Evaluation Program for Geosynthetic Reinforcement

AASHTO’s National Transportation Product Evaluation Program (NTPEP)
Audit Report for Geosynthetic Reinforcement
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:
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:

Page 14 of 16

Auditor Name:
Audit Report Number: ______

REV 30– 2/11

AASHTO’s National Transportation Product Evaluation Program (NTPEP)
Audit Report

Evaluation Program for Geosynthetic Reinforcement

Summary Report For

______Product Line

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 Evaluation Program for Geosynthetic Reinforcement audit report provides a comprehensive review of the consistency of the product line, allowing products representative of the line to be tested and the results of that testing applied to the remaining products in the line not subjected to the full suite of tests, in accordance with AASHTO PP66-10. The evaluation includes a desktop review of the facility’s quality manual and an on-site review of the facility’s processes and their quality management system documentation.

The desktop review and the on-site review were conducted jointly by auditors ______. Geosynthetic manufacturer ______was represented by ______, during the on-site audit which was completed on ______.

The evaluation findings follow. Deviations from program requirements are noted in red.

The audit was conducted to evaluate the ______product line, including ______. Raw materials used include ______. Raw materials, including COA’s and QC/QA test results, were traceable to the finished product and found to be consistent throughout the specified product line. The manufacturing process from raw material to finished product was found to be consistent for all production lines used to produce products for this product line (______). The QC/QA processes used by the manufacturer, including raw material specification requirements used by the manufacturer to procure and evaluate raw materials used in the product line, and quality control for the finished geogrid products, appear adequate to maintain consistency of the as-manufactured products. Therefore, the manufacturer was found to be compliant with regard to the definition of a geosynthetic reinforcement product line in the NTPEP work plan and AASHTO PP66-10, for the product line as specified herein.

Page 14 of 16

Auditor Name:
Audit Report Number: ______

REV 30– 2/11

AASHTO’s National Transportation Product Evaluation Program (NTPEP)
Audit Report

Table of Contents

Section 1: Geosynthetic Reinforcement Product Line Summary and Production Line Overview 5

Section 2: Product Raw Materials Information 6

Section 3: QMS QC/QA Requirements 7

Section 4: Sample Reports for Resin and Geosynthetic Testing 12

Section 5: Manufacturing Process Control 13

Section 6: Records Retention and Traceability 14

Section 7: Geosynthetic Reinforcement Identification Markings 15

Section 8: Report Signature 17

Section 9: Sampling 17

Page 14 of 16

Auditor Name:
Audit Report Number: ______

REV 30– 2/11

AASHTO’s National Transportation Product Evaluation Program (NTPEP)
Audit Report

Section 1: Geosynthetic Reinforcement Product Line Summary and Production Line Overview

Product Line / Product Designation

a)  Manufacturing Plants Used to Produce Product Line:

Does the company own plants at other locations that produce, or help to produce, one or more of the products within the product line under consideration? YES NO

If yes, does each plant have its own unique geosynthetic marking? YES NO List other locations:

Plant Name / Physical Address / Mailing Address / City, State, Country

Auditor Note: Obtain information to identify the production lines used to produce products for the product line under consideration, and describe any differences between production lines that produce products for the same product line as defined in the NTPEP REGEO work plan. If more than one production line used to produce a geosynthetic reinforcement product (e.g., a different production line may be used to produce the yarn that is used to manufacture the final product), identify each production line used and what part of the product manufacturing process is conducted on each production line.

b)  Production Line Details:

Manufacturing Plant /
Production Line Identification/Description / Products Manufactured on the Production Line

Section 2: Product Raw Materials Information

YES / NO / N/A
1) Identify raw materials received at the plant to form the products in the product line:
Resin – describe resin used: ______
Additives – identify type of additives: ______
Coatings – identify type of coatings: _
Fibers– Describe fibers used: ______
Yarns – identify types:
2) Describe Raw Material Lot definition and Numbering System:
Resin: ______
Additives: ______
Coatings:
Fibers: ______
Yarns:
3) Are Certificates of Analysis furnished by the raw materials Manufacturers for each lot?
Resin: ______
Additives: ______
Coatings: ______
Fibers: ______
Yarns: ______
4) Is regrind (reworked material) used as a source of resin for the products produced?
If the answer to Question #4 is yes, what % of the product source is regrind? ______
If the answer to Question #4 is yes, how is the quality of the final product maintained with consideration to the possibility that some losses in the raw material properties due to the regrind process could occur? ______
5) Are post-consumer recycled materials used as a resin source for the raw materials used in the final products or to otherwise form the final products?
If the answer to Question #5 is yes, how are these products segregated from the products that meet AASHTO PP66-10 and the NTPEP work plan? ______
Comments:

Page 14 of 16

Auditor Name:
Audit Report Number: ______

REV 30– 2/11

AASHTO’s National Transportation Product Evaluation Program (NTPEP)
Audit Report

Section 3: QMS QC/QA Requirements

A) QMS Manual Information
QMS Manual Identification:
Date of Revision of Approved QMS:
Facility has this manual available?
Comments:
B) Manufacturer QC/QA for Raw Materials / YES / NO / N/A /
1) Does the manufacturer have property specifications for raw materials used in their geosynthetic reinforcement products:
a)  For resin?
b)  For fibers?
c)  For Yarns?
d)  For coatings?
e)  Other ______
2) Identify properties used in the manufacturer’s raw materials specifications:
a)  For resin:
a.  Melt index
b.  Carbon black content
c.  Other ______
d.  Are lot specific values for all these properties included in the COA? If not, which ones are not included? ______
b)  For fibers:
a.  Denier
b.  Tenacity
c.  Tensile strength
d.  Molecular weight
e.  CEG
f.  Other ______
g.  Are lot specific values for all these properties included in the COA? If not, which ones are not included? ______
c)  For yarns:
a.  Denier
b.  Tenacity
c.  Tensile strength
d.  Molecular weight
e.  CEG
f.  Other ______
g.  Are lot specific values for all these properties included in the COA? If not, which ones are not included? ______
d)  For coatings:
a.  Brookfield viscosity
b.  Density
c.  Gel temperature
d.  Durometer (Shore A) Initial
e.  Other:
f.  Are lot specific values for all these properties included in the COA? If not, which ones are not included? ______
e)  For other raw materials (e.g., additives such as carbon black, antioxidants, coloring, etc.):
a.  Properties used: ______
b.  Are lot specific values for all these properties included in the COA? If not, which ones are not included? ______
______
3) Do the manufacturer’s raw material specifications meet AASHTO PP66-10 requirements?
4) Manufacturer raw material QC/QA approach used:
a)  Visual check of raw material supplier Certificate of Analysis (COA) in comparison to geosynthetic manufacturer raw material specifications
b)  QC/QA tests conducted by manufacturer or contracted outside lab
5) Do the raw material QC/QA procedures as described in the QMS:
a)  Specify the QC/QA process and procedures for the raw materials?
b)  The timing and frequency of random sampling, and sample size, considering lot size?
c)  Require raw materials QC/QA testing prior to using them in production?
If the answer to 5(c) is no, how is final product identified/traced that contains raw material(s) that did not meet specification requirements?
Summarize the raw materials QC/QA program, including sampling frequency relative to raw materials lot size/definition, sample size, when/where the material is sampled, QC/QA tests conducted on each raw material type, and corrective action taken when the QC/QA tests fail to meet one or more geosynthetic manufacturer raw material(s) property specifications:
a)  When/where sampling of raw materials is conducted:
b)  Raw materials sampling frequency and size:
c)  QC/QA tests conducted on (if not applicable, insert “N/A”):
1)  Resin:
2)  Fibers:
3)  Yarns:
4)  Coatings:
5)  Other raw materials (e.g., additives such as carbon black, antioxidants, coloring, etc.):
d)  Corrective action taken when QC/QA test results don’t meet geotextile manufacturer property specifications (usually, these are the same as the supplier’s specifications):
e)  Other raw materials evaluation activities done by the geosynthetic manufacturer:

Auditor Note – Verify that the QMS manual contains the information/requirements identified in the table below.

C) Quality Control Inspection and Testing (geosynthetic Product) / YES / NO / N/A
1) Does the QMS include procedures for the inspection and testing of geosynthetics during and at the completion of the production of the geosynthetic products?
2) Do the procedures in the QMS:
a)  Require visual inspections of the final product?
b)  Specify the QC/QA process and procedures
c)  Describe a method for random sampling?
d)  Describe the timing and frequency of geosynthetic random sampling, and sample size, considering lot size?
e)  Specify the lot numbering system for the geosynthetic products?
Provide the definition of a lot used for the geosynthetic products:
3) Does the QMS include an example of a quality control test report form?
4) Does the QMS document procedures and measurements used to verify the consistency of the manufacturing process (e.g., processing temperatures, fiber and rib forming processes, etc.) and condition of the manufacturing equipment?
5) Does the QMS describe quality control procedures for the coating used (PET geosynthetics only) and how it is applied to the polyester yarns/ribs to form the final product, considering both application rate and quality of the coating?
6) Does the QMS establish traceability from the final geosynthetic product back to the resin lot used?
7) Are the documents that establish traceability of the final geosynthetic product maintained along with the inventory?
Comments:
D) Statistical Analysis of Test Results / YES / NO / N/A
1) Does the QMS include a document describing the statistical process control plan?
2) Does the plan include methods such as control charts to monitor production facility quality control test results to identify trends and make production adjustments as necessary?
Corrective action taken when QC/QA test results don’t meet product property specifications (include how failing sample is related to specific rolls of product produced and action taken with those particular rolls):
E) QC/QA Testing Plan and Procedures
Test Name / Testing Performed by: / Test Interval / No Testing Performed or N/A
In House / Outside lab
Tests for Raw Materials:
- Melt Index (ASTM D1238)
- Carbon black content
- Denier
- Tenacity
- Tensile strength
- Molecular weight
- Carboxyl end group content
- Brookfield viscosity (coatings only)
Geosynthetic Tests:
- Mass per Unit Weight (ASTM D 5261)
- Single rib tensile strength (ASTM D6337)
- Wide width tensile strength (ASTM D4595 or ASTM D6337)
- Aperture size and rib width (hand measure)
- Junction strength (GRI-GG2)
1Names, addresses, and contact information for outside laboratory facility(ies) used:
Other testing done on production products that is not lot specific:

Section 4: Sample Reports for Raw Materials and Geosynthetic Testing

Auditor Note – Maintain example hard copies of the test records, certificates of analysis, and reports gathered during the audit.

Sample Test Reports: Please provide sample reports representing quality control testing in accordance with WSDOT T925/AASHTO PP66-10 Specification:

·  Raw materials – Melt Index, molecular weight, carboxyl end group content, tensile strength, denier, Brookfield viscosity, etc.

·  Geosynthetic – Mass/unit weight, aperture/rib width, single rib tensile strength, wide width tensile strength, junction strength, etc.

Section 5: Manufacturing Process Control

Note: If not applicable, enter “N/A” in box.

A)  Process from resin to fiber/yarn/rib

Control of additives (amount and distribution) and how measured:

Consistency of fiber forming/drawing process, including processing environment, and how measured:

Consistency of yarn weaving process:

B)  Process from fiber/yarn/rib to final product

Consistency of product weaving process, geogrid junction forming process, or geogrid formation process:

For PET geogrids, consistency of coating process, including processing environment, coating rate, and final weight per unit area or thickness of coating, including how measured for each aspect of process:

Section 6: Records Retention and Traceability

YES / NO / N/A
1)  Does the QMS include a process for storing quality control test reports for raw materials and the finished geosynthetic products, as well as raw material COA’s?
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?
3)  Does the QMS establish traceability from the final geotextile product back to the raw material lot used?
4)  Are the documents that establish traceability of the final geosynthetic product maintained along with the inventory?
5)  Regarding the raw materials supplier COA and manufacturer QC/QA data/test results:
a)  Are they traceable to the final geosynthetic products produced?
b)  Was auditor able to verify traceability on site?
Indicate method used by manufacturer to maintain traceability (e.g., raw material lot number included in final product identification, computer database maintained by manufacturer quality staff):
For Auditor – indicate products evaluated for traceability:
6)  Regarding manufacturer QC/QA data/test results for geosynthetic product:
a)  Are they traceable to the final geosynthetic products produced?
b)  Was auditor able to verify traceability on site?
Indicate method used by manufacturer to maintain traceability (e.g., finished product lot number included in final product identification, computer database maintained by manufacturer quality staff, etc.):
For Auditor – indicate products evaluated for traceability:
.
Comments:

Section 7: Geosynthetic Reinforcement Identification Markings

Auditor Note - Insert a picture(s) of the plant’s unique geosynthetic identification markings. Refer to the plant’s pre-audit documentation or previous audit report.