the grips? 3) 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? 4) Is the specimen placed approximately at the centerline of the head of the testing machine? 5) Is a convenient rate of loading used up to ½ the specified yield strength or ¼ the specified tensile strength, whichever is smaller? 6) Rate of loading between 10,000 psi/min. and 100,000 psi/min. to the yield point? 7) Tensile strength reported to the nearest psi? Comments:
PLANT - City, ST Page 19 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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• Weld Shear Apparatus Weld Shear Test – For WWR Yes No A) Apparatus (ASTM A1064, A370) Support and Gripping Devices (Wedge Type) – ASTM A 370: 1) Upper platen fitted with a ball and socket or similar self-aligning arrangement for supporting the weld tester? 2) Liners for the lower jaws; available in pairs and in various thicknesses? 3) Liners have flat, parallel faces? 4) Are the faces of the grips serrated and in good physical condition? 5) Grips aligned to hold specimen at approximately the centerline of head of testing machine? Weld Shear Tester: 1) Is the weld Tester similar to the device shown in Figure 1, ASTM A1064 2) Is the weld tester hung in a ball and socket, or similar self-aligning arrangement at the center of the test machine? 3) Does the weld tester use an anvil that fully supports the horizontal wire of the test specimen and allows the vertical wire of the test specimen to move freely in the vertical direction? Comments: None
PLANT - City, ST Page 20 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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• Weld Shear Procedure Weld Shear Test – For WWR Yes No B) Procedure (ASTM A1064, A370) Test Samples and Test Specimens: 1) Is a sample of WWR obtained from each 300,000 ft2 [28,000 m2] of WWR by cutting a full width section from the finished WWR of sufficient length to perform the required testing? 2) Are at least 4 test specimens selected at random from each sample of WWR for weld shear strength testing? 3) When WWR is manufactured with different wire sizes, is the larger wire selected as the “vertical wire” of each test specimen? 4) Does the horizontal wire of each test specimen extend approximately 1 in. on each side of the vertical wire? 5) Is the vertical wire of each test specimen of sufficient length below the horizontal wire so as to be adequately engaged by the grips of the testing machine? 6) Is the vertical wire of each test specimen of sufficient length above the horizontal wire so that the end of the specimen is above the center line of the upper bearing of the weld tester? Testing: 1) Is the test specimen inserted through the notch in the anvil using the smallest notch available in which the vertical wire fits loosely? 2) Is the vertical wire of the test specimen in contact with the surface of the free rotating rollers on the weld tester? 3) Is the horizontal wire of the test specimen supported by the anvil on each side of the slot? 4) Is the test specimen stressed in an axis close to the center line of the vertical wire? 5) Is the horizontal wire held closely to the vertical wire so as to prevent rotation of the horizontal wire? 6) Is a load applied to the test specimen at a rate of stressing not exceeding 100 ksi/min? Calculations and Reporting: 1) Is the weld shear strength of each test specimen reported to the nearest lbf? 2) Is the average weld shear strength determined from the weld shear strength of the 4 test specimens and reported to the nearest lbf? Rejection and Retest: 1) If the minimum weld shear strength requirement is not met, are four additional test specimens taken from four different sheets or rolls and tested? 2) Is the material rejected if the average of all eight weld shear tests performed does not meet the requirement? Comments: None
PLANT - City, ST Page 21 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 7: Quality Management System (QMS) Review
Yes No A) Training 1) Does the manufacturing facility maintain records to ensure that the facility’s personnel are trained to perform physical tests? 2) Do the records: a. Indicate which position(s) or employee(s) are responsible for the training program and maintenance of records? b. List the date(s) of training? Comments: None B) Competency Evaluations 1) Does the manufacturing facility perform competency checks to evaluate staff competency on at least an annual basis? 2) Do the records: a. Indicate the frequency of evaluations? b. Indicate which position(s) or employee(s) are responsible for the training program and maintenance of records? Comments: None
Yes No C) Internal Audits 1) Was a current internal audit presented for review? Comments: D) Management Reviews 1) Was a current management review presented for review? Comments:
E) Review of a Recent Resolution of Non-Conforming Product or Test Results Yes No PLANT - City, ST Page 22 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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1) Does the manufacturing facility document each instance for resolving non- conforming 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? F) Retention of Test Results 1) How does the Manufacturer store quality control test information? G) Review of Previous Corrective Actions N/A Have all deviations noted in the last NTPEP report been corrected Yes No Section Deviation and Corrective Action Response 7-1
Comments: None
PLANT - City, ST Page 23 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 8: Equipment Calibration & Standardization/Verification
QC Testing Equipment Auditor Note – Use the following table to perform the record audit of quality control testing equipment calibration, standardization, and 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. Calibration/Standardization Records Verification Records (Non-mandatory and are performed in addition to the required ITEM Calibration/Standardization)
(Frequency – SP01) Entity Manufacturing Entity Manufacturing *Adequate *Adequate Performing Facility Performing Facility Documentation Documentation Calibration Frequency Verification Frequency Presented? Presented? Universal Testing Machine (calibrate every 12 Months, 1% OA Annual Y accuracy) D695 Monthly with Balances and Scales (standardize OA Annual Y IN Y every 12 months) daily checks Calipers and Monthly with Micrometers (standardize every 12 IN Y months) daily checks Bending Pins (check dimensions initially and physical conditions at IN Monthly Y least every 12 months ) Standard Weights, Shims, Rods (every 3 years) only required if used OA 3 Years Y to standardized equipment in-house OA - denotes performed by an outside agency IN – denotes performed internally Comments:
PLANT - City, ST Page 24 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 9: Record of Testing Performed During the Audit
• WWR Sampled and Tested During the Audit Sheet Description Sample Lot (S) Additional Number Number or Wire Size No. Spacing Details – Width, Roll (R) L by T X by X etc. A S B S C S D S E S F S G S H S I S J S
Deformation Demonstration
D 3 [MD 20] and smaller 4 Sample of Minimum Height (in.) Larger than D 3 [MD 20] through D 10 [MD 65] 4-1⁄2 (Percent of Nominal Wire Diameter) Larger than D 10 [MD 65] 5 Wire Avg. Spacing (# per inch) Average not less than 3.5 nor more than 5.5 deformations per inch [25 mm] Comments
Yield Demonstration
Sample Yield Report attached to this report (please refer to Section 11: Attachments)
PLANT - City, ST Page 25 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 10: Report Signature
The Preceding Report has been reviewed and assured to be accurate by the Lead Auditor. NTPEP Auditor Name:
Signature:
PLANT - City, ST Page 26 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Section 11: Attachments
Meeting Attendance Sheet:
PLANT - City, ST Page 27 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Example of Yield Test Report:
PLANT - City, ST Page 28 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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Mill Test Reports for Samples Tested During Audit:
PLANT - City, ST Page 29 of 29 NTPEP Number: WWR-2016-00-000 Auditor: Ray Rowden
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