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AASHTO’s National Transportation Product Evaluation Program (NTPEP)Evaluation Program for Manufacturers of

Welded Wire Steel for Concrete Reinforcement (WWR)

On-Site Audit Provided by:AASHTO

444 North Capitol Street NW, Suite 249Washington, DC 20001

Phone: 202-624-3695 Fax: 202-624-5469 Email: [email protected]

Pre-Audit Application FormDate

Dear:

We have received your request for an on-site audit of your steel welded wire reinforcement facility, located in location. Thank you for using AASHTO’s National Transportation Product Evaluation Program (NTPEP).

The following information must be provided before the on-site audit can be scheduled: Completed Pre-Audit Application Form Pictures of tagging, marking, and loading information for the finished product (see Section 5 of

Application Form) A sample Product Test Report (PTR) and Mill Test Report (MTR) for each type of WWR

product produced (see Section 6 of Application Form) A copy of your Quality Management System (see Section 7 of Application Form)

Please provide this information to us within thirty (30) days of the date of this letter. Failure to do so could result in a delay or suspension of your listing on the NTPEP website.

The information can be submitted to AASHTO by one of the following methods: Preferred method: Fill out the electronic version of the Pre-Audit Application Form (a copy will

be emailed to you) and email the completed form to [email protected] Fill out the hard copy supplied with this letter and mail it to the address shown above

After the information has been received and reviewed, we will contact you to schedule a date for the on-site audit. Do not hesitate to contact me if you have any questions.

Sincerely,

Katheryn L. MaluskyNTPEP Project EngineerPhone: (202) 624-3695Email: [email protected]

Enclosure

mailto:[email protected]

mailto:[email protected]

AASHTO’s National Transportation Product Evaluation Program (NTPEP)Evaluation Program for Manufacturers of Welded Wire Steel for Concrete

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Pre-Audit Application FormPlease provide the following information and return responses to AASHTO.

Provide all applicable supporting documentation requested.

FacilityName:

Physical Address:

Mailing Address:(if different from above)

Proprietary OwnershipCompany Name:

Address:

Primary ContactName:Title:

Telephone: ( )Cell: ( )Fax: ( )

Email:

ManagementQC Manager:

Plant Manager:

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Pre-Audit Application Form

Table of Contents

Section 1: Testing Personnel..........................................................................................................3

Section 2: Standard Specifications................................................................................................4

Section 3: Size and Type of Material Produced by the Manufacturer......................................5

Section 4: Product Information.....................................................................................................6

Section 5: Packaging, Marking, and Loading Information........................................................9

Section 6: Certifications and Test Results .................................................................................10

Section 7: Quality Management System.....................................................................................11

Section 8: Signature......................................................................................................................17

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Section 1: Testing Personnel

Note – Please complete the following table naming individuals trained to perform the following functions. If several candidates fulfill each function, please select those who will work shift one more frequently. Conversely, if few candidates fulfill multiple roles please enter them in the corresponding positions.

Name Normal Workdays /

Hours

Phys

ical

Tes

ting

QC SamplingQC SamplingQA SamplingQA SamplingQC TestingQA Testing

QC SupervisorQC SupervisorQA SupervisorQA Supervisor

Comments:

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Section 2: Standard Specifications

Auditor Note - Indicate if current versions of the following ASTM standards are available at the manufacturing facility.

ASTM

Standard Specification for Steel Wire, Plain, for Concrete Reinforcement A82-07

Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete A185-07

Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement A496-07

Standard Specification for Steel Welded Wire Reinforcement, Deformed, for Concrete A497-07

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

Standard Specification for Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete A1064-09

Standard Test Methods and Definitions for Mechanical Testing of Steel Products A370-12a

Standard Practices for Packing, Marking, and Loading Methods for Steel Products for Shipment A700-05

Standard Practices for Force Verification of Testing Machines E4-09a

Standard Test Methods for Tension Testing of Metallic Materials E8-09

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

Comments: None

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Section 3: Size and Type of Material Produced by the Manufacturer

A) Type, Form, and Production MethodWire:Type: Plain Deformed

WWR:Type: Plain Deformed Form: Sheet Rolled Other Method: Coiled Rod Stock Straight Rod Stock Both If other, please list:

B) Common SizesSize Information:Please provide a list of the most common/typical sized wire mesh produced at this facility.

Size/Number Spacings Nominal Diameter Nominal AreaSI Units

mm [in.]

Inch-Pound Units

in. [mm]

SI Units

mm [in.]

Inch-Pound Units

in. [mm]

SI Units

mm2 [in.2]

Inch-Pound Units

in.2 [mm2]

Comments:

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Section 4: Product Information

YES NOA) General

1) Does the company own facilities in other locations?

2) If yes, does each facility have its own unique identification information?List other locations:

B) Billet InformationGeneral Billet Information:1) Does the manufacturer produce rod for the production of WWR? (If NO, proceed to question 2): (a) Indicate the rolling process(es) used:

Straight Line Cross Country Jump Mill OtherIf Other, please describe:

(b) How many rolling mills does the manufacturer have in operation?

Purchased Billet Documentation Requirements:2) Does the manufacturer purchase rod for the production of WWR? If Yes, please complete items 2(a) thru 2(f): (a) Does the manufacturer retain copies of all rod certifications on file?

(b) How long are rod certifications retained?

(c) Do rod certifications include the type of steel (chemistry)?

(d) Do rod certifications include the origin of the steel?

(e) Do rod certifications include the heat number?

(f) How is traceability maintained on rod?

Heat No. Grade

Other Method Describe:

Comments:

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Section 4: Product Information (Continued)

YES NOC) Wire Information

General Wire Information:

1) What is the annual WWR production capacity?

2) Has the production capacity changed within the last year?

(a) If yes, explain:3) Indicate the process(es) used to produce wire: Cold Draw Rolled 4) Does the manufacturing facility have any foreign steel in its inventory?

(a) If yes, how is it processed?

(b) How is foreign steel identified?

Traceability of wire during fabrication into WWR:

5) Does the manufacturing facility maintain identity of the rod/wire/WWR throughout the fabrication process?

(a) If yes, how is it processed?

Mesh made from purchased wire:

6) Does product documentation include the following:

(a) The rod certificate with chemical test results?

(b) The plant that produce the wire? (c) A statement indicating the wire was melted and manufactured in

the U.S.A? (d) Physical test results?

(e) Minimum specification requirements?YES NO

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Section 4: Product Information (Continued)

YES NOD) General: All Product Documentation

1) Is the packaging, marking, and loading of finished product in accordance with ASTM A700?2) Does the tag affixed to each roll/bundle of product include the following? (Check all that apply)

Size of Wire ASTM Specification Name/Mark of Manufacturer

Other Describe:3) What does the manufacturing facility’s product documentation include? (Check all that apply)

Certifications Invoices Process Worksheets

Other Describe:

4) Does the manufacturer keep copies of all product documentation on file?

5) How long is product documentation retained?

6) How does the manufacturer furnish product documentation for a DOT project?

With the shipment Mailed after the shipment with an invoice Furnished to a fabricator

Other method Describe:

Comments:

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Section 5: Steel Welded Wire Reinforcement Information

Please provide pictures (hard copy or electronic) of your typical product tag showing the information (at a minimum the tag should indicate: name of the manufacturer, description of the material, specification, and other such information as may be specified by the purchaser).

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Section 6: Certifications and Test Results

*Please provide a sample Certifications representing each type of material produced (A82; A185; A496; A497; and/or A1064) as well as the test results for the material.

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Section 7: Quality Management System

Please attach supporting documentation for each the following requirements:

Organization and Staff

Does the manufacturing facility’s quality system documentation include: YES NOA) Organization and Organizational Policies

1) Organization chart showing relevant internal organizational components?

2) Quality system policy statement (set by management) and quality objectives?

B) Position Descriptions1) Position descriptions for each technical operational position shown on the facility’s

organization chart?2) Do the position descriptions:

(a) Identify the position?

(b) Describe the duties associated with the position?

(c) Describe the required skills, education and experience?

(d) Indicate the supervision exercised and received?

C) Training1) Written procedures used to ensure that the facility’s personnel are trained to

perform physical tests?2) Do the procedures indicate the following: (a) What position(s) or employee(s) are responsible for the training program and

maintenance of records? (b) Distribution of records to management?

D) Competency Evaluations1) Written procedures used to evaluate staff competency to ensure that each physical

test is performed in accordance with standard procedures?2) Do the procedures indicate the following:

(a) The frequency of evaluations? (b) What position(s) or employee(s) is responsible for evaluating staff

competency and maintaining records? (c) Distribution of records to management?

Comments:

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Quality Management

Does the manufacturing facility’s quality system documentation include: YES NOE) Contract Review

1) A written procedure for processing steel welded wire reinforcement orders and the review of contracts for producing steel welded wire reinforcement?

2) Do the procedures ensure that:

(a) The requirements are adequately defined, documented and understood?

(b) Records of contract reviews are maintained?

(c) The client shall be informed of any deviations from the contract?

F) Customer Feedback1) Written procedures describing the customer feedback system?

2) Do the procedures indicate the following:

(a) What position(s) or employee(s) are responsible for customer feedback?

(b) Methods used to solicit, evaluate and respond to customer feedback?

(c) Conditions under which corrective action will be implemented?

G) Internal Audits1) Written procedures for performing internal audits?

2) Do the procedures indicate the following: (a) What position(s) or employee(s) are responsible for ensuring that internal

audits are performed? (b) The frequency, scope and criteria used for performing the audits?

(c) Conditions under which corrective action will be implemented?

H) Management Reviews1) Written procedures for performing management reviews?

2) Do the procedures indicate the following: (a) What position(s) or employee(s) are responsible for ensuring that

management reviews are performed? (b) The frequency, scope and criteria used for performing the management

review(s)?(c) Conditions under which corrective action will be implemented?

Comments:

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I) Corrective Action1) Written procedures describing the actions taken when failures or nonconformities

exist in any of the following areas: product, equipment, customer feedback, internal and external audits, and management reviews?

2) Do the procedures indicate the following: (a) What position(s) or employee(s) are responsible for implementing corrective

action(s)? (b) Methods used to identify and implement corrective action(s)?

Comments:

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Sampling and Testing

Does the manufacturing facility’s quality system documentation include: YES NOJ) Sampling Plan

1) Written procedures describing sampling for quality control and quality assurance?


(a) Number and frequency of samples taken?

(b) Sample selection process, including sampling required for retesting?

(c) The position(s) or employee(s) responsible for sampling?

(d) Required sample preparation?

K) Testing Plan1) Written procedure describing testing for quality control and quality assurance?


(a) Number of samples required for testing?

(b) Tests required to be performed?

(c) The position(s) or employee(s) responsible for testing?

(d) How test results are interpreted?

(e) The position(s) or employee(s) responsible for approving test results?

(f) Criteria and procedures for retesting?

L) Retesting Plan1) Does the manufacturer have written procedures describing their retesting plan?


(a) When retesting is performed?

(b) Retest sampling requirements?

(c) Special retesting conditions?

(d) Criteria for acceptance of retest results?

(e) Instructions for reporting original test results and retests results?Comments:

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Equipment Standardization and Checking

Does the manufacturing facility’s quality system documentation include: YES NOM) Lab Equipment List

1) List(s) giving a general description of physical test equipment requiring standardization or checks?

2) Does the information for each item listed include:

(a) Interval between standardization or checks?

(b) Reference to standardization or check procedures?

(c) Location of standardization or check records?

N) Lab Equipment Plan1) Written procedures for ensuring that equipment standardizations and checks are

performed for all required equipment at specified intervals?2) Do the procedures indicate the following: (a) Position(s) or employee(s) responsible for standardization and check

activities? (b) How to handle equipment which is newly acquired, removed from service, or

does not meet accuracy requirements? (c) In-house equipment standardization and check procedures, when they cannot

be referenced in applicable standards? (d) Certificates or other documents that establish traceability of in-house

equipment or reference standards used for standardization and checks?Comments:

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Product Control and Records

Does the manufacturing facility’s quality system documentation include: YES NOO) Recording and Maintaining Product Information and Test Results

1) Written procedures used to produce and check Certifications?

2) Do the procedures: (a) Identify position(s) or employee(s) responsible for maintaining and reviewing

Certifications? (b) Describe distribution of Certifications?

(c) Identify location of Certifications?

P) Handling Raw Material for DOT Products1) A written procedure to ensure that WWR made for DOT projects does not include

any foreign steel?2) Does the procedure:

(a) Identify the responsible position(s) or employee(s)?

(b) Indicate how foreign steel is identified, labeled and segregated?

Q) Labeling and Storage of Finished Product1) A written procedure describing how finished product is labeled, packaged and

stored?R) Control of Nonconforming Product

1) Written procedures describing the actions to take when product fails to meet specification requirements?

2) Do the procedures indicate the following: (a) What position(s) or employee(s) is responsible for making decisions related to

non conforming product? (b) How nonconforming product is identified, labeled and segregated?

(c) What is done with the nonconforming product?

(d) Who is responsible for taking corrective action?Comments:

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Section 8: SignatureSignature: Date:

I certify that all responses are truthful and accurate.

Name: Title:

Mill Name: Location (City, State):

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