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