Audit Report - NTPEP

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Nov 15, 2013 (3 years and 7 months ago)

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AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Contact

Evaluation of
Name and Location

Information


Audit Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
1

of 5
0



Plant


Name:


Physical Address:






Mailing Address:


(if different from above)






Proprietary Ownership


Company Name:


Physical Address:








Primary Contact


Name:


Title:


Telephone:


Email:


Fax:




Management


QC Manager:


Plant Manager:




Auditor Contact


Name:


Telephone:


Address:




Email:


AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Contact

Evaluation of
Name and Location

Information


Audit Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
2

of 5
0



DOT Official Contact


Name:


Title / Organization:


Telephone:


Address:






Email:



DOT Official Contact


Name:


Title / Organization:


Telephone:


Address:






Email:



DOT Official Contact


Name:


Title / Organization:


Telephone:


Address:






Email:



Other Attendee Contact


Name:


Title / Organization:


Telephone:


Address:






Email:








AASHTO’s National
Transportation Product Evaluation Program (NTPEP)

Report


Evaluation of

Summary


Audit Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
3

of 5
0


Ev
aluation Program for Plastic Pipe Facil
ities Producing PVC

Pipe




Summary

Report For

Manufacturer: Location



Introduction

The National Transportation Product Evaluation Program (NTPEP) is a program under the sponsorship of
the American Association of State Highway and Transportation Officials (AASHTO). The NTPEP
Eva
luation Program for PVC

Pipe Facili
ties

provides a comprehe
nsive review of the pr
oduction and
testing of
pipe and of the quality management system. The evaluation starts with a desktop review of the
facility’s quality manual and concludes with an on
-
site review of the facility’s processes and their quality
manage
ment system documentation.


The desktop review and the on
-
site review were conducted by Lead Auditor Katheryn
Malusky

(
AASHTO
)

/ Evan Rothblatt (AASHTO) / Dan Stegmaier (AASHTO) / Pete Spellerberg (AASHTO)
.
Contech

was represented by Jason Richards (Plant Manager), Sam Shadowen (Quality Assurance
Manager), Joe Richardson (Quality Assurance Manager


Perry, GA), during the on
-
site audit which was
completed on Thursday, February 28,

20
11
.


The evaluation findings foll
ow.
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)



The plant had current versions of all applica
ble AASHTO and ASTM standards. These standards
were located


PVC

Plastic Pipe Size and Type Produced (Section 4)


Audit of Training and Competency Evaluation Records (Section 6)


Sample / Yard Inspection (Section 7)


Manufacturing Process Walk
-
through
(Section 8)


Quality Control Testing Equipment and Procedures (Section 9)

AASHTO’s National
Transportation Product Evaluation Program (NTPEP)

Report


Evaluation of

Summary


Audit Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
4

of 5
0




The following quality tests were demonstrated satisfactorily and the equipment for each test was
in adequate condition:


Records Review (Section 10)



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Table of

Evaluation of

Contents


Audit Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
5

of 5
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Table of Contents



Section

1: Testing Personnel

................................
................................
................................
.......

6

Section


2:

Corrugated Pipe Identification Markings

................................
................................

6

Section


3: Standard Specifications

................................
................................
.............................

7

Section


4: Size and Type of Material Produced by the Plant

................................
...................

9

Section

5: Product Information

................................
................................
................................

10

Section

6:

Training and Competency Evaluation Records

................................
....................

12

Section

7: Yard Inspection

................................
................................
................................
........

13

Section


8:

Manufacturing Process Walk
-
through

................................
................................
...

17

Section

9: Quality Control Testing Facilities and Procedures

................................
...............

18

Section 10: Records Review

................................
................................
................................
........

43

Section 11: Sample Reports for
Compound

and Pipe Testing

................................
.................

47

Section 12: Quality Management System (QMS) Requirements

................................
.............

48

Section 13: Report Signature

................................
................................
................................
........

1


AASHTO’s National Transportation Product Evaluation
Program (NTPEP)

Sections 1& 2

Evaluation of

Personnel and
Markings


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
6

of 5
0



Section 1: Testing Personnel


Auditor Note



List the
plant personnel approved to perform quality Control tests
.

Obtain the information during
the audit or refer to the plant’s pre
-
audit documentation or previous audit report.


Identification of the personnel approved to run quality control testing at the pl
ant:


Name


Position


1)





2)





3)





4)





5)





6)





7)





8)





9)





10)





11)





12)





13)





14)





15)












Section 2: PVC

Pipe

Identification Markings


Auditor Note

-

Insert
a p
icture
(s)

of
the plant’s u
nique
p
ipe
i
dentification
m
arkings
.


Refer to the plant’s pre
-
audit
documen
tation or previous audit report
AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 3

Evaluation of

Standard
Specifications


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
7

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S
ection 3: Standard Specifications


Auditor Note

-

Indicate if current versions of the following AASHTO & ASTM standards are available at the
plant.


AASHTO

ASTM

Poly (Vinyl Chloride) (PVC) Profile Wall Drain Pipe and Fittings
Based on Controlled Inside
Diameter

M 304
-
10




Standard Test Methods for Determining the Izod Pendulum Impact
Resistance of Plastics



D 256
-
10



Standard Practice for Conditioning Plastics for Testing



D 618
-
08



Standard Test Method for Tensile Properties of Plastics



D 638
-
10


Standard Test Method for Deflection Temperature of Plastics
Under Flexural Load in the Edgewise Position



D 648
-
07



Standard Terminology Relating to Plastics



D 883
-
11



Standard Test Method for Dilute Solution Viscosity of Vinyl
Chloride Polymers




D 1243
-
95 (08)






Standard Terminology for Abbreviated Terms Relating to Plastic



D 1600
-
08



Standard Specification for Rigid Poly (Vinyl Chloride) (PVC)
Compounds and Chlorinated Ploy (Vinyl Chloride) (CPVC)
Compounds



D 1784
-
11



Standard Test Method for Adequacy of Fusion of Extruded
Poly(Vinyl Chloride) (PVC) Pipe and Molded Fittings by Acetone
Immersion



D 2152
-
95

(10
)


Standard Test Method for Determining Dimensions of
Thermoplastic Pipe and Fittings



D 2122
-
98 (10)


Standard Practice for Underground Installation of Thermoplastic
Pipe for Sewers and Other Gravity
-
Flow Applications



D 2321
-
11



Test Method for Determination of External Loading
Characteristics of Plastic Pipe by Parallel
-
Plate Loading



D 2412
-
11


Test Method for Determination of Impact Resistance of
Thermoplastic Pipe and Fittings by Means of a TUP (Falling
Weight)



D 2444
-
99 (10)


Standard Specification for Joints for Drain and Sewer Plastic Pipes
Using Flexible Elastomeric Seals



D 3212
-
07



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 3

Evaluation of

Standard
Specifications


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
8

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Standard Terminology Relating to Plastic Piping Systems

Standard Specification for Elastomeric Seals (Gaskets) for Joining
Plastic Pipe



F 412
-
09



Comments:

None


AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 4

Evaluation of

Size and
Type of
Material


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
9

of 5
0



Section 4: Size and Type of Material Produced by the
Plant


Auditor Note



Indicate

all applicable

AASHTO

pipe pr
oduced at this location. Refer to the pre
-
audit
documentation or the plant’s previous audit report.



Specification
M304
:
Indicate

all applicable
pipe produced at this
location:

Size inches [mm]

St

4 [100]


5 [125]


6 [150]


7 [175]


8 [200]


9 [225]


10 [250]


12 [300]


15 [375]


18 [450]


21 [525]


24 [600]


27 [673]


30 [750]


36 [900]


42 [1050]


48 [1200]


AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
5

Evaluation
of

Product Information


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
10

of 5
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Section 5: Product Information


Auditor Note



Complete the following section using information acquired by the pre
-
audit documentation.



YES

NO

A)

General


1) Does the company own plants at other locations?




2) If yes, does each plant have its own unique pipe marking?




List other
locations:

N/A

B)

Compound

Information


1) H
ow is compound

received at the plant?



by Railcar



by Truckload with Hopper



by Truckload of Boxes



by Other Method:




I
f Other Method,
Please Describe:



2) Please Describe your Lot Numbering System:



3) Are Certificate
s of Analysis furnished by

Man
ufacturers for each lot of compound
?




Please identify and describe what
blends your facility uses:


Comments:

None




C)

Pipe Information

The following
tables include details for quality control testing. Please indicate, for each test shown, whether your
facility conducts the test in
-
house, by a second party facility, or by a third party facility. If the test is conducted
by a second party facility or t
hird party facility, please indicate the interval tested as well as the contact
information and address for the facility. (The in
-
house and second parties are the manufacturer and owner

agency
(DOT), and a third party is an impartial testing facility not u
nder the control or influence of either the
manufacturer or owner.)



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
5

Evaluation
of

Product Information


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
11

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• QC Test Matrix


M304


Matrix of Quality Control Tests, Facilities, and Intervals
(M
304
)

TEST NAME

Testing Performed:

Test I
nterval:

In
-
House

By a
Second
Party
Facility
1

By a

Third
Party
Facility
1

M304

Compound

Tests
:





Tensile Strength and Modulus
of Elasticity





Impact Resistance (Izod)





Deflection Temperature





Flammability





Pipe

Tests
:





Wall Thickness





Inside Diameter





Perforation Locations and
Dimensions





Pipe Stiffness





Pipe Flattening





Low Temperature Flexibility





Impact Resistance (Tup)





Acetone Immersion





Soiltightness





Watertightness





1
Names, addresses, and contact information for second and/or third party facilities used:




AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 6

Evaluation of

Audit of Training


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
12

of 5
0


Section
6: Audit of Training and Competency Evaluation Records


A)

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.

Name:


Name:



Training
Record
Adequate?

Competency
Eval. Recd’s
Adequate?



Training
Record
Adequate?

Competency
Eval. Recd’s
Adequate?


Compound

Tests

YES

NO

YES

NO

N/A

Compound Tests

YES

NO

YES

NO

N/A

Tensile Strength and
Modulus of Elasticity






Tensile Strength
and Modulus of
Elasticity






Impact Resistance
(Izod)






Impact Resistance
(Izod)






Deflection Temperature






Deflection
Temperature






Flammability






Flammability






Pipe Tests






Pipe Tests






Wall Thickness






Wall Thickness






Inside Diameter






Inside Diameter






Perforation Locations
and Dimensions






Perforation
Locations and
Dimensions






Pipe Stiffness






Pipe Stiffness






Pipe Flattening






Pipe Flattening






Low Temperature
Flexibility






Low Temperature
Flexibility






Impact Resistanc
e
(Tup)






Impact Resistance
(Tup)






Acetone Immers
ion






Acetone Immersion






Soiltightness






Soiltightness






Watertightness






Watertightness







1) Do the training records indicate that at least one person is trained for each quality control
test performed

in house?

YES


NO



Comments:

None

AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 7

Evaluation of

Sample/Yard
Inspection


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
13

of 5
0


Section
7
:
Sample / Yard Inspection


A)

Split Sample Selection

Product Trade Name:

None

Sample 1

Sample 2

Sample 3

Sample 4

Spec:


Spec:


Spec:


Spec:


Size:


Size:


Size:


Size:


Is a compound

sample available for split sample testing?

Yes

No

Yes

No

Yes

No

Yes

No









Split sample testing is requested for:

Pipe only


Compound

and Pipe

Pipe only


Compound

and Pipe

Pipe only


Compound

and Pipe

Pipe only


Compound

and Pipe

B)

Raw Materials

Are compound

lot test results available?

Yes

No

Yes

No

Yes

No

Yes

No









C)

Finished Product Test
s

Are production facility test reports are available for the same lot of pipe?

Yes

No

Yes

No

Yes

No

Yes

No









Compound

Lot #


Compound

Lot #


Compound

Lot #


Compound

Lot #


Pipe Lot #


Pipe Lot #


Pipe Lot #


Pipe Lot #


Compound

Manufacturer
(s)
:


Compound

Manufacturer
(s)
:


Compound

Manufacturer
(s)
:


Compound

Manufacturer
(s)
:


D)

Split Sample Markings Verifications (Conducted by auditor)


1) Do pipe markings:

Yes

No



a) exist along the pipe at intervals not exceeding
4.9

ft [
1
.5 m]?





b) include the Manufacturer’s name or trademark?





c) include nominal size?





d) include the specification designation?





e) identify the plant designation code?





f) identify the date of manufacture or an appropriate code?




Comments:

None

AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 7

Evaluation of

Sample/Yard
Inspection


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
14

of 5
0


Auditor Note



After the split sample sizes and specs are decided on, the auditor should conduct the yard inspection
of the AASHTO pipe in the yard noting

any
physical defects
.

In addition the auditor should

select

three random
samples
of M304 pipe

to verify proper quality control records.



YES

NO

E
)

Visual Inspection of Pipe in the Yard (Conducted by auditor)


Pipe Inspections




1) The auditor shall inspect exterior and
interior walls to ensure that:




a.

free from delamination?




b.

free from blowouts?




c.

free of foreign inclusion and visible defects?




d.

the ends are cut squarely and do not affect joining?




2) The auditor shall inspect non
-
AASHTO pipe to ensure th
at it is not marked M304
?




3)
The auditor shall inspect to ensure
that
damaged pipe has been marked according to
the
manufacturer

s Quality
Manual?




Comments:

None


Fittings and Couplings Inspections




1) The auditor shall inspect exterior and interior walls to
ensure that:




a.

free of foreign inclusion and visible defects?




b.

t
he ends are cut squarely and do not affect joining?




2) The auditor shall inspect fittings and couplings to ensure the markings include:




a.

Manufacturer Name or Trademark?




b.

Specification?




Comments:

None





Auditor Note



To gather the proper information for the record traceability (using three randomly selected samples
from the yard) complete the following chart titled
Test

Record Audit.

AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 7

Evaluation of

Sample/Yard
Inspection


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
15

of 5
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Section 7
:
Sample/Yard Inspection


• M304

Yard Samples


F
)

M294
Random Sample Information and Record Audit

M304

Yard
Sample 1

M304

Yard
Sample 2

M304

Yard
Sample 3

Size:


Size:


Size:


Shift:


Shift:


Shift:


Manuf.

Date:


Manuf.

Date:


Manuf.

Date:


Plant:


Plant:


Plant:


Compound

Lot #:


Compound

Lot #:


Compound

Lot #:


Records available, records indicate
tests are
performed at required frequency and results meet
spec.
requirements

for:


Quality Control Test

Specified
Interval

Sample 1

Sample 2

Sample 3

YES

NO

N/A

YES

NO

N/A

YES

NO

N/A

COMPOUND

TESTS











Tensile Strength and Modulus of
Elasticity

once per year per
formulation










Impact Resistance (Izod)

once per year per
formulation










Deflection Temperature

once per year per
formulation










Flammability

once per year per
formulation










PIPE TESTS











W
all Thickness

one per hour per
line










Inside Diameter

one per hour per
line










Perforation Locations and Dimensions

one per hour per
line










Pipe Stiffness

one per hour per
line










Pipe Flattening

one per hour per
line










Low Temperature Flexibility

one per year










Impa
ct Resistance (Tup)

one per day per
line










Acetone Immersion

Once per lot per
line










Soiltightness

Once per year










Watertightness

Once per year










Comments:

None

AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 7

Evaluation of

Sample/Yard
Inspection


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
16

of 5
0




H
)

Additional Test

Record Audit


In addition to a revie
w of the test records for the M304

yard sample
s

selected, test records are reviewed for AASHTO

pipe produced on up to three additional weeks throughout the year since the previous audit.

Auditor Note
: If any tests have not been performed, collect all pertinent testing documentation for that lot of pipe.


Records available, records indicate
tests are
performed at required frequency and results meet
spec.
requirements

for:

Additional Test Record
s

Review
ed

All Tests
Performed

Date Produced

Line

Size

Compound

Lot
#

Line

Size

Compound

Lot
#

Line

Size

Compound

Lot #

YES

NO

Week 1





















































































Week
2





















































































Week
3





















































































Comments:

None



AASHTO’s National
Transportation Product Evaluation Program (NTPEP)

Section 8

Evaluation of

Manufacturing Walk
-
Through


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
17

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Section
8
:
Manufacturing Process
Walk
-
through


Auditor Note



Complete the following after the yard inspection and the selection of the split samples. The
compound

samples shall be taken at this point.



YES

NO

A)

Quality Control of
Compound


Compound

Blending

N/A



1)

Are

compounds

composed of virgin resin and reworked material?




2)

Is it understood that a new lot is established each time a component
or
component ratio changes by more than ±1.5%?




3)

What process does
the plant use to verify
and control 2)?



Comments:

None



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
18

of 5
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Section
9
:
Quality Control Testing Facilities and Procedures


Auditor Note



After conductin
g the manufacturing process walk
-

through, audit the testing facilities and quality
control testing procedure.




Yes

No

A)

Quality Control Plant: General Requirements


1)

Is there an assigned QC Manager responsible for assuring all sampling and
testing is done correctly?




Name:



2)

Is this the same person identified in the QMS?




3)

Is the
plant’s
test equipment adequately housed to allow proper operation of
all required test equipment in accordance
with the applicable test
procedures?




4)

Is a
ll test facility equipment in proper working order?




5)

Is there d
ocumentation
which
indicates that required maintenance has been
performed?




6)

Are test results recorded properly
using forms contained in the
plant’s
QM
?




7)

Is there evidence to indicate that the plant intends to retain copies of
NTPEP
test reports for a minimum of 5 years?




Comments:



Auditor Note



Based on the information gathered for training in Section 5, conduct the audit of the applicable test
methods:

















AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
19

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• Izod Pendulum Impact Resistance


Test
Method A: Cantilever Beam Test


Izod Pendulum Impact Resistance

(
Test Method A: Cantilever Beam Test
)

Yes

No

A)

Apparatus

(ASTM D

256

sec.
6.0
)


1)

A machine with massive base having a pendulum holding and releasing mechanism
and a mechanism for
indicating the breaking energy of the specimen
?




2)

A jig for positioning the specimen in the vise
?




3)

Graphs or tables to aid in the calculation of the correction for friction and windage?




4)

A single or multimembered arm with a bearing and head with striker
?




5)

Is the arm sufficiently rigid to maintain the proper clearances and geometric
relations between the machine parts
and the specimen
?




6)

Is the striker of the pendulum hardened steel and a cylindrical surface having
a
radius of curvature of 0.80 ± 0.20 mm
?




7)

Location of the line of contact of the striker at the
center of precussion of the
pendulum within ±2.54 mm
?




8)

The position of the pendulum holding and
releasing mechanism with the vertical
height of fall of the striker at 610 ± 2 mm
?




9)

The effective
length of the pendulum between 0.33 and 0.40 m
?




10)

The machine provided with a basic pendulum capable of delivering an energy of
2.7 ± 0.14 J within ± 0.5 % of its nominal capacity?




11)

A vise to clamp the specimen rigidly in position?




12)

The striking surface comes within 0.2 % of scale of touching the front face of a
standard specimen when the
pendulum is free hanging?




13)

Means provided for determining the energy expended by the pendulum in breaking
the specimen?




14)

The vise, pendulum, and frame shall be sufficiently rigid to maintain correct
alignment of the hammer and specimen?




15)

The base shall be sufficiently massive that the impact will not cause it to move?




16)

A check of the calibration




17)

Micrometers


To measure the width of the specimen and the depth of plastic
material remaining in the specimen under the notch




Comments:








AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
20

of 5
0





Izod Pendulum Impact Resistance


Test Method A: Cantilever Beam Test


Izod Pendulum Impact
Resistance

(
Test Method A: Cantilever Beam Test
)

Yes

No

B
)

Procedure
(ASTM D
256

Sec.
10
.0)


1)

At least five and preferably ten or more individual determinations of impact
resistance on each sample
?




2)

Specimens with the same nominal width (±0.3 mm)
?




3)

Lightest standard pendulum that is expected to break each specimen in the group
with a loss of not more than 85% of

its energy
?




4)

Machine with the proper pendulum in place for conformity with the requirements
of Section 6 before starting the tests
?




5)

Proper correction for windage and friction
?





6)

One reading of Factor A: the position the pointer attains after the swing.




7)

One reading of Factor B: until a swing causes no additional movement of the
pointer.




8)

Average A and B reading
?




9)

Specimens for conformity with the requirements of Sections 7, 8, and 10.1?





10)

The width of each specimen after notching to the nearest 0.025mm?




11)

The depth of material remaining in the specimen under the notch of each specimen
to the nearest 0.025mm
?




12)

Specimen positioned precisely clamped in the vise
?




13)

“Impacted end” of the specimen as shown and dimensioned in Fig. 6 is the end
projecting above the vise
?




14)

The record of the indicated breaking energy of the specimen together with a
description of the appearance of the broken specimen
?




15)

Determination of the correction to obtain the new breaking energy
?




16)

Comparison of the net value so found with the energy requirement of the hammer
specified in 10.2
?




17)

Obtaining the impact resistance under the notch in J/m?




18)

Calculation of the average Izod impact resistance of the group of specimens?




19)

Calculation of the standard deviation of the group of values?




Comments:




AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
21

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0






Izod Pendulum Impact Resistance


Test Method C: Cantilever Beam Test for
Materials of Less than 17 J/m


Izod Pendulum Impact Resistance

(
Test Method C: Cantilever Beam Test
for Materials of Less than 17 J/m
)

Yes

No

A)

Apparatus

(ASTM D

256

sec.
12.0
)


1)

A machine with massive base having a pendulum holding and releasing
mechanism and a mechanism for indicating the breaking energy of the
specimen
?




2)

A jig for positioning the specimen in the vise
?




3)

Graphs or tables to aid in the calculation of the correction for friction and
windage?




4)

A single or multimembered arm with a bearing and head with striker
?




5)

Is the arm sufficiently rigid to maintain the proper clearances and geometric
relations between the machine parts
and the specimen
?




6)

Is the striker of the pendulum hardened steel and a cylindrical surface having a
radius of curvature of 0.80 ± 0.20 mm
?




7)

Location of the line of contact of the striker at the center of precussion of the
pendulum within ±2.54 mm
?




8)

The position of the pendulum holding and releasing mechanism with the vertical
height of fall of the striker at 610 ± 2 mm
?




9)

The effective length of the pendulum between 0.33 and 0.40 m
?




10)

The machine provided with a basic pendulum capable of delivering an energy of
2.7 ± 0.14 J within ± 0.5 % of its nominal capacity?




11)

A vise to clamp the specimen rigidly in position?




12)

The striking surface comes within 0.2 % of scale of touching the front face of a
standard specimen when the
pendulum is free hanging?




13)

Means provided for determining the energy expended by the pendulum in
breaking the specimen?




14)

The vise, pendulum, and frame shall be sufficiently rigid to maintain
correct
alignment of the hammer and specimen?




15)

The base shall be sufficiently massive that the
impact will not cause it to move?




16)

A check of the calibration




17)

Micrometers


To measure the width of the specimen and the depth of plastic
material remaining in the specimen under the notch




Comments:


AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
22

of 5
0




Izod Pendulum Impact Resistance


Test Method C: Cantilever Beam Test for
Materials of Less than

17 J/m


Izod Pendulum Impact Resistance

(
Test Method C: Cantilever Beam Test for
Materials of Less than 17 J/m
)

Yes

No

B
)

Procedure
(ASTM D
256

Sec.
16
.0)


1)

At least five and preferably ten or more individual determinations of impact
resistance on each
sample
?




2)

Specimens with the same nominal width (±0.3 mm)
?




3)

Lightest standard pendulum that is expected to break each specimen in the group
with a loss of not more than 85% of

its energy
?




4)

Machine with the proper pendulum in place for conformity with the requirements
of Section 6 before starting the tests
?




5)

Proper correction for windage and friction
?





6)

One reading of Factor A: the position the pointer attains after the swing.




7)

One reading of Factor B: until a swing causes no additional movement of the
pointer.




8)

Average A and B reading
?




9)

Specimens for conformity with the requirements of Sections 7, 8, and 10.1?





10)

The width of each specimen after notching to the nearest 0.025mm?




11)

The depth of material remaining in the specimen under the notch of each
specimen to the nearest 0.025mm
?




12)

Specimen positioned precisely clamped in the vise
?




13)

“Impacted end” of the specimen as shown and dimensioned in Fig. 6 is the end
projecting above the vise
?




14)

The record of the indicated breaking energy of the specimen together with a
description of the appearance of the broken specimen
?




15)

Determination of the correction to obtain the new breaking energy
?




16)

Comparison of the net value so found with the energy requirement of the hammer
specified in 10.2
?




17)

Obtaining the impact resistance under the notch in J/m?




18)

Calculation of the average Izod impact resistance of the group of specimens?




19)

Calculation of the standard deviation of the group of values?




20)

Estimation of the magnitude of the energy to toss each different type of material
and each different specimen size(width)?




Comments:


AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


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Report


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_______________

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REV 1


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23

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0




Izod Pendulum Impact Resistance


Test Method D: Notch Radius Sensitivity
Test


Izod Pendulum Impact Resistance

(
Test Method D: Notch Radius Sensitivity
Test
)

Yes

No

A)

Apparatus

(ASTM D

256

sec.
18.0
)


1)

A machine with massive base having a pendulum holding and releasing
mechanism and a mechanism for indicating the breaking energy of the
specimen
?




2)

A jig for positioning the specimen in the vise
?




3)

Graphs or tables to aid in the calculation of the correction for friction and
windage?




4)

A single or multimembered arm with a bearing and head with striker
?




5)

Is the arm sufficiently rigid to maintain the proper clearances and geometric
relations between the machine parts
and the specimen
?




6)

Is the striker of the pendulum hardened steel and a cylindrical surface having a
radius of curvature of 0.80 ± 0.20 mm
?




7)

Location of the line of contact of the striker at the center of precussion of the
pendulum within ±2.54 mm
?




8)

The position of the pendulum holding and releasing mechanism with the vertical
height of fall of the striker at 610 ± 2 mm
?




9)

The effective length of the pendulum between 0.33 and 0.40 m
?




10)

The machine provided with a basic pendulum capable of delivering an energy of
2.7 ± 0.14 J within ± 0.5 % of its nominal capacity?




11)

A vise to clamp the specimen rigidly in position?




12)

The striking surface comes within 0.2 % of scale of touching the front face of a
standard specimen when the
pendulum is free hanging?




13)

Means provided for determining the energy expended by the pendulum in
breaking the specimen?




14)

The vise, pendulum, and frame shall be sufficiently rigid to maintain
correct
alignment of the hammer and specimen?




15)

The base shall be sufficiently massive that the
impact will not cause it to move?




16)

A check of the calibration




17)

Micrometers


To measure the width of the specimen and the depth of plastic
material remaining in the specimen under the notch




Comments:




AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


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Report


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_______________

Audit Report Number: ____________




REV 1


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Page
24

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0



Izod Pendulum Impact Resistance


Test Method D: Notch Radius Sensitivity
Test


Izod Pendulum
Impact Resistance

(
Test Method D: Notch Radius Sensitivity
Test
)

Yes

No

B
)

Procedure
(ASTM D
256

Sec.
22
.0)


1)

Test of ten specimens of each notch radius
?




2)

Specimens with the same nominal width (±0.3 mm)
?




3)

Lightest standard pendulum that is expected to break each specimen in the group
with a loss of not more than 85% of

its energy
?




4)

Machine with the proper pendulum in place for conformity with the requirements
of Section 6 before starting the tests
?




5)

Proper correction for windage and friction
?





6)

One reading of Factor A: the position the pointer attains after the swing.




7)

One reading of Factor B: until a swing causes no additional movement of the
pointer.




8)

Average A and B reading
?




9)

Specimens for conformity with the requirements of Sections 7, 8, and 10.1?





10)

The width of each specimen after notching to the nearest 0.025mm?




11)

The depth of material remaining in the specimen under the notch of each
specimen to the nearest 0.025mm
?




12)

Specimen positioned precisely clamped in the vise
?




13)

“Impacted end” of the specimen as shown and dimensioned in Fig. 6 is the end
projecting above the vise
?




14)

The record of the indicated breaking energy of the specimen together with a
description of the appearance of the broken specimen
?




15)

Determination of the correction to obtain the new breaking energy
?




16)

Comparison of the net value so found with the energy requirement of the hammer
specified in 10.2
?




17)

Obtaining the impact resistance under the notch in J/m?




18)

Calculation of the average Izod impact resistance of the group of specimens?




19)

Calculation of the standard deviation of the group of values?




20)

Calculation of the average impact resistance of each group
?

(except that within
each group the type of break must be homogenously C, H, C and H, or P)




21)

Checking the break of the specimen with the 0.25
-
mm radius notch
?

(If the
specimen does not break, the test is not applicable.)




22)

Checking the specimens tested with the 1.0
-
mm radius notch whether they are
failed as in category NB, non
-
break or
not
?



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
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Page
25

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0



Comments:



• Izod Pendulum Impact Resistance


Test Method E: Cantilever Beam
Reversed
Notch Test


Izod Pendulum Impact Resistance

(
Test Method E: Cantilever Beam
Reversed Notch Test
)

Yes

No

A)

Apparatus

(ASTM D

256

sec.
25.0
)


1)

A machine with massive base having a pendulum holding and releasing
mechanism and a mechanism for indicating
the breaking energy of the
specimen
?




2)

A jig for positioning the specimen in the vise
?




3)

Graphs or tables to aid in the calculation of the correction for friction and
windage?




4)

A single or multimembered arm with a bearing and head with striker
?




5)

Is the arm sufficiently rigid to maintain the proper clearances and geometric
relations between the machine parts
and the specimen
?




6)

Is the striker of the pendulum hardened steel and a cylindrical surface having a
radius of curvature of 0.80 ± 0.20 mm
?




7)

Location of the line of contact of the striker at the center of precussion of the
pendulum within ±2.54 mm
?




8)

The position of the pendulum holding and releasing mechanism with the vertical
height of fall of the striker at 610 ± 2 mm
?




9)

The effective length of the pendulum between 0.33 and 0.40 m
?




10)

The machine provided with a basic pendulum capable of delivering an energy of
2.7 ± 0.14 J within ± 0.5 % of its nominal capacity?




11)

A vise to clamp the specimen rigidly in position?




12)

The striking surface comes within 0.2 % of scale of touching the front face of a
standard specimen when the
pendulum is free hanging?




13)

Means provided for determining the energy expended by the pendulum in
breaking the specimen?




14)

The vise, pendulum, and frame shall be sufficiently rigid to maintain
correct
alignment of the hammer and specimen?




15)

The base shall be sufficiently massive that the
impact will not cause it to move?




16)

A check of the calibration




17)

Micrometers


To measure the width of the specimen and the depth of plastic
material remaining in the specimen under the notch




Comments:



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
26

of 5
0



Izod Pendulum Impact Resistance


Test Method E: Cantilever Beam
Reversed Notch Test


Izod
Pendulum Impact Resistance

(
Test Method E: Cantilever Beam
Reversed Notch Test
)

Yes

No

B
)

Procedure
(ASTM D
256

Sec.
29
.0)


1)

At least five and preferably ten or more individual determinations of impact
resistance on each sample
?




2)

Specimens with the same nominal width (±0.3 mm)
?




3)

Lightest standard pendulum that is expected to break each specimen in the group
with a loss of not more than 85% of

its energy
?




4)

Machine with the proper pendulum in place for conformity with the requirements
of Section 6 before starting the tests
?




5)

Proper correction for windage and friction
?





6)

One reading of Factor A: the position the pointer attains after the swing.




7)

One reading of Factor B: until a swing causes no additional movement of the
pointer.




8)

Average A and B reading
?




9)

Specimens for conformity with the requirements of Sections 7, 8, and 10.1?





10)

The width of each specimen after notching to the nearest 0.025mm?




11)

The depth of material remaining in the specimen under the notch of each
specimen to the nearest 0.025mm
?




12)

Specimen positioned precisely clamped in the vise
?

(Clamp the specimen so
that the striker impacts it on the face opposite the notch.)




13)

“Impacted end” of the specimen as shown and dimensioned in Fig. 6 is the end
projecting above the vise
?




14)

The record of the indicated breaking energy of the specimen together with a
description of the appearance of the broken specimen
?




15)

Determination of the correction to obtain the new breaking energy
?




16)

Comparison of the net value so found with the energy requirement of the hammer
specified in 10.2
?




17)

Obtaining the impact resistance under the notch in J/m?




18)

Calculation of the average Izod impact resistance of the group of specimens?




19)

Calculation of the standard deviation of the group of values?




Comments:





AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


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Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
27

of 5
0



• Tensile Properties of Plastics


Tensile Properties of Plastics

Yes

No

A
)

Apparatus

(ASTM D

638

sec.
5.0
)


Testing Machine




1)

Fixed grips rigidly attached to the fixed
and the movable members of the testing
machine
?




2)

Self
-
aligning grips with free movement into alignment as soon as any load is applied
so that the long axis of the
test

specimen will coincide with the direction of the
applied pull together the center line of the grip assembly
?




3)

The slippage relative to the grips of the specimen is prevented insofar as possible
?




4)

Drive Mechanism

A

drive mechanism for imparting to the movable member a
uniform, controlled velocity with respect to the stationary member, with this velocity
to be regulated as specified in Section 8
?




5)

Load Indicator

A suitable load
-
indicating mechanism capable of showing the total
tensile load carried by the test specimen when held by the grips
?




6)

T
he total elastic longitudinal strain of the system constituted by these parts does not
exceed 1 % of the total
longitudinal strain between the two gage marks on the test
specimen at any time during the test and at any load up to the rated capacity of the
machine

for the fixed member, movable member, drive mechanism, and grips?




7)

Crosshead Extension Indicator

A suitable extension indicating mechanism capable
of showing the amount of change in the separation of the grips, that is, crosshead
movement
?




Extension Indicator (extensometer)




8)

A suitable instrument for determining the distance between two designated
points
within the gage length of the test specimen as the specimen is stretched
?




9)

Setting of the
extensometer at the full gage length of the specimen
?




10)

Instrument with free of inertia at the specified speed of testing
?




11)

Modulus
-
of
-
Elasticity Measurements

for modulus
-
of
-
elasticity measurements, an
extensometer with a maximum strain

error of 0.0002 mm/mm

that automatically and
continuously records
?




12)

Low
-
Extension Measurements

the

extensometer system must meet at least Class C
(Practice E83) requirements, which include a fixed strain error of 0.001 strain or
61.0 % of the indicat
ed strain, whichever is greater
?




13)

High
-
Extension Measurements

for making measurements at elongations greater
than 20 %, measuring techniques with error no greater than
±
10 % of t
he measured
value
?




14)

Micrometers

Apparatus for measuring the width and thickness of the test specimen
complied with
the requirements of Test Method D5947
?




Comments:



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


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Report


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_______________

Audit Report Number: ____________




REV 1


8/11


Page
28

of 5
0




Tensile Properties of Plastics


Tensile
Properties of Plastics

Yes

No

B
)

Procedure
(ASTM D
638

Sec.
10
.0)


1)

Measurement of the width and thickness of each specimen to the nearest 0.025mm
using the
applicable

test methods in D5947
?




2)

Measurements of the width of specimens produced by a Type IV die

as the distance
between the
cutting

edges

of the die in the narrow
section
?




3)

Measure
ment of

the diameter of rod specimens, and the inside and outside diameters of
tube specimens, to the nearest 0.025 mm (0.001 in.) at a minimum of two points 90°
apart
?




4)

A
lign
ment of

the long axis of the specimen and the grips with an imaginary line joining
the points of attachment of the grips to the machine
?




5)

Check of proper
distance

in case of flat/tub and rod specimens
?




6)

Evenly and firmly tightened grips
?




7)

Attachment of the extension indicator
?




8)

Setting the speed of testing at the proper rate as required in Section 8
?




9)

Recording of the load
-
extension curve of the specimen
?




10)

Recording of the load and extension at the yield point and the load and extension
at the moment of rupture?




Comments:





















AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


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_______________

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REV 1


8/11


Page
29

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0



• Deflection Temperature of Plastics under Flexural Load in the Edgewise
Position


Deflection Temperature of Plastics Under Flexural Load in the Edgewise
Position

Yes

No

A
)

Apparatus

(ASTM D
648

Sec.
7.0, 10.0
)


1)

Specimen supports allowing the load to be applied on top of the specimen
vertically and midway between the supports
?




2)

The contact edges of the supports and of the piece by which load is applied with
the roundness of a radius of 3 ±
0.2 mm
?




3)

Immersion bath with suitable liquid heat
-
transfer
?




4)

Deflection measurement device suitable for measuring specimen deflection of at
least 0.25 mm with a readable capability of 0.01 mm or better
?




5)

Weights enabling the specimen to be loaded to a fiber stress of 0.455 Mpa ± 2.5
% or 1.82 Mpa ± 2.5 %
?




6)

Temperature measurement system with digital indicating with the minimum
accuracy of ± 0.5
°C?




7)

Thermometer 1C or 2C, having ranges from
-
20 to 150
°C

or
-
5 to 300
°C

respectively, whichever temperature is most suitable
?




8)

Automatic shut off the heat system
?




9)

Sound an alarm or record the temperature system in case of the deflection of the
specimen being reached?





10)

Sufficient heat transfer liquid to cover thermometers to the point specified in
their calibration?




Comments:
















AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
30

of 5
0




• Deflection Temperature of Plastics under Flexural Load in the Edgewise
Position


Deflection Temperature of Plastics Under Flexural Load in the Edgewise
Position

Yes

No

B
)

Procedures

(ASTM D
648

Sec.
12.0
)


1)

Obtaining the nominal width and depth value for the specimen with a suitable
micrometer at several points along the span
?




2)

Positioning the test specimens edgewise in the apparatus and ensuring of them
properly aligned on the supports so
that the direction of the testing force is
perpendicular to the direction of the molding flow
?




3)

Positioning of the thermometer bulb or sensitive part of the temperature
measuring devices to be as close as possible to the test specimen (within 10 mm)
without touching it
?




4)

Being sufficient of the stirring of the liquid
-
heat transfer medium ensuring that
temperature of the medium is within 1.0
°C

at any point within 10 mm of the
specimen?




5)

Suitable temperature of the bath
?




6)

Careful applying the loaded rod to the specimen and lowering the assembly into
the bath
?




7)

Adjusting the load so that the desired stress of 0.455 Mpa or 1.82 Mpa is
obtained
?




8)

Adjusting the deflection measurement device to zero or recording its starting
position after five minutes of applying load?





9)

Heating the liquid heat
-
transfer medium at a rate of 2.0 ± 0.2
°C
/min?




10)

Recording of the temperature of the liquid heat
-
transfer medium at which the
specimen has deflected the specified amount at the specified fiber stress?




Comments:












AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

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REV 1


8/11


Page
31

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0



• Dilute Solution Viscosity of Vinyl Chloride Polymers


Dilute Solution Viscosity of
Vinyl Chloride Polymers

Yes

No

A
)

Apparatus

(ASTM D
1243

Sec.
6.0
)


1)

Transfer Pipets
?




2)

Volumetric Flasks, 100
-
mL, glass
-
stoppered, in accordance with National
Institute of Standards and Technology
Circular C
-
434
?




3)

Viscometer, Ubbelohde Series U
-
1 or Cannon
-
Ubbelohde No. 75
?




4)

Water Bath, at 30 ±

0.5°
C, controlled to within ±

0.01°C
?




5)

Timer, as specified in Test Method D445, graduated in divisions of 0.1 s or less
?




6)

Filter Funnel, fritted
-
glass
?




7)

Thermometer, standard, in accordance with Method E77
?




Comments:

























AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


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REV 1


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32

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0


• Dilute Solution Viscosity of Vinyl Chloride Polymers


Dilute Solution Viscosity of Vinyl Chloride Polymers

Yes

No

B
)

Procedures

(ASTM D
1243

Sec.
8.0
)


1)

Weighing 0.2 ± 0.002 g of the sample with moisture content below 0.1 %
?




2)

Adding 50 to 70 mL of cyclohexanone to the flask, taking care to wet the resin so
that lumps do not form
?




3)

Heating (not exceed 12 h) the flask at 85 ± 10
°C

until the resin is dissolved?




4)

Checking gel
-
like particles (If any, prepare a new solution)
?




5)

Cooling the solution to the test temperature by immersing flask in the 30
°C

bath
for a minimum time of 30 min
?




6)

Measurement at 30
°C

the flow time of the prepared solution and of the pure
solvent (aged at 85 ± 10
°C
) in the viscometer
?




7)

The flow time of the solution or the solvent within 0.1 % on repeat runs on the
same filling?





Comments:

























AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


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Report


Auditor Name:
_______________

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REV 1


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33

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0




• Adequacy of Fusion of Extruded Poly Pipe and Molded Fittings by Acetone
Immersion


Adequacy of Fusion of Extruded Poly Pipe and Molded Fittings by Acetone

Immersion

Yes

No

A
)

Apparatus

(ASTM D
2152

Sec.
4.0
)


1)

A c
ontainer

which is e
ither individual, sealable for each specimen or one large,
airtight container capable of holding several specimens without touching one
another
?




2)

Precision hydrometer, graduated in thousandths, with a minimum range of 0.780
to 0.790 g/mL
?




3)

A

cylinder large enough to immerse the hydrometer
?




4)

A t
hermometer

with ASTM 12C total immersion
, range from −20°C to 102°C
accurate to 0.2°C, or equivalent
?




Comments:
























AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
34

of 5
0







• Adequacy of Fusion of Extruded Poly Pipe and Molded Fittings by Acetone
Immersion


Adequacy of Fusion of Extruded Poly Pipe and Molded Fittings by Acetone
Immersion

Yes

No

B
)

Procedures

(ASTM D
2152

Sec.
9.0
)


1)

Standard Laboratory Atmosphere of 23 ± 2
°C
?




2)

Sufficient dried acetone into the container to ensure complete immersion of the
specimen?




3)

Allowing specimen to stand immersed for 20 min without being agitating
?




4)

Inspection for signs of attack
?




Comments:























AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
35

of 5
0


• Wall
Thickness


Micrometer


Wall Thickness

Yes

No

A)

Apparatus

(ASTM D 2122 Sec. 7.0)



1)

A cylindrical or ball anvil tubing micrometer readable to ±

0.001 in. (±

0.02 mm)?




Comments:


B)

Procedure
(ASTM D 2122 Sec. 7.0)


1)

Pipes cut cleanly and burrs removed?




2)

S
pecimens condition
ed

and tested
at
:




a.

73.4°F ±

3.6°F (23°C ±

2°C)?




b.

50% ±

5% relative humidity?




3)

Conditioned for not less than
24

hr
(where required, in accordance with D618)?




4)

A minimum of eight measurements taken at closely spaced intervals

and averaged
?




5)

Wall Thickness range (in percentage) calculated?




Comments:
















Wall Thickness


Ultrasonic Gauge


Wall Thickness via Alternative Apparatus

Yes

No

A)

Apparatus
(D 2122 Sec. 4.0)

NTPEP (Approved Alternate Procedure) Appendix #4


1
)
D
evice

Used
?

Ultrasonic



Laser


Electronic


Nuclear



3) Has the apparatus
used been validated in accordance with D 2122?




4) Is each gauge and transducer identified?



Gauge S/N:

__________


Transducer S/N:

__________



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
36

of 5
0



Comments:


B)

Procedure for Wall Thickness via Ultrasonic gauge


1)
T
wo sets
(8 measurements/set)
of
l
iner
t
hickness readings taken per shift?




2)
O
ne of the sets taken with a micrometer
in accordance with D
2122?




4)
E
ach

set of

measurements

comprised of at least eight readings?




5) Are the numbers from each
reading

recorded?




6) Does the
record

indicate

whether
a

micrometer or ultrasonic gauge was used?




Comments:






• Inside Diameter


Inside Diameter

Yes

No

A)

Apparatus
(ASTM D 2122 Sec. 8.0)


1)

Metal
r
ule
,
tape, or caliper

accurate to 0.03 mm and
having at least 0.01 in. (0.2 mm)
graduations?




OR




2)

Tapered plug gage, having a taper ratio of 1:100 and accurate to ±

1% of its taper and
±

0.001 in. (±

0.02 mm)

of its diameter and a
45° by 1/8 in (3 mm) face bevel located
on the entrance of the end of the gage?




Comments:


B)

Procedure

(ASTM D 2122 Sec. 8.2)


1)

A

metal rule
, steel tape, or caliper

used to determine the a
verage
inside
diameter
from
two diameter measurements, the first at the seam (0°) and the second 90° from the
seam
?




OR




2)

A p
lug gage inserted into
the
pipe, causing round out but no expansion

used to
determine the inside diameter
?




Comments:




AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
37

of 5
0



• Length of Pipe


Length of Pipe

Yes

No

A)

Apparatus
(ASTM D 2122 Sec. 12.0)


1)

Steel tape or rule with marked graduations
of ¼”
or less
(240”x 0.01 x 0.1) accurate to
± 6 mm in 3 m?




Comments:


B)

Procedure
(ASTM D 2122 Sec. 12.2)


1)

Pipe stress free and at rest
on a flat surface and in a straight line?




2)

Length measured?





Comments:



















AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
38

of 5
0





• Unit Weight


Unit Weight

Yes

No

A)

Apparatus


1)

Steel tape or rule with marked
graduations having a tolerance o
f 10% of
the nominal
length
?





2)

Balance or scale, accurate to 0.1% of the load applied?




Comments:


B)

Procedure


1)

Pipe length determined according to D 2122?




2)

Pipe length weighed?




3)

Calculations performed
correctly to produce result in units of weight per foot
?




Comments:























AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
39

of 5
0




• Determination of External Loading Characteristics of Plastic Pipe by
Parallel
-
Plate Loading


Determination of External Loading Characteristics of Plastic Pipe by
Parallel
-
Plate Loading

Yes

No

A
)

Apparatus

(ASTM D
2412

Sec.
6.0
)



1)

A properly calibrated compression testing machine of the constant
-
rate
-
of
-
crosshead movement
type meeting the requirements of Test Method D695
?




2)

The rate of head approach as 0.50 ± 0.02 in.
/min
?




3)

Applying of the load to the specimen through two parallel steel bearing plates
?




4)

The condition of plate with flat, smooth, and clean
?




5)

The thickness of the plates less than 0.25 in.
?




6)

The plate length that equal or exceed the specimen length
?




7)

The plate width that more than the pipe contact width at maximum pipe
deflection plus 6.0 in.
?




8)

Measurement of the change in inside diameter, or deformation parallel to the
direction of loading, with a suitable deformation indicator meeting the
requirements of Test Method D695?





9)

Measurement of the changes in diameter during loading by continuously
recording plate travel or
by periodically computing it?




Comments:

















AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
40

of 5
0



• Determination of External Loading Characteristics of Plastic Pipe by Parallel
-
Plate Loading


Determination of External Loading Characteristics of Plastic Pipe
by
Parallel
-
Plate Loading

Yes

No

B
)

Procedures

(ASTM D
2412

Sec.
9.0
)


1)

Determination of the length of each specimen to the nearest 1/32 in. or better by
making and averaging at least four equally spaced measurements around the
perimeter
?




2)

Measurement of the wall thickness of each specimen in accordance with Test
Method D2122 with minimum eight measurements equally spaced around one end
and calculation of the average wall
thickness
?




3)

Determination whether a line of minimum wall thickness exists along the length
of the
specimen?




4)

Determination of

the average outside diameter to the nearest 0.01 in. (0.2 mm)
using a circumferential wrap tape or by averaging the maximum and minimum
outside diameters as measured with a micrometer or caliper
?




5)

Calculation of the average pipe inside diameter for OD
-
controlled pipe
?




6)

Calculation of the average pipe inside diameter for ID
-
controlled pipe
?




7)

Location of the pipe section with its longitudinal axis parallel to the bearing
plates with laterally center position in the testing machine?





8)

Placement of the first and successive specimen followed by the orientation of
minimum wall thickness?




9)

Compression of the specimen at a constant rate of 0.5 ± 0.02 in. /min.?




10)

Recording of the load
-
deflection measurements continuously or intermittently
with reference to the relative
movement of the bearing plates?




11)

Note of the load and deflection at the first evidence of each of
the following
significant events when and if they occur: line cracking or crazing, wall cracking,
wall delamination, rupture?




12)

Record of type and position of each event with respect to the corresponding load
and deflection?




Comments:









AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
41

of 5
0


• Determination of the Impact Resistance of Thermoplastic Pipe and Fittings


Determination of
the Impact Resistance of Thermoplastic Pipe and Fittings

Yes

No

A
)

Apparatus

(ASTM D
2444

Sec.
4.0
)


1)

The mass of the tup to be 6, 12, 20, or 30 lb
?




2)

The sufficient length of the drop tube to provide for a fall of at least 10 ft
?




3)

Care about tup falls freely
?




4)

Means

provided (1) to hold the tup at steps of 2 in. (50.8 mm) for a distance of 2
to 10 ft (610 mm to 3.0 m) above the specimen holder, (2) to release the tup in a
reproducible manner, (3) to allow the tup to fall freely, and (4) to catch the tup on
the first
rebound
?




5)

The V
-
block holder with the minimum length of the specimen being tested and
having a
90
-
deg included angle
?




6)

The side supports with sufficient depth to support the specimen in the V and not
on the top edges of the V
-
block
?




7)

The flat
-
plate holder with approximate size of 8by 12 by 1 in.?





8)

The groove with about 0.12 in. in depth with the edges rounded to a radius of
about 0.06 in.?




Comments:






















AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
42

of 5
0




• Determination of the Impact Resistance of Thermoplastic Pipe and Fittings


Determination of
the Impact Resistance of Thermoplastic Pipe and Fittings

Yes

No

B
)

Procedures

(ASTM D
2444

Sec.
9.0
)


1)

Impaction of one of the sets using energy estimated to cause 15 % of the
specimens to fail
?




2)

Impaction of the second set at an energy estimated to cause 85 % to fail?





Preliminary Tests

3)

Selection of a tup estimated to cause failure of some specimens when dropped
from a height of 5
ft
?




4)

Plot of the test results on probability graph paper to serve as the basis for
estimating the
proper drop height for the final test
?

Final Tests




5)

100 test specimens divided into two equal groups
?




6)

Estimation of the drop height at which 85 % of the specimens will pass?





7)

Estimation of the drop height at which 85 % of the specimens will fail?




8)

At least one pass and at least one fail (to be acceptable)?




9)

A straight line plot followed by the test result on normal probability paper?




10)

Analyzing a graph with the intercept of the plot?




Comments:
















AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
43

of 5
0



S
ection 10: Records Review


Auditor Note



This section details the audit of record traceability for the
compound

and pipe testing as well as
other documents established by the work

plan.


A)

General

Plant

Requirements


1)

Does the facility:




a.

Have a current copy of the Company’s Quality
System Manual?




b.

Have current versions of all AASHTO, ASTM and Company Test Procedures?
(Completed from
the list in Section 3)




c.

Maintain copies of previous NTPEP Audit Reports?




Comments:



B)

Record Traceability


1)

Statistical Analysis of Test Results
:




a.

Does the plant follow their procedures?




b.

Do the records show that each plant is monitored separately?




c.

Do the records include total manufacturer product quality trends?




2)

Does the plant follow their procedures for the following:




a.

Test Results and Product Traceability (Storing and
Locating Test Reports)?




b.

Resolving Non
-
Conforming Test Results?




c.

Equipment Maintenance?




d.

Internal
Quality Audits?




e.

Management Reviews?




f.

Contract Reviews?




g.

Customer Feedback?




Comments:



AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
44

of 5
0


Auditor Note



The auditor shall use records maintained at the facility to conduct the following
sections of the
audit.


C)

Additional
Compound

Testing and Control Information


General Requirements




1)

Are Lot Numbers defined as a railcars or truckloads (hopper truckloads or truckloads
of boxes) of
compound
?




2)

Are the lot numbers carried through to the finished product?




3)

Are
compound

quality control tests completed prior to using
compound
s in
production?




4)

Is
compound

testing completed prior to production runs?




5)

Do
Certificates of Analysis
(Resin) i
ncludes the following lot specific data:




a.

Melt Index?




b.

Density?




Comments:

None


AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
45

of 5
0



D)

Additional Pipe Testing Requirements


General Requirements




1)

Does the plant use reworked plastic meeting the requirements of Section
5.1

(M

304
)?




2)

Is the use of recycled plastic not allowed?




Report Traceability Requirements




1)

Is each pipe quality control sample designated with a sample control number?




2)

Do reports for each sample include:




a.

Identification of the plant?




b.

Date?




c.

Shift Manufactured?




d.

Production Line?




e.

Lot Designation?




3)

Does the lot designation trace to the
compound

lot test results?




Comments:

None


AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section
9

Evaluation of

QC Testing
Facilities and
Procedures


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
46

of 5
0


• Equipment Calibration

E)

Equipment Calibration, Standardizations
, and Checks


Auditor Note



Use the

following table to perform the record audit of quality control testing equipment
calibration, standardization, and checks.


Equipment Calibration, Standardization & Checking

ITEM


Cal/Verify
(C/V)

Written
Procedure

Do the records contain the following?

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 N
o.

Name

of

W
orker

ID of

C/V

equip.
used

Date

Work
done

Detailed

results

Ref
erence

to pro
cedure

used

Parallel Plate

Test Machine

(calibrate at least every 12
Months, 1% accuracy)
D695












Ult
rasonic Gauge

(
calibrate at
least

every 12 months)

D2122












Ultrasonic Transducer

(
check at
least

every 12 months)

D2122












Standard
Blocks

(
Calibrated
once
-

used to check ultrasonic
measurements
)












Balances, Scales and Weights
(standardize every 12 months,
0.5% accuracy)












Calipers

(calibrate
at least
every 12 month
)












Micrometers
(calibrate
at least
every 12 month
)












Temperature

Measuring
Device

(calibrate

at least
every
12

months
)












Comments:

O.A. means calibration was completed by an Outside Agency.


N
one





AASHTO’s National Transportation
Product Evaluation Program (NTPEP)

Section 11

Evaluation of

Sample Reports


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
47

of 5
0



Sect
ion 11: Sample Reports for Compound

and Pipe Testing


Auditor Note



Insert hard copies of the test records
, certificates of analysis,
and reports gathered during the audit.



















AASHTO’s National Transportation Product Evaluation Program (NTPEP)

Section 12

Evaluation of

QMS
Information


Audit
Report


Auditor Name:
_______________

Audit Report Number: ____________




REV 1


8/11


Page
48

of 5
0



Section
12:
Quality Management System

(QMS) Requirements


Auditor Note



Complete the following section based upon information gathered from the
pre
-
audit and during the
audit.


A)

QMS

Report Information


QMS

Report Identification (Posted on NTPEP Website):



Date of Revision of Approved QMS
:



Facility has this manual available?




Comments:

None

AASHTO’s National Transportation Product Evaluation
Program (NTPEP)

Section 14

Evaluation of
*Insert Plant Name and Location*

Annexes


Audit
Report

Auditor Name: _______________

Audit Report Number: ____________




REV 1


8/11



Page
50 of 50


Section 13: Report Signature


The Preceding Report has been reviewed and assured to be accurate by the Lead Auditor.

Auditor Name:


Signature: