Audit Report - NTPEP Audit Documents/MFG... · Wire (ASTM A1064) Welded Wire Reinforcement (ASTM A1064) Introduction . The National Transportation Product Evaluation Program (NTPEP)

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Contact Welded Wire/Wire Reinforcement Information

Audit Report

PLANT: Name, City, ST NTPEP Number: WWR-2019-01-0?? Auditor: Ed Hughes

REV 2/6/2019 © 2019 by the American Association of State Highway and Transportation Officials.

All rights reserved. Duplication is a violation of applicable law.

Page 1 of 35

Facility: Name:

Physical Address:

Mailing Address: Same As Above (if different from above)

Primary Contact

Name: Title:

Telephone: Cell:

Email: Management

QC Manager: Plant Manager:

Auditor Contact

Name: Telephone:

Address:

Email: Other Attendee Contact

Name: Telephone:

Address:

Email: DOT Official Contact

Name: Title / Organization:

Telephone: Address:

Email:

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Audit Welded Wire/Wire Reinforcement Summary

Audit Report




Page 2 of 35

Evaluation Program for Manufacturers of

Welded Wire Reinforcement - WWR

Summary Report For

PLANT - City, State

Wire (ASTM A1064) Welded Wire Reinforcement (ASTM A1064)

Introduction The National Transportation Product Evaluation Program (NTPEP) is program under the sponsorship of the American Association of State Highway and Transportation Officials (AASHTO). The NTPEP Evaluation Program for Manufacturers of Reinforcing Steel for Concrete (Welded Wire Reinforcement-WWR) provides a comprehensive review of the production and testing of WWR and of the quality management system. The evaluation starts with a desktop review of the manufacturing facility’s quality manual and concludes with an on-site review of the facility’s processes and their quality management system documentation. An on-site audit of the PLANT facility, located in City, State, was conducted by Lead Auditor NAME (AASHTO) on DAY, MONTH, DATE, 2016. NAME was accompanied by Name (Auditor). PLANT was represented by NAME (Position). The STATE DOT was represented by NAME (Position). Deviations from program requirements noted in red will require a corrective action report along with supporting evidence for the corrective action to obtain compliance. Deviations from program requirements noted in italics will not require a corrective action report and supporting evidence; however, they will be reevaluated during the next year’s audit and may be subject to further investigation by state transportation agencies. These deviations are also known as Observations. Testing Personnel (Section 1)

• Please refer to Section 1 of the report for the list the plant personnel approved to perform quality control tests.

Standard Specifications (Section 3)

• Standards are maintained by the Quality Control Manager in a binder. • Zinc coated material is not produced by this facility, thus ASTM A641 is not utilized.

NTPEP


Audit Report




Page 3 of 35

Size and Type of Material Produced by the Manufacturer (Section 4) • This manufacturing facility is capable of producing standard sheets and rolls of mesh

using smooth or deformed wire sizes W1.4/D2 through W/D31 as engineered structural fabric in various widths, lengths and wire spacings. Wire Spacing can range from: 2”x 2” to VAR” by VAR”.

• This manufacturing facility is capable of producing low and high carbon wire in diameters of 0.14 to 0.3 inches.

Production Information (Section 5)

• Rod arrives from several domestic and foreign sources. Domestic rod is furnished with origin mill test reports/certifications and tags identifying each coil of rod. Rod is stored by size, grade, and vendor. Information on the coil tags (manufacturer, heat number, coil number, etc.) is transferred to the Wire Rolling Report at time of wire manufacturing.

• Foreign rod arrives with tags and chemical certifications. This steel is tracked like Domestic material, however the job documentation will state what rod (domestic “DR” or foreign “IR”) is to be used for the job. Foreign wire has a “RED” tag for identification, while domestic uses a “BLACK” tag. Foreign rod is stored like domestic by size, grade and vendor. Foreign rod is only used for standard mesh [non-ASTM] products) and the Work Order for the production of wire indicates whether foreign or domestic rod should be used to produce wire for the order. This rod is rolled into the desired wire and sent to the straight & cut operation for eventual use in non-ASTM product.

• All wire is produced internally by the manufacturing facility, from the rod. There are 10 machines from which plain or deformed wire can be produced. This manufacturing facility utilizes 3 lines of deformations.

o one (1) wire rolling line, and o nine (9) wire drawing lines

• Selected heats are drawn/rolled into wire and then processed as: o straightened and cut (straight & cut) bundles, o spools, or o carriers.

• Each spool, carrier or straight & cut bundle of domestic wire manufactured from domestic rod coil is given a unique “WIP spool/WIP Bundle number” which is later transferred to the Production Report for the WWR product being produced. Each WIP tag shows the information from the Job (Work Order Number) and this applies to both longitudinal and transverse wires. OR Bundles of straight & cut wire are identified with a tag listing piece count, description and Job Number. Spools and carriers use a unique spool/carrier number along with a tag listing the Job Number and heat number(s). This applies to both longitudinal and transverse wires.

• This manufacturing facility has seven (7) welded wire mesh production lines. One line utilizes straight & cut wire, two lines use a combination of spool and straight & cut wire and four lines use spool or carrier wire. OR This manufacturing facility has one domestic mesh production line for structural fabric and two foreign mesh production lines for standard mesh (one for rolls and one for mats). The domestic structural fabric line utilizes straight & cut wire and the other two foreign lines use spools, carriers, and

NTPEP


Audit Report




Page 4 of 35

straight & cut wire to produce WWR. The structural mesh line is a single throw line. • The Production Report for the WWR product being produced lists the WIP spool/WIP

Bundle number Job (Work Order Number) lists the Job Number, spool or carrier numbers, and heat numbers which are traceable back to the rod that was used.

• Finished product is stored in the yard according to product style (“style” referring to the spacing, wire size/nominal diameter, steel area, width & length, and overhangs).

• Finished product tags contain the following information: company and location, Customer, date of manufacture, Customer PO number, item description (spacings, wire size, panel size), ASTM specification, Heat numbers, and Domestic Clause. OR company and location, date of manufacture, bundle/roll number (out of total bundles/rolls), job number, item number (which states the origin of the rod used (domestic “DR” or foreign “IR”), product description, lot number, number of pieces in bundle, unit weight (at nominal), area of steel, ASTM specification, piece count and special instructions from sales. A “Buy America” statement is printed only on domestic finished product tags.

• The ability to ship material is controlled by the Inside/Outside Conversion Engineer. All orders can only be shipped with the completed MTR’s.

• The manufacturing area of the production facility was in operation during the on-site audit. Wire

• Rod arrives from several domestic and foreign sources. Domestic rod is furnished with origin mill test reports/certifications and tags identifying each coil of rod. Rod is stored by size, grade, and vendor. Information on the coil tags (manufacturer, heat number, coil number, etc.) is transferred to a WIP report in Oracle Database.

• Foreign rod has tags identifying origin, size and grade. Foreign rod is stored like domestic by size, grade and vendor. Foreign rod is only used for commercial products. The Work Order for the production of wire indicates whether foreign or domestic rod can be used to produce wire for the order.

• All wire is produced internally by the manufacturing facility from rod. There are six wire drawing lines from which plain or deformed wire can be produced. The smooth drawn wire is rolled onto bobbins and the deformed wire is rolled onto coils.

• This manufacturing facility utilizes 3 or 4 lines of deformations. • Each bobbin or coil manufactured from domestic rod is given a unique “WIP number”.

Final product information is transferred from the WIP number to the Finished Product Tag.

• Finished product tags contain the following information: company and location, Customer, date of manufacture, Customer PO number, item description (wire size, diameter, grade), ASTM specification, domestic code. The manufacturing area of the production facility was in operation during the on-site audit.

Physical Analysis (Section 6)

NTPEP


Audit Report




Page 5 of 35

WWR • Reduction in Area, Roundness, and Wire Diameter (for plain wire), are performed after

the rolling/drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR.

• Unit Weight and Deformations are performed after the rolling/drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR.

• Spacing and product sizing are handled by the Plant Foreman and the Plant Mesh Production Line Operators and audited by QC.

• This manufacturing facility performs the Bend test by hand using a horizontal testing rig with verified pins for wire sizes 1.4 through 7 and a hydraulic ram for the remaining sizes. This test is performed after the drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR.

• This manufacturing facility performs Yield Strength (A1064) on wire samples when required by the specification or customer and demonstrated this testing for the audit (refer to Section 11: Attachments).

• Samples are taken every lot at start-up and according to the Plant’s internal specs by production line operators and tested by QC. All testing supporting the test report are from finished wire mesh samples.

• Tensile and Bend testing are performed on the wire after it is produced. Tensile, Bend, and Weld Shear testing are performed on finished WWR product.

Wire • Reduction in Area (for plain wire) is performed after drawing by QC. • Roundness (for plain wire) is performed after the drawing stage by QC. • Wire Diameter (for plain wire) is performed after the drawing stage by QC. • Unit Weight is performed after the drawing stage by QC. • A dial indicator is used for deformation measurements. • Deformations evaluations are performed after the drawing stage by QC. • This manufacturing facility performs the Bend test by gripping the wire in a torsion

machine and wrapping the wire upon itself. The wire is twisted upon itself during this test, so no pin is required. This appears to be a more severe test than required by the standard.

• Yield strength is only measured when required by the customer or by product specification.

• Samples of wire are taken every lot at start-up and every 3 tons and tested by QC. All testing supporting the test report are from finished product samples.

Quality Management System (QMS) Review (Section 7) • Complete training and competency evaluation records were presented for all technicians

during the on-site audit. • The most recent internal audit/management review was completed on January 19 & 26,

2016 and the. Copies of the review/audit summaries was presented to the auditor and reviewed.

NTPEP


Audit Report




Page 6 of 35

• An internal database is utilized for data entry of mesh product mechanical testing. All quality records are permanent records.

Equipment Calibration, Standardization & Checking (Section 8)

• Calibration records for all testing equipment were current and complete. Records of Specimens Tested During Audit (Section 9)

• The following physical tests were performed satisfactorily by NAME and the equipment for each test was in good condition:

o Diameter – For Plain Wire Specimens (ASTM A1064) o Unit Weight – For Deformed Wire Specimens (ASTM A1064) o Bend (ASTM A1064) o Yield Strength (ASTM A1064)

Yield strength on WWR is performed at customers request o Tensile Strength of Transverse and Longitudinal Wires (ASTM A1064) o Reduction in Area – For Plain Wire Specimens (ASTM A1064) o Deformations – For Deformed Wire Specimens (ASTM A1064)

Wire deformations are “Negative Deformations”

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Table of Welded Wire/Wire Reinforcement Contents

Audit Report




Page 7 of 35

Table of Contents

Summary Report For ........................................................................................................... 2

Section 1: Testing Personnel ............................................................................................ 8

Section 2: Welded Wire Reinforcement Identification.................................................. 9

Section 3: Standard Specifications ................................................................................ 12

Section 4: Size and Type of Material Produced by the Manufacturing Facility ....... 13

Section 5: Production Information ................................................................................ 14

Section 6: Physical Analysis ........................................................................................... 18

Section 7: Quality Management System (QMS) Review ............................................. 27

Section 8: Equipment Calibration & Standardization/Verification .......................... 29

Section 9: Record of Testing Performed During the Audit......................................... 30

Section 10: Report Signature ......................................................................................... 32

Section 11: Attachments ................................................................................................. 33

Meeting Attendance Sheet: ............................................................................................ 33

Example of Yield Test Report: ...................................................................................... 34

Mill Test Reports for Samples Tested During Audit:.................................................. 35

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 1 Welded Wire/Wire Reinforcement Personnel

Audit Report




Page 8 of 35

Section 1: Testing Personnel

Title/Responsibility Name

Phys

ical

T

estin

g QC Sampling QC Testing

QC Supervisor Comments: None

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 2 Welded Wire/Wire Reinforcement Markings

Audit Report




Page 9 of 35

Section 2: Welded Wire Reinforcement Identification Product:

Example of rolled Wire

Example of sheet WWR

NTPEP


Audit Report




Page 10 of 35

Tags:

Example of Material

Tag for rolled WWR

Example of Material

Tag for sheet WWR

NTPEP


Audit Report




Page 11 of 35

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 3 Welded Wire/Wire Reinforcement Specifications

Audit Report




Page 12 of 35

Section 3: Standard Specifications

Indicate if current versions of the Primary ASTM standards are available and the version of the Secondary specifications presented by the manufacturing facility.

Primary ASTM Standard Specification for Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete A1064-18

Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire A641 - 09a(2014)

Standard Test Methods and Definitions for Mechanical Testing of Steel Products A370-18

Secondary (current version not required) Current Version Version Presented Standard Practices for Force Verification of Testing Machines E4-16 E4-16

Standard Practices for the Verification and Classification of Extensometer Systems E83-10a E83-16

NTPEP Current Version Version Presented Qualification of Highway Product Manufacturers Through the Use of NTPEP Audits [SP01](2018) [SP01](2018)

Evaluation of Reinforcing Steel Manufacturers [RS](2018) [RS](2018)

Comments:

Standards are maintained by the Quality Control Manager in a binder

Zinc coated material is not produced by this facility, thus ASTM A641 is not utilized.

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 4 Welded Wire/Wire Reinforcement Size & Type

Produced

Audit Report




Page 13 of 35

Section 4: Size and Type of Material Produced by the Manufacturing Facility

A) Wire and WWR Production Type

Wire:

Type: Plain Deformed

WWR:

Type: Plain Deformed

Style: Rolls Sheets Other

If other, please list: Deformations are “Negative Deformations” B) Typical Material Produced

Product Information: WWR This manufacturing facility is capable of producing standard sheets and rolls of mesh using smooth or deformed wire sizes W1.4/D2 through W/D31 as engineered structural fabric in various widths, lengths and wire spacings. Wire Spacing can range from: 2”x 2” to VAR” by VAR”. Wire: This manufacturing facility is capable of producing low and high carbon wire in diameters of 0.14 to 0.3 inches.

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 5 Welded Wire/Wire Reinforcement Product

Information

Audit Report




Page 14 of 35

Section 5: Production Information

YES NO A) Facility Information

1) Does the manufacturing facility own facilities in other locations?

How many are NTPEP audited locations: B) Rod Information

Rod Documentation Process:

1) How does the manufacturing Facility maintain documentation for the rod used in the production of WWR?

(a) Does the manufacturing facility retain copies of all rod certifications on file?

(b) How long are rod certifications retained? Indefinitely

2) How is traceability maintained on rod after the Manufacturing Facility receives them?

Describe:

Rod arrives from several domestic and foreign sources. Domestic rod is furnished with origin mill test reports/certifications and tags identifying each coil of rod. Rod is stored by size, grade, and vendor. Information on the coil tags (manufacturer, heat number, coil number, etc.) is transferred to the Wire Rolling Report at time of wire manufacturing.

Verification of a randomly selected Domestic Rod Certification (Does the rod certificate show):

(a) The chemical test results?

(b) The plant that produce the rod?

(c) A statement indicating the rod was melted and manufactured in the U.S.A?

(d) Any physical test results?

Foreign Rod Usage and Traceability:

1) Does the manufacturing facility have foreign rod in its inventory?

NTPEP


Information

Audit Report




Page 15 of 35

If yes, how is foreign steel identified throughout the WWR manufacturing process?

Foreign rod has tags identifying origin, size and grade and the coils are painted orange. Foreign rod is stored like domestic by size, grade and vendor. Foreign rod is only used for standard mesh [non-ASTM] products) and the Work Order for the production of wire indicates whether foreign or domestic rod should be used to produce wire for the order. This rod is rolled into the desired wire and sent to the straight & cut operation for eventual use in non-ASTM product.

Comments: None

C) Wire Manufacturing Information General Wire Information:

1) Indicate the process(es) used to produce wire.

Drawn Rolled Both

2) Indicate the number of lines of deformations for deformed wire: 2

3) Describe each of the wire production lines:

All wire is produced internally by the manufacturing facility, from the rod. There are two wire rolling lines from which plain or deformed wire can be produced.

o One roller only wire production line (producing spools and carriers)

o One roll-straighten-cut wire production line

Traceability of domestic wire manufacture:

1) How does the manufacturing facility maintain identity of the wire throughout the wire manufacturing process?

Each bobbin, coil, spool, carrier or straight & cut bundle of domestic wire manufactured from domestic rod coil is given a unique “WIP spool/WIP Bundle number” which is later transferred to the Production Report for the WWR product being produced. Each WIP tag shows the information from the Job (Work Order Number) and this applies to both longitudinal and transverse wires.

NTPEP


Information

Audit Report




Page 16 of 35

D) Welded Wire Reinforcement (WWR) Manufacturing Information General WWR/Wire Information:

1) Wire Feed: Spools Straight Cut & Bundles Carriers

2) Transverse Wire Single Throw Double Throw Bobbins

3) Describe the WWR/Wire production lines:

WWR This manufacturing facility has one domestic mesh production line for structural fabric and two foreign mesh production lines for standard mesh (one for rolls and one for mats). The domestic structural fabric line utilizes straight & cut wire and the other two foreign lines use spools, carriers, and straight & cut wire to produce WWR. The structural mesh line is a single throw line. Wire Each bobbin or coil manufactured from domestic rod is given a unique “WIP number”. Final product information is transferred from the WIP number to the Finished Product Tag

Traceability of domestic WWR/Wire fabrication:

1) How does the manufacturing facility maintain identity of the WWR/Wire during the fabrication process?

The Production Report for the WWR product being produced lists the WIP spool/WIP Bundle number Job (Work Order Number) which are traceable back to the rod that was used. Finished product is stored in the yard according to product style (“style” referring to the spacing, wire size/nominal diameter, steel area, width & length, and overhangs).

Comments: None

NTPEP


Information

Audit Report




Page 17 of 35

YES NO

E) General: Product Identification/Documentation 1) The tag affixed to each roll/bundle of WWR/Wire includes the following information:

Finished product tags contain the following information: company and location, Customer, date of manufacture, Customer PO number, item description (spacings, wire size, panel size), ASTM specification, Heat numbers, and Domestic Clause.

2) What does the manufacturing facility’s product documentation include? (Check all that apply)

Certifications Invoices Process Worksheets

Other Describe:

3) Does the manufacturing facility keep copies of all product documentation on file?

4) How long is product documentation retained?

5) Does each group of Sheets/Rolls in a bundle have a tag affixed?

Other method Describe: Comments: The manufacturing area of the production facility was in operation

during the on-site audit.

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 6 Welded Wire/Wire Reinforcement Physical Analysis

Audit Report




Page 18 of 35

Section 6: Physical Analysis • Reduction in Area

Reduction in Area – Plain Wire Specimens Yes No A) Apparatus (ASTM A1064)

1) Caliper or other measuring device, readable and accurate to at least 0.001in.? Comments: None

B) Procedure (ASTM A1064) 1) Following the tension test, is the reduced diameter of the test specimen determined

using a micrometer or caliper and reported?

2) Is the reduction of area determined from the difference between the test specimens’ reduced area and the original cross section area expressed as a percentage of the original cross section area and reported to the nearest percent?

Comments:

Reduction in Area (for plain wire) is performed after the rolling/drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR.

• Wire Roundness

Roundness – Plain Wire Specimens Yes No A) Apparatus (ASTM A1064)


B) Procedure (ASTM A1064) 1) Are the maximum/minimum diameters of the test specimen determined to the nearest

0.001 in. using a micrometer or caliper and reported?

Comments:

Roundness (for plain wire) is performed after the rolling/drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR.

• Wire Diameter

Diameter – For Plain Wire Specimens Yes No A) Apparatus (ASTM A1064)


B) Procedure (ASTM A1064) 1) The diameter of the test specimen determined to the nearest 0.001 in. using a

micrometer or caliper and reported?

NTPEP


Audit Report




Page 19 of 35

Comments:

Wire Diameter (for plain wire) is performed after the rolling/drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR.

• Unit Weight Unit Weight – Deformed Wire Specimens Yes No

A) Apparatus (ASTM A1064) 1) Balance or scale with sufficient readability? 2) Wire sample of sufficient length for accurate calculation? Comments: None

B) Procedure (ASTM A1064) 1) Where is the specimen obtained that is used for

Unit Weight calculation? After rolling/drawing of the wire from rod 2) Mass per unit length determined and reported to the nearest 0.001 lb/ft? 3) Unit Weight verified within +6% of nominal weight?

Comments: Unit Weight is performed after the rolling/drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR.

• Deformation Measurement

Deformation Measurement – Deformed Wire Specimens Yes No A) Apparatus

1) Tape measure or other measuring device? 2) Caliper or other depth measuring device? Comments: None

B) Procedure • Determination of Average Spacing

1) Average spacing determined by dividing a measured length (10 inches min.) of the wire specimen by the number of individual deformations in any one row of deformations?

2) Spacing measurements not made over area containing any identification markings? • Determination of Average Height

3) Height determined by averaging at least two typical deformations from each line of deformations?

4) Height determinations based on measurements at the center of indentions or raised ribs?

5) Is the minimum average height of the center of typical deformations based on the nominal wire diameters?

Comments:

Deformations evaluations are performed after the rolling/drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR.

NTPEP


Audit Report




Page 20 of 35

NTPEP


Audit Report




Page 21 of 35

• WWR Dimensions Plain or Deformed WWR Yes No

A) Apparatus (ASTM A1064) 1) Steel tape or rule readable and accurate to 0.1 in. or less? Comments: None

B) Procedure (ASTM A1064) WWR Width: 1) Center to center distance between the outside longitudinal wires determined and

reported?

WWR Length: 2) Overall length of the longitudinal wires in flat sheets determined and reported? Transverse Wire Overhang: 3) Length of the transverse wire that extends beyond the centerline of each longitudinal

edge wire determined and reported?

Wire Spacing: 4) Center to center distance between wires in the WWR mat determined and reported?

Comments: Spacing and product sizing are handled by the Plant Foreman and the Plant Mesh Production Line Operators and audited by QC.

NTPEP


Audit Report




Page 22 of 35

• Bend Test Apparatus Bend Test – Plain & Deformed Wire and WWR Yes No

A) Apparatus (ASTM A1064) 1) Is a bend test jig of a suitable design available and operational?

2) How is the force applied to the bend test jig? Describe: By hand using a horizontal testing rig with verified pins.

3) Will the bend test jig bend a wire through 180° (for smooth) or 90° (for deformed) after rebound?

4) Are bending pins of required sizes available and in good condition?

Comments: This test is performed after the drawing stage by Plant Mesh Production Line Operators and verified by QC prior to use in WWR

• Bend Test Procedure

Bend Test Yes No B) Procedure (ASTM A1064)

1) Are bend test specimens obtained from the finished wire? 2) Is one bend test made, prior to WWR fabrication, from each 10 tons or less of each

size of wire or fraction thereof in a lot, or a total of seven samples, whichever is less? (A lot shall consist of all coils of a single size produced at the same time)

3) Are these coiled test specimens straightened before test? 4) Are test specimens obtained by cutting from the finished welded wire reinforcement

a full width section, of sufficient length to perform the bend test?

5) Is one bend test made for each 75,000 ft2 of WWR or remaining fraction thereof? 6) Are test specimens taken from between the welds? 7) For plain wire test specimens, is the proper pin diameter used?

For wire W7 [MW45] and smaller: 1d (d= the nominal wire diameter) For wire larger than W7 [MW45] : 2d (d= the nominal wire diameter)

8) Are plain wire test specimens bent at room temperature (50-100 degrees Fahrenheit) through 180°?

9) For deformed wire test specimens, is the proper pin diameter used? For wire D6 [MD39] and smaller: 2d (d= the nominal wire diameter) For wire larger than D6 [MD39] : 4d (d= the nominal wire diameter)

10) Are deformed wire test specimens bent at room temperature (50-100 degrees Fahrenheit) through 90°?

11) Is the test specimen wrapped closely around the pin? 12) Is the test specimen inspected for cracking on the outside of the bent portion? 13) If a test specimen fails the bend test is the material accepted only if two additional

test specimens taken from the same sheet or roll pass the bend test?

Comments: None

NTPEP


Audit Report




Page 23 of 35

• Tension Test Apparatus Tension Test – Plain & Deformed Wire and WWR Yes No

A) Apparatus (ASTM A1064, A370) Loading System – ASTM A 370: 1) Is the Load Testing Machine maintained in good operating condition? 2) Are specimens loaded axially? 3) Is the Load Testing Machine of sufficient capacity to test all wire (sizes) produced by

plant?

Gripping Devices (Wedge Type) – ASTM A 370: 1) Liners/shims available in pairs and in various thicknesses? 2) Liners/shims have flat, parallel faces? 3) Are the faces of the grips serrated and in good physical condition? 4) Grips aligned to hold specimen at approximately the centerline of head of testing

machine?

Yield Strength Determination Equipment (ASTM A370): See Comments Below Does the manufacturing facility perform the Yield test? If “YES”, check which method is

used:

Drop of Beam or Halt of Gauge - Note 1 – The equipment required is a loading machine with measurements accurate to 1% of the applied load?

Auto-Graphic - Able to accurately display “bend of knee”? Total Extension Under Load Method:

a. Extensometer Class B-1? b. Resolution of 0.00005 in. /in.?

Offset Method (0.2% Offset): c. Extensometer Class B-1? d. Resolution of 0.00005 in. /in.? Reduction of Area Equipment (ASTM A370): 1) A device for measuring the mean diameter of the reduced specimen to the same

accuracy as the original dimensions?

Comments:

This manufacturing facility performs Yield Strength (A1064) on wire samples when required by the specification or customer and demonstrated this testing for the audit (refer to Section 11: Attachments).

NTPEP


Audit Report




Page 24 of 35

• Tension Test Procedure Tension Test – Plain & Deformed Wire and WWR Yes No

B) Procedure (ASTM A1064, A370) Number of Tests: 1) For WWR, is one tension test made for each 75,000 ft2 or remaining fraction thereof? 2) Is one tension and one bend test made from each 10 tons or less of each size of wire or

fraction thereof in a lot, or a total of seven samples, whichever is less? (A lot shall consist of all coils of a single size produced at the same time)

Test Specimens: 1) Are test specimens obtained by cutting wire from either across or between the welds of

finished welded wire reinforcement?

2) Are no less than 50% of test specimens taken from across the welds? 3) For test specimens taken from across the welds, is the welded intersection located

approximately at the center of the wire specimen, and, does the wire forming the welded intersection extend approximately 1 inch beyond each side of the intersection.

Test Procedure: 1) Is the test specimen full size (not reduced diameter)? 2) Total test specimen length at least: the gage length, + two wire diameters between

each gage mark and the grips, + the length of material required to fill the grips completely with some protruding beyond the grips?

3) Are grips fully supported within the head of the testing machine and shimmed so that no more than ½ in. of the grip protrudes from the head of the machine?

4) Is the specimen placed approximately at the centerline of the head of the testing machine?

5) Is a convenient rate of loading used up to ½ the specified yield strength or ¼ the specified tensile strength, whichever is smaller?

6) Rate of loading between 10,000 psi/min. and 100,000 psi/min. to the yield point? 7) Tensile strength reported to the nearest psi?

Comments: Samples are taken every lot at start-up and according to the Plant’s internal specs by production line operators and tested by QC. All testing supporting the test report are from finished wire mesh samples.

NTPEP


Audit Report




Page 25 of 35

• Weld Shear Apparatus Weld Shear Test – For WWR Yes No

A) Apparatus (ASTM A1064, A370) Support and Gripping Devices (Wedge Type) – ASTM A 370: 1) Upper platen fitted with a ball and socket or similar self-aligning arrangement for

supporting the weld tester?

2) Liners for the lower jaws; available in pairs and in various thicknesses? 3) Liners have flat, parallel faces? 4) Are the faces of the grips serrated and in good physical condition? 5) Grips aligned to hold specimen at approximately the centerline of head of testing

machine?

Weld Shear Tester: 1) Is the weld Tester similar to the device shown in Figure 1, ASTM A1064

2) Is the weld tester hung in a ball and socket, or similar self-aligning arrangement at the center of the test machine?

3) Does the weld tester use an anvil that fully supports the horizontal wire of the test

specimen and allows the vertical wire of the test specimen to move freely in the vertical direction?

Comments: None

NTPEP


Audit Report




Page 26 of 35

• Weld Shear Procedure Weld Shear Test – For WWR Yes No

B) Procedure (ASTM A1064, A370) Test Samples and Test Specimens: 1) Is a sample of WWR obtained from each 300,000 ft2 [28,000 m2] of WWR by cutting

a full width section from the finished WWR of sufficient length to perform the required testing?

2) Are at least 4 test specimens selected at random from each sample of WWR for weld shear strength testing?

3) When WWR is manufactured with different wire sizes, is the larger wire selected as the “vertical wire” of each test specimen?

4) Does the horizontal wire of each test specimen extend approximately 1 in. on each side of the vertical wire?

5) Is the vertical wire of each test specimen of sufficient length below the horizontal wire so as to be adequately engaged by the grips of the testing machine?

6) Is the vertical wire of each test specimen of sufficient length above the horizontal wire so that the end of the specimen is above the center line of the upper bearing of the weld tester?

Testing: 1) Is the test specimen inserted through the notch in the anvil using the smallest notch

available in which the vertical wire fits loosely?

2) Is the vertical wire of the test specimen in contact with the surface of the free rotating rollers on the weld tester?

3) Is the horizontal wire of the test specimen supported by the anvil on each side of the slot?

4) Is the test specimen stressed in an axis close to the center line of the vertical wire? 5) Is the horizontal wire held closely to the vertical wire so as to prevent rotation of the

horizontal wire?

6) Is a load applied to the test specimen at a rate of stressing not exceeding 100 ksi/min? Calculations and Reporting: 1) Is the weld shear strength of each test specimen reported to the nearest lbf? 2) Is the average weld shear strength determined from the weld shear strength of the 4

test specimens and reported to the nearest lbf?

Rejection and Retest: 1) If the minimum weld shear strength requirement is not met, are four additional test

specimens taken from four different sheets or rolls and tested?

2) Is the material rejected if the average of all eight weld shear tests performed does not meet the requirement?

Comments: None

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 7 Welded Wire/Wire Reinforcement QMS Requirements

Audit Report




Page 27 of 35

Section 7: Quality Management System (QMS) Review

Yes No A) Training

1) Does the manufacturing facility maintain records to ensure that the facility’s personnel are trained to perform physical tests?

2) Do the records: a. Indicate which position(s) or employee(s) are responsible for the training

program and maintenance of records?

b. List the date(s) of training? c. List associated specifications? Comments: None

B) Competency Evaluations 1) Does the manufacturing facility perform competency checks to evaluate staff

competency on at least an annual basis?

2) Do the records: a. Indicate the frequency of evaluations? b. Indicate which position(s) or employee(s) are responsible for the training

program and maintenance of records?

c. List associated specifications? Comments: None

Yes No C) Internal Audits

1) Was a current internal audit presented for review? Comments: The most recent internal audit was completed on Month, Day, 2016 and

reviewed by the Auditor. D) Management Reviews

1) Was a current management review presented for review? Comments: The most recent management review was completed on Month, Day, 2016 and

reviewed by the Auditor.

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 7 Welded Wire/Wire Reinforcement QMS Requirements

Audit Report




Page 28 of 35

E) Retention of Test Results

1) How does the Manufacturer store quality control test information?

F) Review of a Recent Resolution of Non-Conforming Product or Test Results

Yes No

1) Does the manufacturing facility document each instance for resolving non-conforming product or test results?

2) Does the documentation clearly identify the deficiencies? 3) Does the documentation require that product produced subsequent to the deficiency

will be quarantined pending an investigation of the failure?

4) Does the investigation include: a) Obtaining and testing check samples? b) If check sample meets requirements, reasons for original failure documented? c) After reasons are documented, is the quarantined material released? d) If check sample fails requirements, corrective action taken?

G) Review of Previous Corrective Actions N/A Have all deviations noted in the last NTPEP report been corrected Yes No

Section Deviation and Corrective Action Response

Comments: None NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 8 Welded Wire/Wire Reinforcement Equipment Records

Audit Report




Page 29 of 35

Section 8: Equipment Calibration & Standardization/Verification

QC Testing Equipment

ITEM Frequency – SP01

PER

FORM

ING

EN

TITY

CA

LIBR

ATI

ON

VER

IFIC

ATI

ON

STA

ND

AR

DIZ

E

COMMENTS

OA IN Universal Testing Machine

• calibrate every 12 Mos. • 1% accuracy A-D695

N/A N/A

Extensometer • calibrate every 12 Mos. • 1% accuracy A-D695

N/A N/A

Balances and Scales • verify prior to use N/A N/A

Calipers and Micrometers • verify prior to use N/A N/A

Bending Pins • verify every 12 Mos. N/A N/A

Standard Weights, Shims, Rods

• verify every 36 Mos. N/A N/A

Comments:

OA - denotes performed by an outside agency IN – denotes performed internally

All equipment calibration/verification records were current, well organized and contained the required NTPEP Work Plan details.

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 9 Welded Wire/Wire Reinforcement Audit Testing

Audit Report




Page 30 of 35

Section 9: Record of Testing Performed During the Audit • WWR Sampled and Tested During the Audit This is an example copy from the comparison report.

Wire Sampled and Tested During the Audit This is an example copy from the comparison report.

CORRECTIVE ACTION:

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 9 Welded Wire/Wire Reinforcement Audit Testing

Audit Report




Page 31 of 35

Yield Demonstration

Sample Yield Report attached to this report (please refer to Section 11: Attachments)

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 10 Evaluation of Welded Wire/Wire Reinforcement Report Signature

Audit Report




Page 32 of 35

Section 10: Report Signature

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

NTPEP Auditor Name:

Signature:

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 11 Welded Wire/Wire Reinforcement Miscellaneous

Documentation

Audit Report




Page 33 of 35

Section 11: Attachments Meeting Attendance Sheet:

NTPEP


Documentation

Audit Report




Page 34 of 35

Example of Yield Test Report:

NTPEP


Documentation

Audit Report




Page 35 of 35

Mill Test Reports for Samples Tested During Audit:

NTPEP