Metal Pipe
Technical Committee Meeting Agenda
Working Session #4
Monday, May 18, 2015 4:00 PM – 5:00 PM
Please sign the attendance sheet via the iPad
1) 4:00 PM to 4:05 PM: Call to Order and Introductions (Katheryn Malusky)
2) 4:05 PM to 4:10 PM: Volunteers for Chairman and Vice-Chairman for this technical
committee (Katheryn Malusky)
3) 4:10 PM to 4:45 PM: Review of Drafted work plan (attached)
a) Is this a work plan for corrugated steel drainage products or corrugated metal
drainage products?
b) How should we include Buy America requirements into the work plan?
c) Are the frequencies on inspections, measurement and tests appropriate – instead
maybe they are per coil, per diameter, per length of pipe, etc.
d) What should be the full details on sampling and testing of coupons for annual
product conformance testing? For tensile, yield, coating thickness, metal
thickness, steel composition…
e) There also seems to be some redundancy in the annual product conformance
testing sections and could possibly be combined.
f) Change/remove all language that refers to resin
g) Add appendix for audit agenda
h) Other appendices?
i) Program participant responsibilities
i) Additional terms
j) Remove rework
k) Better define coatings
l) We prefer the term fabricators to manufacturers
m) Other Keywords
i) Fabricator
ii) Corrugated metal pipe
4) 4:45 PM to 4:55 PM: Open Discussion
5) 4:55 PM to 5:00 PM: Review of Action Items resulting from this meeting
NTPEP Committee Work Plan for
Corrugated Steel Drainage Pipe
Fabricators
NTPEP Designation: CMDP-15
Revised - March 2015
National Transportation Product Evaluation Program
444 North Capitol Street N.W., Suite 249
Washington, D.C. 20001
NTPEP Committee Work Plan for
Evaluation of Corrugated Steel Drainage Pipe Manufacturers
NTPEP Designation: CMDP-15
1.
SCOPE
1.1
The National Transportation Product Evaluation Program (NTPEP) serves the member
departments of the American Association of State Highway and Transportation Officials
(AASHTO).
1.2
This NTPEP Committee Work Plan (hereafter referred to as the “work
plan”) covers the requirements, auditing and testing criteria for the
National Transportation Product Evaluation Program (NTPEP)
evaluation of CSDP (Corrugated Steel Drainage Pipe) Manufacturers.
This work plan is intended to be utilized with NTPEP document SP01,
Qualification of Highway Product Manufacturers Through the Use of
NTPEP Audits, to provide a comprehensive audit program for Corrugated
Steel Drainage Pipe.
1.3
The purpose of the program is to establish a list of manufacturing plants
that conform to the quality control and product testing requirements of
this program. AASHTO member departments can then use this information
in their quality assurance program for Manufacturer/product acceptance.
This may include utilizing this information to establish a qualified
Manufacturer list, a qualified products list, or both. By participating in
this program, the Manufacturer agrees to produce product that meets or
exceeds the requirements in the required AASHTO Specification(s) and
follow the minimum quality control provisions of their Quality Program.
1.4
NTPEP validates this program through testing the Manufacturer’s
product(s) to verify compliance with the applicable standard and auditing
the Manufacturer’s in-plant quality control facilities and procedures. The
Manufacturer agrees that NTPEP may use the test results and audit
reports along with other relevant information for review and verification
of compliance with this NTPEP program and the applicable AASHTO
Specification(s).
1.5
This work plan may involve hazardous materials, operations, and
equipment. It does not purport to address all safety problems associated
with its use. It is the responsibility of the user of this work plan to establish
the appropriate safety and health practices and determine the
applicability of regulatory limitations prior to use.
2.
Referenced Documents
2.1
AASHTO Standards:
2.2
2.3

AASHTO M36
Drains
Corrugated Steel Pipe, Metallic Coated, for Sewers and Storm

AASHTO M190
Arches
Bituminous-Coated Corrugated Metal Culvert Pipe and Pipe

AASHTO M218
Pipe
Steel Sheet, Zinc-Coated (Galvanized), for Corrugated Steel

AASHTO M245
Storm Drains
Corrugated Steel Pipe, Polymer-Precoated, for Sewers and

AASHTO M246
Steel Sheet, Metallic-Coated and Polymer-Precoated, for
Corrugated Steel Pipe

AASHTO M274
Pipe
Steel Sheet, Aluminum-Coated (Type 2), for Corrugated Steel

AASHTO M289
Steel Pipe
Aluminum-Zinc Alloy Coated Steel Sheet for Corrugated

AASHTO T65
Mass[Weight] of Coating on Iron or Steel Articles with Zinc
or Zinc-Alloy Coatings

AASHTO T213
Articles
Mass [Weight] of Coating on Aluminum-Coated Iron or Steel

AASHTO T241
Helical, Continuously Welded Seam Corrugated Steel Pipe

AASHTO T249
Helical Lock Seam Corrugated Steel Pipe
ASTM Standards:

ASTM A 760
Corrugated Steel Pipe, Metallic-Coated for Sewers and Drains

ASTM A 780
Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized
Coatings

ASTM A 796
Structural Design of Corrugated Steel Pipe, Pipe Arches, and
Arches for Storm and Sanitary Sewers and Other Buried
Applications

ASTM A 929
Steel Sheet, Metallic-Coated by the Hot-Dip Process for
Corrugated Steel Pipe
NTPEP Documents:

SP01
Qualifications of Highway Product Manufacturers Through the
Use of NTPEP Audits
3.
terminology
3.1
Auditor – A NTPEP representative to review submittals, coordinates
auditing and testing, and report audit findings.
3.2
Audits – Documented reviews of a Manufacturer’s plant and associated
test facilities by a NTPEP Auditor and any AASHTO transportation
agency co-auditor that wishes to participate.
3.3
Coatings – A protective film consisting of one or more coats, applied in a
predetermined order by prescribed methods
3.4
Independent Laboratory – An outside laboratory that performs raw
material or finished product tests for the Manufacturer. NTPEP reserves
the right to audit the independent laboratory for the tests that are being
performed for the Fabricator.
3.5
Initial Audit- The first audit conducted at a Manufacturer, which has not
had an audit conducted by the NTPEP.
3.6
Manufacturer– An individual producer of corrugated steel pipe. The
corporate name (actual location) will be included in the NTPEP program.
3.7
NTPEP (National Transportation Product Evaluation Program)- The
entity responsible for overseeing all areas of the program are being run
according to what is noted in this Standard Practice as well as assisting in
the resolution of any conflicts which may arise.
3.8
NTPEP Designated Laboratory – A laboratory qualified by NTPEP to
perform the specific tests as outlined in the Standard Practice and has on
site qualified technicians and equipment necessary to perform the tests per
ASTM and AASHTO standards.
3.9
NTPEP Follow-Up Audit- An audit of a Manufacturer’s location and associated
laboratory which are included in the program. These audits are conducted by NTPEP
and/or an AASHTO transportation agency to determine compliance with the program
requirements. These audits may be performed due to: an incomplete initial/annual audit
where nonconformance is found, reports of noncompliant product from an AASHTO
transportation agency, or any other reason deemed significant to NTPEP.
3.10
NTPEP Corrugated Steel Pipe Technical Committee – The NTPEP Technical
Committee that includes transportation agencies of the AASHTO and members of
Industry. The members are volunteers who are interested in the advancement of the
product. The Technical Committee appoints a Chairman and a Vice-Chairman.
3.11
NTPEP Split Sample Comparison Testing – Sample(s) selected from the
manufacturing line or stockyard to be tested by the Manufacturer and the
NTPEP designated laboratory. The results of both testing locations are
then compared.
3.12
QMS Desktop Audit – Complete review of a Manufacturer’s Quality
Management System (QMS) and the corresponding documentation by
NTPEP or its designee.
3.13
Quality Management System (QMS) – The documented process used by
the Manufacturer for quality control/quality assurance.
Rework – A process that brings the product into conformance with
applicable standards.
3.14
3.15
Repair – A condition where the product cannot be returned to applicable
standards; however a subsequent operation can be performed to return
the product to a condition that will meet fit, form, and function. Cosmetic
appearance typically will not meet engineering requirements.
3.16
Subcontractors – A person who or business that contracts to provide
some service or material necessary for the performance of another
contract
3.17
Suppliers
3.18
Additional terminology can be found in applicable AASHTO and ASTM
Standards.
4.
ADDITIONAL QUALITY MANAGEMENT SYSTEM (QMS)
REQUIREMENTS
The Manufacturer’s Quality Management System (QMS) written procedures must
include the following for reinforcing steel:
4.1
Handling Raw Materials for DOT Products - The QMS will include a
written procedure for documenting traceability of steel and iron materials
to comply with “Buy America” requirements. This procedure will indicate
the responsible individuals and how steel (either foreign or domestic) is
identified and traced through each manufacturing step. The “Buy
America” requirement for reinforcing steel begins with the melting
process (i.e. melting of the scrap into the finished billet/bloom) through
the finished product. In addition, the QMS will include how each product
(either foreign or domestic) not manufactured by the particular location,
is identified, tracked and documented (on the MTR) for the manufacturing
steps performed by the Manufacturer.
4.2
Labeling and Storage of Finished Product – The QMS will include a
written procedure describing how finished product is labeled, packaged
and stored. It will also include an explanation of the markings used for
the pipe, as required by the governing AASHTO/ASTM product
specification
4.3
Finished Product – As a minimum the QMS will describe the
Manufacturer’s inspection process to conduct visual inspections of the
pipe’s lock seams, rerolled ends and other workmanship items described
in AASHTO M36 during production. The procedure will require the
Manufacturer to monitor the process and finished product and perform
and record the results of the following inspections at the minimum
frequency indicated



4.4
Inspection
Workmanship (per AASHTO M36)
Lock Seam (AASHTO T249)
Others
Frequency
continuous, recorded at least once per shift
continuous, recorded at least once per shift
Quality Control Inspection–The QMS will include an example of a quality
control test report form. The QMS will reference the AASHTO, ASTM, or
in house procedures and calibrations. The QMS will describe any
Manufacturer procedure used.
Note: The Manufacturer’s procedures are subject to approval. The
Manufacturer’s test procedures which pertain to the tests providing useful
information to evaluate the product are included in this requirement.
4.4.1
The QSM will require that the Manufacturer perform and record the
results of at least the following quality control measurements and
tests, at the minimum frequency indicated on each production run of
each pipe diameter, type and machine:
Measurement and Test
Frequency

Shape
Once per shift

Wall Thickness
Once per shift

Coating Weight or Thickness
Once per shift

Inside Diameter
Once per shift

Pipe Length
Once per shift

Lock Seams
Once per shift

Dimensions, spacing and placement of rivets
Once per shift

Thickness of polymer coating
Once per shift

End Finish
Once per shift

Welded Seams
Once per shift

Annular or Helical Corrugation
Once per shift

Perforation Location and Dimensions
Once per shift
5.
ANNUAL PRODUCT CONFORMANCE TESTING
5.1
The NTPEP program requires that product samples be tested to determine
conformance with the appropriate AASHTO/ASTM Materials
Specifications.
5.2
The NTPEP Auditor, or their representative, will select samples during
each annual Manufacturer audit for testing by the Manufacturer and the
NTPEP Designated Laboratory.
5.3
Samples:
5.3.1
Corrugated Steel Drainage Pipe Samples are obtained; cut into test specimens and tested
for:
– Tensile/Yield/Elongation
– Coating Thickness
-Others?
5.3.3
The NTPEP Auditor will instruct the Manufacturer on the proper labeling of the samples.
The NTPEP Designated Laboratory test specimens will be located adjacent to the
previous (Manufacturer) test specimens. The manufacturer will send (freight paid by the
Manufacturer) the test specimens to the NTPEP Designated Laboratory for testing.
5.3
Retest Samples:
5.4.1
Additional material will be obtained from the same heat/lot and kept at the
Manufacturer’s location in the event the Manufacturer or NTPEP Designated Laboratory
tested specimens fail or are invalid. This material will be tested as directed by NTPEP
and may be discarded only after being notified that the audit is complete.
6.
NTPEP On-Site Audits
6.1
Quality Control Testing Evaluation - Each Manufacturer will be asked to
demonstrate the quality control tests they perform as stated in their QMS.
While performing each test, the most current AASHTO or ASTM test
methods will be referenced. The equipment used for each test will be
examined and applicable records will be reviewed. The auditor will also
select three random weeks (within the previous 12 months) of test reports
for resin and pipe produced in accordance with AASHTO M294 and M252
to review.
6.2
Split Samples for Comparison Testing – The auditor(s) will select samples
of CSDP pipe available at the time of the audit for testing in accordance
with SP01, Section 8, “Annual Product Conformance Testing”. The
auditor(s) may select pipe from the production line or from the yard in
order to comply with SP01. All sampling and testing will be in
accordance with the appropriate AASHTO/ASTM specifications. The split
samples will be for testing at the Manufacturer’s testing facility and the
NTPEP’s designated laboratory. Manufacturer samples tested during the
audit will be observed by the auditor(s).
Note: - If major deficiencies are noted during the on-site audit, a follow-up audit will be
required to be completed.
7.
ANNUAL PRODUCT CONFORMANCE TESTING
7.1
The NTPEP program requires that pipe and resin samples be tested to
determine conformance with the appropriate AASHTO/ASTM Materials
Specifications.
7.1.1
The NTPEP Auditor will select three sets of samples (Ref.: SP01,
Section 8, “Annual Product Conformance Testing”) from the yard
during each annual Manufacturer audit (one set to be tested by the
Manufacturer, one set to be tested by the NTPEP designated
laboratory, and one for retesting as required in Section 6.6). All
samples will be from the same lot of material.
7.2
Manufacturer Samples:
7.2.1
Products - Once initial product evaluation has been established, a
NTPEP Auditor will sample pipe during each annual plant audit. At a
minimum, all pipe sizes will be sampled and tested in accordance with
SP01, Section 8, “Annual Product Conformance Testing” with at least
1 pipe sample being taken during each plant audit. The NTPEP or
Transportation Agency Auditor will select and label the samples to be
tested.
7.2.2
If requested, a Transportation Agency testing facility can be included
in the split sampling process.
7.2.3
The Manufacturer will report the results from their testing using the
standard format provided by NTPEP within 15 days of their on-site
audit being completed.
7.3
NTPEP Designated Laboratory Samples:
7.3.1
The NTPEP Auditor will instruct the Manufacturer on the proper
labeling of the NTPEP designated laboratory samples. These samples
will be located adjacent to the previous (Manufacturer) samples and
from the same lot(s) and in the same quantities as obtained in SP01,
Section 8.3. “Manufacturer Samples”. The Manufacturer will send
(freight paid by the Manufacturer) the companion samples to the
NTPEP designated laboratory for testing.
7.3.2
Once the NTPEP Project Engineer sends the Manufacturer the results
from the NTPEP designated laboratory testing, the Manufacturer has
the opportunity to provide an explanation of any significant
differences between the NTPEP designated laboratory and
Manufacturer sample test results, including any corrective actions
found necessary in the manufacturing process or testing procedures
within 15 days of receiving the test results.
7.4
Retest Samples:
7.4.1
Additional material (one additional set of samples) will be obtained
from the same heat/lot and kept at the Manufacturer’s location in the
event the NTPEP designated laboratory sample fails. The auditor will
sign the retained sample. This sample will be tested as directed by
NTPEP.
7.4.2
Testing for product conformance performed by an independent
laboratory will be witnessed as part of the audit. All conformance
testing will be in accordance with this Section.
8.
If during the testing portion of the audit or during NTPEP designated laboratory testing at
least one tested sample fails to meet specification requirements or when the Manufacturer
is found during an audit to have neglected one or more aspects of the governing QMS
during manufacturing, the nonconformance will be addressed as outlined in SP01,
Section 10, “Resolution of Testing /Audit Nonconformances and Disputes”.
9.
keywords
NTPEP; Corrugated Steel Drainage Pipe; Manufacturer