ntpep audit documents/ppp...please refer to section 1 of the report for the list of personnel...

Plant

Name:

Physical Address:

Mailing Address: SAME AS ABOVE

(if different from above)

Primary Contact

Name:

Title:

Telephone:

Email:

Management

QC Manager:

Plant Manager:

Auditor Contact

Name:

Telephone:

Address:

Email:

Other Attendee Contact

Name:

Title:

Organization:

Telephone:

Email:

DOT Official Contact

Name:

Title:

Organization:

Telephone:

Email: NTPEP

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

Plastic Pipe (HDPE and Polypropylene) Summary

Audit Report

Plant Name:

NTPEP Number: THP-2019-01-0??

Auditor: name REV:1/29/2019

© 2019 by the American Association of State Highway and Transportation Officials. All rights reserved. Duplication is a violation of applicable law.

of 54

Evaluation Program for Manufacturers of Plastic Pipe

Summary Report For Plant – City, State

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 manufacturers of plastic pipe (HDPE and Polypropylene) provides a

comprehensive review of the production and testing of plastic pipe and of the quality management

system. The evaluation starts with a desktop review of the 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 (Name) facility, located in (Location), was conducted by Lead Auditor (Name)

(AASHTO) on (date). (Facility) was represented by Name (Position) and 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 of personnel approved to perform quality control

tests.

Pipe Identification Markings (Section 2)

Please refer to Section 2 of the report for the pipe identification markings used at this facility.

Plastic Pipe Size and Type Produced (Section 3)

NTPEP



Audit Report

Plant Name:




of 54

Quality Control Testing (Section 4)

Please refer to Section 4 of the report for quality control testing frequencies performed on

manufactured pipe.

Standard Specifications (Section 5)

The plant had current versions of all applicable AASHTO and ASTM standards, and the NTPEP

work plan and SP01

Quality Management System Records Review (Section 6)

Training and competency records for all technicians were reviewed and found to be organized

and complete.

The most recent internal audit was completed on DATE and the most recent management review

was completed on DATE. Copies were presented to the auditor and reviewed.

Corrective actions from the previous NTPEP audit were reviewed and found to be implemented

as described. or There were no Corrective Actions from the previous NTPEP audit.

Manufacturing Walkthrough (Section 7)

Comparison/Record Samples (Section 8)

These samples were selected for comparison sample testing:

Test specimens cut from each sampled pipe and an associated sample of resin/compound for each

pipe were sent to TRI or PSI Lab for testing.

The following samples were randomly selected for record traceability (review of test reports

and CoAs) during the walkthrough:

All of the records contained the proper information and indicated that testing was performed

within specified intervals.

No additional test reports and CoA’s were reviewed for pipe produced during other random

weeks since the sampled pipe was from a sufficient range of dates.

The manufacturer’s test results were well organized which allowed traceability records to be

easily reviewed.

Quality Control Testing Equipment and Procedures (Section 9)

The following quality control tests were demonstrated satisfactorily by Name for each type of

pipe (M 252, M 294 and M 330) and the equipment for each test was in adequate condition:

o Density – Gradient Technique (ASTM D1505)

o Density – Displacement Method (ASTM 792)

o Density – Ultrasound Method (ASTM D4703 & D4883)

o Melt Index (ASTM D1238)

o NCLS (ASTM F2136)

o Carbon Content (ASTM D4218)

o Wall Thickness – Micrometer (ASTM D2122)

o Wall Thickness – Ultrasonic Gauge (ASTM D2122)

o Inside Diameter (ASTM D2122)

o Length of Pipe (ASTM D2122)

NTPEP



Audit Report

Plant Name:




of 54

o Unit Weight (ASTM D2122)

o Perforation Locations and Dimensions (AASHTO M 294)

o Perforation Locations and Dimensions (AASHTO M 252)

o Water Inlet Area (AASHTO M 252)

o Water Inlet Area (AASHTO M 294)

o Brittleness (ASTM D2444)

o Pipe Stiffness & Flattening (ASTM D2412)

o Oxidative-Induction Time (ASTM D3895)

o Elongation at Break (ASTM D638)

o Un-notched Constant Ligament Stress Crack Test - UCLS (ASTM F3181)

The equipment utilized to complete the quality control testing at this plant was well organized.

NTPEP

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

Plastic Pipe (HDPE and Polypropylene) Contents

Audit Report

Plant Name:



© 2019 by the American Association of State Highway and Transportation Officials.

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

of 54

Table of Contents

Section 1: Testing Personnel ............................................................................................ 6

Section 2: Pipe Identification Markings ......................................................................... 7

Section 3: Sizes and Types of Pipe Produced ................................................................. 8

Section 4: Quality Control Testing Matrix ................................................................... 10

Section 5: Standard Specifications ................................................................................ 12

Section 6: Quality Management System Records Review ........................................... 14

Section 7: Manufacturing Walkthrough ....................................................................... 18

Section 8: Comparison/Record Samples ....................................................................... 21

Section 9: Quality Control Testing Evaluation ............................................................ 27

Section 10: Report Signature ......................................................................................... 54

Section 11: Miscellaneous Documents ........................................................................... 55

NTPEP

AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 1

Plastic Pipe (HDPE and Polypropylene) Personnel

Audit Report

Plant Name:





of 54

Section 1: Testing Personnel Identification of the personnel approved to run quality control testing at the plant

Resin/Compound Testing: Testing performed on virgin resin, resin blends (including recycle resin)

and compounds.

Production Testing: Line checks and testing performed during production which may include

workmanship, carbon black, unit weight, pipe diameter, pipe length, wall thickness, etc.

Lab Testing: Lab testing on conditioned pipe including, but not limited to, stiffness/flattening,

brittleness, and any other test performed in the lab.

Name

Resin/Compound

Testing Production Testing Lab Testing

Comments: None

NTPEP


Plastic Pipe (HDPE and Polypropylene) Markings

Audit Report

Plant Name:





of 54

Section 2: Pipe Identification Markings

NTPEP


Plastic Pipe (HDPE and Polypropylene) Sizes and Types of

Pipe

Audit Report

Plant Name:





of 54

Section 3: Sizes and Types of Pipe Produced

Specification M 252: Indicate all applicable pipe produced at this location: Key: St = Straight Co = Coil C1 = Class 1 Perforations C2 = Class 2 Perforations

Type C – No Inner Wall Type CP – No Inner Wall with Perforations Type S – Smooth Inner Wall

Type SP – Smooth Inner Wall with Perforations Type D – Smooth Inner Wall joined to Smooth Outer Wall

Type DP – Smooth Inner Wall joined to Smooth Outer Wall with Perforations

Single-Wall Dual-Wall

C CP S SP

Size inches [mm] St Co St Co Size inches [mm] C1 C2

4 [100] 4 [100] 6 [150] 6 [150] 8 [200] 8 [200] 10 [250] 10 [250]

Specification M 294 V M 294 R : Indicate all applicable pipe produced at this

location: Single-Wall Dual-Wall Triple-Wall

C CP S SP D DP

Size inches [mm] C1 C2 C1 C2 C1 C2

12 [300]

15 [375]

18 [450]

21 [525]

24 [600]

27 [673]

30 [750]

36 [900]

42 [1050]

48 [1200]

54 [1350]

60 [1500]

Specification M 330: Indicate all applicable pipe produced at this location: Single-Wall Dual-Wall Triple-Wall

C CP S SP D DP

Size inches [mm] C1 C2 C1 C2 C1 C2

12 [300]

15 [375]

18 [450]

21 [525]

24 [600]

27 [673]

30 [750]

36 [900]

42 [1050]

48 [1200]

54 [1350]

NTPEP


Plastic Pipe (HDPE and Polypropylene) Sizes and Types of

Pipe

Audit Report

Plant Name:





of 54

60 [1500]

Comments: None

NTPEP


Plastic Pipe (HDPE and Polypropylene) Quality Control

Testing

Audit Report

Plant Name:





of 54

Section 4: Quality Control Testing Matrix

Matrix of Quality Control Tests, Facilities, and Intervals

Please indicate for the QC tests shown below if your facility conducts the test in house or indicate the name of the outside facility used

(Second or Third Party). Additionally, indicate the frequency of record testing. Please indicate contact information for second/third

party facilities below.

Quality Control Test Minimum

Frequency

In-house/Outside

Facility

M 252

Frequency

M 294

Frequency

M 330

Frequency

M 252 & M 294 VIRGIN RESIN TESTS Density Each Lot

Melt Index Each Lot

NCLS (Blended Resins) Initially/Quarterly

M 294 R RESIN TESTS

Density Each Lot

Melt Index Each Lot

M 330 COMPOUND TESTS

Density Each Lot /

Quarterly

Melt Index Each Lot /

Quarterly

Izod Impact Strength Initially/Quarterly

Oxidative-Induction Time Initially/Quarterly

Tensile Strength/Elongation at

Yield Initially/Quarterly

Flexural Modulus (1% Secant) Initially/Quarterly

PIPE TESTS

Workmanship 1 / Shift

Unit Weight 2 / Shift

Color Content/Carbon Black 1 / Day

Wall Thickness 2 / Shift

Inside Diameter 1 / Shift

Pipe Length 1 / Shift Perforation Location/dimension 1 / Shift Water Inlet Area 1 / Shift Pipe Stiffness/Flattening 2 / Week

Brittleness 2 / Week

Liner NCLS 2 / Year¹

Stub Compression No NTPEP

Requirement³

ADDITIONAL PIPE TESTS for M 294 R

Density Each Lot

Melt Index Each Lot

Oxidative-Induction Time Each Lot

Elongation at Break Each Lot

NTPEP


Plastic Pipe (HDPE and Polypropylene) Quality Control

Testing

Audit Report

Plant Name:





of 54

Un-notched, Constant Ligament

Stress Crack (UCLS) Each Lot

Liner NCLS Each Lot²

Second and/or third party facilities used

Comments: None

NTPEP


Plastic Pipe (HDPE and Polypropylene) Standard

Specifications

Audit Report

Plant Name:





of 54

Section 5: Standard Specifications

Auditor Note - Indicate if current versions of the following AASHTO & ASTM standards are available at the plant.

Primary HDPE AASHTO ASTM

Specification for Corrugated Polyethylene Drainage Pipe M 252-18

Specification for Corrugated Polyethylene Pipe, 300- to 1500-mm Diameter M 294-18

Standard Practice for Qualification of Highway Product Manufacturers

Through the Use of NTPEP Audits SP01 -18

NTPEP Committee Work Plan for the Evaluation of High Density

Polyethylene Drainage Pipe Manufacturers HDPE-18

HDPE Recycle N/A

Standard Test Method for Oxidative-Induction Time of Polyolefins by

Differential Scanning Calorimetry D3895-14

Un-notched, Constant Ligament Stress Crack Test (UCLS) for HDPE

Materials Containing Post-Consumer Recycled HDPE F3181-16

Tensile Properties of Plastics – Elongation at Break D638-14

Primary Polypropylene N/A

Specification for Polypropylene Pipe, 300 to 1500 mm (12 to 60 in.)

Diameter M 330-18

Standard Test Methods for Determining the Izod Pendulum Impact

Resistance of Plastics D256-10e1

Standard Test Method for Oxidative-Induction Time of Polyolefins by

Differential Scanning Calorimetry D3895-14

NTPEP Committee Work Plan for the Evaluation of Polypropylene Drainage

Pipe Manufacturers PPP-17

Secondary

Test Method for Tensile Properties of Plastics D638-14

Test Method for Flexural Properties of Unreinforced and Reinforced Plastics

and Electrical Insulation Materials D790-17

Test Method for Melt Flow Rates of Thermoplastics by Extrusion

Plastometer D1238-13

Standard Test Methods for Density and Specific Gravity (Relative Density)

of Plastics by Displacement

OR

Test Method for Density of Plastics by the Density-Gradient Technique

OR

Standard Test Method for Density of Polyethylene by the Ultrasound

Technique

D792-13

D1505-10

D4883-08

Standard Practice for Compression Molding Thermoplastic Materials into

Test Specimens, Plaques, or Sheets D4703-16

Standard Test Method for Determination of Carbon Black Content in

Polyethylene Compounds by the Muffle Furnace Technique D4218-15

NTPEP


Plastic Pipe (HDPE and Polypropylene) Standard

Specifications

Audit Report

Plant Name:





of 54

Test Method for Determining Dimensions of Thermoplastic Pipe and Fittings D2122-16

Test Method for Determination of External Loading Characteristics of Plastic

Pipe by Parallel-Plate Loading D2412-11

Test Method for Determination of Impact Resistance of Thermoplastic Pipe

and Fittings by Means of a TUP (Falling Weight) D2444-17

Specification for Polyethylene Plastics Pipe and Fittings Materials D3350-14

Test Method for Notched, Constant Ligament-Stress (NCLS) Test to

Determine Slow-Crack-Growth Resistance of HDPE Resins or HDPE

Corrugated Pipe

F2136-18

Comments:

NTPEP


Plastic Pipe (HDPE and Polypropylene) QMS Review

Audit Report

Plant Name:





of 54

Section 6: Quality Management System Records Review

Audit of Training and Competency Evaluation records

Auditor Note – The auditor shall select two random names from Section 1 to verify training and competency

evaluation records are complete.

Training and Competency Evaluations Yes No

A) Training

1) Does the manufacturing facility maintain records to ensure that the facility’s

personnel are trained to perform physical tests initially?

2) Do the training records for the individual(s) listed above:

a. List the date(s) of training and identification of the trainer?

b. Indicate that all relevant training has been completed?

B) Competency Review

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

competency on at least an annual basis?

2) Do the competency evaluation records for the individual(s) listed above:

a. List the date(s) of the review and identification of the reviewer?

b. Indicate that all relevant competency evaluations have been completed?

Comments:

NTPEP



Audit Report

Plant Name:





of 54

Quality Management Yes No

C) Internal Audits

1) Was a current internal audit presented?

2) Are internal audits performed at least annually?

3) Do internal audits cover all processes that affect product quality (production, quality

testing, training, shipping, etc)?

4) Do internal audits determine if quality system processes are being followed?

D) Management Reviews

1) Was a current management review presented?

2) Are management reviews performed at least annually?

3) Do management reviews determine the effectiveness of quality system processes?

Comments:

The most recent internal audit was completed on DATE, and the most recent

management review was completed on DATE. Copies of these were presented

to the auditor and reviewed.

E) Pipe Testing Report Requirements

1) Do test reports include identification of the plant, date of production, shift, line, and

lot designation?

2) Does the lot designation trace to the resin lot test results?

3) Are test results recorded properly using forms contained in the plant’s QSM?

4) Is there evidence to indicate that the plant intends to retain copies of test reports for a

minimum of 7 years?

5) Please describe the test reporting system:

Comments: None

NTPEP



Audit Report

Plant Name:





of 54

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

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

Have all deviations noted in the last NTPEP report been corrected? N/A

Section Deviation and Corrective Action Response Yes No

8

Comments: None

NTPEP



Audit Report

Plant Name:





of 54

• Equipment Calibration

F) QC Testing Equipment Record Checks

Auditor Note – Use the following table to perform the record audit of quality control testing equipment calibration, standardization, and checks. *Adequate documentation on each record includes: (1) Model & Serial No., (2) Name of worker, (3) ID of equipment used for calibration, (4) Date of calibration, (5) Detailed calibration results, and (6) Reference to calibration procedure used.

ITEM

Frequency – SP01

PE

RF

OR

MIN

G

EN

TIT

Y

CA

LIB

RA

TIO

N

VE

RIF

ICA

TIO

N

ST

AN

DA

RD

IZE

COMMENTS

OA IN

Parallel Plate Test Machine

calibrate every 12 Mos. N/A N/A

Ultrasonic Gauge/Transducer

calibrate every 12 Mos.

verify prior to use N/A

Balances and Scales

verify prior to use N/A N/A

Standard Weights

verify every 60 Mos.

Calipers and Micrometers

verify prior to use N/A N/A

Standard Gage Blocks

verify every 60 Mos. N/A N/A

Melt Index Heater

standardize prior to use

Muffle Furnace

standardize prior to use N/A N/A

Temperature Measuring Device

standardize prior to use N/A N/A

Comments:

OA - denotes performed by an outside agency

IN – denotes performed internally

NTPEP


Plastic Pipe (HDPE and Polypropylene) Manufacturing

Walkthrough

Audit Report

Plant Name:





of 54

Section 7: Manufacturing Walkthrough

YES NO

A) General

1) Does the company own plants at other locations?

How many are

NTPEP audited

locations?

B) Plant Walkthrough

Manufacturing line

1) How many manufacturing lines produce AASHTO pipe?

2) Identify each line and size range of AASHTO pipe produced:

Comments:

C) Resin/Compound Information

1) How is virgin resin received at the plant? by Railcar by Truckload with Hopper by Truckload of

Boxes

by Other Method:

2) How is recycled resin

received at the plant?

3) How is compound received

at the plant?

4) Please describe your lot numbering

system:

5) Are the lot numbers carried through to the finished product?

6) Are resin and compound quality control tests completed prior to

using resins/compounds in production?

7) Do resin/compound Certificates of Analysis include the

following lot specific data:

a. Melt Index?

b. Density?

8) Is full cell classification testing completed and reported prior to

use?

9) Are samples of the resin/compound used to produce AASHTO

pipe retained while the pipe remains in the yard?

D) Resin Blends

1) Does the facility use resin blends to produce AASHTO pipe?

NTPEP



Walkthrough

Audit Report

Plant Name:





of 54

2) Are resin blends composed of virgin resin and reworked

material?

3) Is recycled material used in blends used to produce AASHTO

pipe?

4) Are non-PPI certified resin blends used to produce AASHTO

pipe?

5) Please describe method used for certifying resin blend (non-

PPI):

6) For non-PPI approved blends, is full cell class and NCLS

determined for each blend lot? N/A

7) For non-PPI approved blends, is full cell class and NCLS

determined for each blend quarterly? N/A

8) Is it understood that a new lot is established each time a

component resin or component ratio changes by more than

±1.5%?

Comments:

YES NO

E) Reworked Material

1) Is reworked material used in the production of AASHTO pipe?

2) What process does the plant use to assure that reworked ASTM or other non

AASHTO material isn’t used in the production of AASHTO pipe?

F) Color and Ultraviolet Stabilization (M 330 only)

1) How are colored (non-black) polypropylene compounds

protected from Ultraviolet (UV) degradation in the

production of AASHTO M 330 pipe?

Comments: None

G) Yard Walkthrough

Pipe Inspections

1) Do pipe markings:

a. exist along the pipe at intervals not exceeding 10 ft

(3m)?

b. include the Manufacturer’s name or trademark?

c. include nominal size?

NTPEP



Walkthrough

Audit Report

Plant Name:





of 54

d. include the specification designation?

e. identify the plant designation code?

f. identify the date of manufacture or an appropriate

code?

g. for recycled pipe, include the words “Contains

Recycle Resins”?

2) The auditor shall inspect pipe walls to ensure they are:

a. free from delamination?

b. free from blowouts?

c. free of foreign inclusion and visible defects?

d. cut squarely at the ends and do not affect joining?

3) The auditor shall inspect to ensure that damaged pipe has been

marked according to the Manufacturer’s Quality Manual?

4) How is pipe marked / separated in the yard?

5) How is damaged pipe marked / handled?

Comments

: None

YES NO

Fittings and Couplings Inspections

1) The auditor shall inspect exterior and interior walls to ensure

a. they are free of foreign inclusion and visible defects?

b. the ends are cut squarely and do not affect joining?

2) The auditor shall inspect fittings and couplings to ensure the

markings include:

a. the Manufacturer name or trademark?

b. AASHTO M 252, M 294 or M 330?

Comments:

NTPEP


Plastic Pipe (HDPE and Polypropylene) Comparison/Record

Samples

Audit Report

Plant Name:





of 54

Section 8: Comparison/Record Samples

Comparison Sample Information

A) Comparison Sample Selection

Specification: Specification: Specification: Specification:

Size: Size: Size: Size:

Type: Type: Type: Type:

Shift: Shift: Shift: Shift:

Manuf. Date: Manuf. Date: Manuf. Date: Manuf. Date:

Resin #1

(supplier/lot):

Resin #1

(supplier/lot):

Resin #1

(supplier/lot):

Compound 1

(supplier/lot):

Resin #2

(supplier/lot):

Resin #2

(supplier/lot):

Resin #2

(supplier/lot):

Compound 2

(supplier/lot):

Resin #3

(supplier/lot)

Resin #3

(supplier/lot)

Resin #3

(supplier/lot)

Compound 3

(supplier/lot)

Compound 4

(supplier/lot)

Dry or Melt

Blended

Dry or Melt

Blended

Dry or Melt

Blended

Blend ID: Blend ID: Blend ID: Blend ID:

Cell class Cell class Cell class

Comparison sample testing is requested for:

Pipe only Resin and Pipe



Pipe only Compound and Pipe

B) Raw Materials and Finished Product Testing

Are resin/compound lot results available? Yes

No

Yes

No

Yes

No

Yes

No

Are production facility test reports available for the same lot of pipe? Yes

No

Yes

No

Yes

No

Yes

No

Comments: None NTPEP



Samples

Audit Report

Plant Name:





of 54

Auditor Note – To gather the proper information for the record traceability (using three randomly selected samples

from the yard) complete the following charts.

• M 252 Yard Samples

C) M 252 Random Sample Information and Record Audit

M 252 Yard Sample 1 M 252 Yard Sample 2 M 252 Yard Sample 3

Size: Size: Size:

Type: Type: Type:

Shift: Shift: Shift:

Manuf. Date: Manuf. Date: Manuf. Date: Resin #1

(supplier/lot)

Resin #1

(supplier/lot)

Resin #1

(supplier/lot)

Resin #2

(supplier/lot)

Resin #2

(supplier/lot)

Resin #2

(supplier/lot)

Resin #3

(supplier/lot)

Resin #3

(supplier/lot)

Resin #3

(supplier/lot)

Blend ID: Blend ID: Blend ID:

Records available, records indicate tests are performed at required frequency and results meet spec. requirements for:

Quality Control Test Specified

Interval

Sample 1 Sample 2 Sample 3

YES NO N/A YES NO N/A YES NO N/A RESIN TESTS

Density Each Lot

Melt Index Each Lot

PIPE TESTS

Diagnostic Tests


Carbon Black Content 1 / Day

Dimensional Analysis Tests



Pipe Length 1 / Shift

Perforations Locations 1 / Shift

Perforations Dimensions 1 / Shift

Water Inlet Area 1 / Shift

Performance Tests

Pipe Stiffness 2 / Week

Pipe Flattening 2 / Week

Brittleness (TUP) 2 / Week

Comments: None

NTPEP



Samples

Audit Report

Plant Name:





of 54


D) M 294 Random Sample Information and Record Audit

M 294 V Yard Sample 1 M 294 R Yard Sample 2 M 294 R Yard Sample 3

Size: Size: Size:

Type: Type: Type:


Manuf. Date: Manuf. Date: Manuf. Date:

Resin #1

(supplier/lot):

Resin #1

(supplier/lot):

Resin #1

(supplier/lot):

Resin #2

(supplier/lot):

Resin #2

(supplier/lot):

Resin #2

(supplier/lot):




Interval


YES NO N/A YES NO N/A YES NO N/A RESIN TESTS

Density Each Lot

Melt Index Each Lot

NCLS (M 294 Blended Resins Only) Initially/Quarterly

PIPE TESTS

Diagnostic Tests


Carbon Black Content 1 / Day

Recycle - Density Each Lot

Recycle - Melt Index Each Lot








Performance Tests




NCLS (Pipe) 2 / Year / Dia. / Plant

Recycle - OIT Each Lot

Recycle – Elongation at Break Each Lot

Recycle - UCLS Each Lot

Comments: None

NTPEP



Samples

Audit Report

Plant Name:





of 54


E) M 330 Random Sample Information and Record Audit

M 330 Yard Sample 1 M 330 Yard Sample 2 M 330 Yard Sample 3

Size: Size: Size:

Type: Type: Type:


Manuf. Date: Manuf. Date: Manuf. Date:

Compound 1

supplier/lot:

Compound 1

supplier/lot:

Compound 1

supplier/lot:

Compound 2

supplier/lot:

Compound 2

supplier/lot:

Compound 2

supplier/lot:

Compound 3

supplier/lot:

Compound 3

supplier/lot:

Compound 3

supplier/lot:

Compound 4 Compound 4 Compound 4:




Interval


YES NO N/A YES NO N/A YES NO N/A COMPOUND TESTS

Density Each Lot

Melt Index Each Lot

NCLS Initially/Quarterly

IZOD Impact Strength Initially/Quarterly

Oxidative-Induction Time Initially/Quarterly

Tensile Strength/Elongation at Yield Initially/Quarterly

Flexural Modulus (1% Secant) Initially/Quarterly

PIPE TESTS

Diagnostic Tests









Performance Tests




NTPEP



Samples

Audit Report

Plant Name:





of 54

NCLS (Pipe Liner) 1 / Year / Dia. / Plant

Comments: None

NTPEP



Samples

Audit Report

Plant Name:





of 54

• Additional Test Records

F) Additional Test Record Audit

In addition to a review of the test records for the M 252, M 294, and M 330 yard samples selected, test records are

reviewed for AASHTO pipe produced on up to three additional weeks throughout the year since the previous audit.

Auditor Note: If any tests have not been performed, collect all pertinent testing documentation for that lot of pipe.


Additional Test Records Reviewed All Tests

Performed

Date Produced Line Size Resin Lot # Line Size Resin Lot # Line Size Resin Lot # YES NO

Week 1

Week 2

Week 3

Comments:

NTPEP


Plastic Pipe (HDPE and Polypropylene) QC Tests

Audit Report

Plant Name:





of 54

Section 9: Quality Control Testing Evaluation

• Density – Gradient Technique

Density Determination (Resin, Compound) Yes No

A) Apparatus (AASHTO M 294/M 330 sec. 6.1.1) (ASTM D1505 sec. 5.0)

1) A Density Gradient Tube with a suitable graduate with ground glass stopper?

2) Constant Temperature Bath with a means of controlling the temperature of the

liquid in the tube at 23°C ±0.1°C?

3) Several glass floats covering the density range approximately evenly?

4) A pycnometer?

5) Liquids suitable for the preparation of a density gradient?

6) Hydrometers, with 0.001 graduations, covering the range of densities to be

measured?

7) An analytical Balance having a sensitivity of 0.001 g?

8) A siphon or pipet arrangement constructed so that the rate of flow of liquid may be

regulated to 10 mL/min ±5 mL/min?

9) Wire screen basket and long wire?

B) Procedure (ASTM D1505 sec. 9.0)

1) Three representative test specimens wetted with the less dense of the two liquids

used in the tube?

2) Specimens placed gently in the tube?

3) Tube and specimens allowed to reach equilibrium (10 min or more)?

4) Float height of each specimen read by a line through the individual center of

volume?

Note – When a cathetometer is used, heights are measured from an arbitrary level

using a line through the center of volume.

5) Heights of the three specimens averaged?

6) Specimens removed without destroying the gradient by slowly withdrawing a wire

screen basket attached to a long wire?

7) Density reported as the average of two D1550 density determinations? (ref. D3350,

Sec. 10.1.3)

Comments: NTPEP



Audit Report

Plant Name:





of 54

• Density – Displacement Method

Density Determination (Resin, Compound) Yes No

A) Apparatus (ASTM D792, Method A, secs. 9.0 & 10.0)

1) An analytical balance readable to the nearest 0.0001 g?

Note: Required for materials having densities less than 1.00 g/cm3 and sample

weights less than 10 g.

2) An immersion vessel for holding the water and immersed test specimen?

3) A means of determining the weight of the test specimen while immersed in water?

4) A temperature measuring device readable to 0.1°C or better, for checking the

temperature of the 23°C immersion water?

5) Distilled or de-mineralized water for immersing the test specimen?

B) Procedure (ASTM D792 secs. 7.0, 11.0, 12.0 & 13.0)

1) Test conducted in a standard laboratory atmosphere of 23 ± 2°C and 50 ± 5%

relative humidity?

2) Test specimen weighing 1 to 5 g weighed to the nearest 0.0001 g (a)?

3) Temperature of the immersion water measured to the nearest 0.1°C and recorded?

4) Test specimen immersed in water and the immersed weight determined to the

nearest 0.0001 g (b)?

5) Specific gravity of the specimen calculated as follows: a/(a-b)

6) Density of the specimen calculated as follows:

Density23C, g/cm3 = Sp. Gr. 23/23°C x 0.9975

7) Density reported as the average of two density determinations? (ref. D3350, Sec

10.1.3)

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• Density – Ultrasound Method - Apparatus

Density Determination (Resin) – Ultrasound Method Yes No

A) Apparatus (ASTM D4703 and D4883)

Apparatus for Preparing Plaques:

1) D4703 plaque molding equipment?

2) Two-roll mill that can be heated to a temperature high enough to flux the

materials to be tested.

3) Press, with platens that can be heated to at least 177°C, molds, and backing

plates?

4) Oven, capable of maintaining a temperature of at least 175°C?

5) Polyester film, or aluminum foil for use as a parting agent in the molding

operation?

6) Device for lowering the temperature of the platens at a rate of 15 ± 2°C/min.?

Apparatus for Determining Density:

1) A DS 500 ultrasonic instrument supplied by Deguise Technologies, Inc.?

2) Has the instrument’s electronics been calibrated (D4883, Note 9)?

3) Has the instrument’s output been calibrated or compared to D792 or D1505 test

results by generating a calibration curve made up of a minimum of 30 data

points covering the density range of interest?

4) A water bath containing clean demineralized water maintained at a temperature

of 23 ± 2°C (73.4 ± 3.6°F)?

B) Procedure (ASTM D4703 and D4883)

Procedure for Preparing Plaques:

1) Test plaque prepared in accordance with the molding procedure specified in

Practice D4703, Annex 1, Procedure C?

2) Polyethylene plastic placed in the chase between polyester film or aluminum

foil parting sheets backed by smooth backing plates?

3) With the platens at the molding temperature, assembly inserted between the

platens?

4) With the platens closed and contact pressure applied, platens allowed to heat to

within 65°C of the molding temperature?

5) Plaque heated for 5 minutes then full pressure applied as quickly as possible?

6) Heating continued for 3 to 5 min.?

7) Heat turned off and press cooled at a rate of 15 ± 2°C/min until a platen

temperature of 76°C is reached?

8) Platens cooled to a temperature of 40°C or lower?

NTPEP



Audit Report

Plant Name:





of 54

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• Density – Ultrasound Method - Procedure

Density Determination (Resin) – Ultrasound Method Yes No

C) Procedure (ASTM D4703 and D4883)

Procedure for Determining Density:

1) Dimensions of test specimen cut from the test plaque: 80 to 100 mm long, 35 to

45 mm wide, and 1.9 ± 0.2 mm thick? (3.15 to 3.94 in. long, 1.38 to 1.77 in.

wide, and 0.075 ± 0.01 in. thick)?

2) Test specimen free of foreign matter, voids, surface marks, and other surface

flaws?

3) Test specimen conditioned at 23 ± 2°C (73.4 ± 3.6°F) for not less than 40h prior

to test in accordance with Procedure A of Practice D618?

OR

4) If testing is performed before the sample has become fully conditioned has a

correlation between the conditioning time and measured density been

established and applied to obtain the predicted density?

5) Test specimen placed in the instrument’s water bath and allowed to condition

for approximately 10 minutes prior to measurement?

6) Each sample tested four times (from different locations on the specimen) and the

average determined?

a) If the density of one determination is equal or greater than ± 0.0004

g/cm3 from the average, is the determination discarded?

b) If two determinations are equal or greater than ± 0.0004 g/cm3 from the

average, is a new plaque made?

OR

7) If data has demonstrated that the resin samples have good uniformity, is one

determination made per sample?

8) Is the average density reported as the density at 23°C in g/cm3?

Comments: NTPEP



Audit Report

Plant Name:





of 54

• Melt Index (Apparatus) Melt Index (Resin, Compound) Yes No

A) Apparatus (AASHTO M 294/M 330 Sec. 6.1.1) (ASTM D1238 Sec. 5.0)

1) Plastometer as specified in D1238: consisting of a) a dead weight piston, b) a heated

steel cylinder that is thermostatically controlled, c) a die at lower end, and d) a

weighted piston operating within the cylinder?

2) Cylinder as specified in D1238: 50.8 mm in diameter and 162 mm in length, supported

by at least two 6.4 mm high-strength screws or by at least two 10 mm diameter rods

with a) a hole having diameter of 9.5504 mm ±0.0076 mm, displaced 4.8 mm from the

cylinder axis, b) two wells for a thermal sensor and a thermometer, and c) a 3.2 mm

plate, with hole centered under die countersunk from below and allows free passage of

extrudate, attached to the bottom of the cylinder?

3) Die as specified in D1238: with a) an outside diameter (9.5504 ± .0076 mm) which

allows free fall through hole in cylinder, b) a bore of 2.0955 mm ±0.0051 mm

diameter, 8.000 mm ±0.025 mm length which is smooth and straight with no visible

tool marks, and c) a finish of approximately 12 rms or better?

4) Piston as specified in D1238: a) made of steel with an insulating bushing at the top, b)

has a land 9.4742 mm ± 0.0076 mm in diameter and 6.35 mm ±0.13 mm in length, c)

has threads and flats immediate above the land (Optional), d) has a diameter above the

land no larger than 8.915 mm, e) has a finish of 12 rms, f) is scribed with two

references marks 4 mm apart, g) has a bottom located 48 mm above the die, and h) has

a weight, including the load , within ±0.5% of the selected load?

5) Heater as specified in D1238: a) capable of heating the apparatus such that the

temperature at 10 mm above the die can be maintained with ±0.2°C (0.5 °F) of desired

temperature, b) capable of maintaining the temperature of the barrel from 10 mm to 75

mm above the top of the die within ±1% of the set temperature, c) with heat supplied by

electric band heaters covering the entire length of the cylinder, d) insulated with 38 mm

of foamed glass insulation, e) equipped with a 3.2 mm thick insulating plate attached to

the bottom of the cylinder, and f) calibrated at least once a year to a NIST traceable

light-gage probe-type thermocouple or platinum-resistance thermometer?

6) Temperature Controller: capable of ±0.2°C (0.5 °F) of desired temperature?

7) Thermometer: having a range of 4°C and graduated in 0.2°C (0.5 °F) divisions?

8) Apparatus Level to facilitate vertical alignment of bore?

9) Accessory Equipment: to charge samples to cylinder, a funnel, a die plug, a tool for

cutting off the extruded sample, a timer or stop watch, cleaning equipment, go/no-go

gauges, a balance accurate to ± 0.001 g, a weight or weight-piston support?

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• Melt Index (Procedure)

Melt Index (Resin, Compound) Yes No

C) Procedure (AASHTO M 294/M 330 Sec. 6.1.1) (ASTM D1238 Sec. 9.0)

1) Test conditions 190/2.16 (ref. D3350, Section 10.1.4)?

2) Apparatus inspected for cleanliness, bore of extruder properly aligned, and die bore

diameter checked?

3) Temperature stability verified and within ±0.2°C?

4) Die and Piston inserted?

5) Temperature of cylinder, with piston and die in place, stable 15 minutes before

testing begins?

6) Piston removed and placed on insulated surface?

7) Cylinder charged within 1 minute with weighed portion of resin and piston

reinserted?

8) Appropriate weight added to make a total load of 2.16 kg?

9) Time allowed for the resin to soften and begin to melt.

10) Some resin purged to move the piston to a position such that subsequent travel of

the piston will place the lower scribe mark at the reference start position 7.0 ± 0.5

min from the completion of the charge.

11) Purge completed at least 2 minutes prior to start of test?

12) Test begins, the timer is reset to zero and the initial cut-off is made?

13) Final cut-off made exactly 6 minutes after initial cut-off?

14) If extrudate contains visible bubbles, is extrudate discarded?

15) Extrudate weighed to the nearest 1 mg once cool?

16) Weight multiplied by a factor of 1.67 (ref. D1238, Table 2)?

17) Duplicate determinations made and averaged (ref. D3350, Section 10.1.4)?

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• NCLS - Apparatus NCLS (Apparatus) Yes No

A) Apparatus (ASTM F2136 Sec. 5.0)

1) Blanking Die, suitable for cutting test specimens?

2) Stress Cracking Testing Apparatus

a. accurate to 0.5% of the calculated or applied load?

b. lever loaded machine having lever arm ratio of 2:1 to 5:1?

c. dead weights?

d. any other method for producing a constant ligament stress?

3) Constant Temperature Bath, capable of maintaining 122°F ± 2°F (50°C ± 1°C)?

4) Notching Device having a blade approximately 0.2 to 0.3 mm thick?

5) Micrometer readable to ±0.001 in. (±0.025 mm)?

6) Balance or Scale readable to ±0.1g?

7) Microscope, equipped with a micrometer to measure depth of notch?

8) Compression-Molding Press and Suitable Chase for Compression-Molding

specimens?

9) Metal Shot?

10) Timing device, readable to the nearest 0.1 hr (6 minutes)?

Reagents

11) 10% non-ylphenoxy poly (ethyleneoxy) ethanol (Igepal CO-630 from Rhone-

Poulenc or equivalent) by volume in 90% deionized water?

B) NCLS Resin/Compound Specimen Preparation (ASTM F2136 Sec. 7.0)

1) Compression mold pellet specimens into 0.075 in. (1.9 mm) sheet?

2) Sheet trimmed by 0.6 in. (15 mm) on each side (This step is optional.)?

3) Specimens die cut from sheet having:

a. length: 2.36 in ±0.01 in. (60.00 mm ±0.25 mm)?

b. width: 0.125 in ±0.001 in. (3.20 mm ±0.02 mm)?

c. thickness: 0.075 in ±0.003 in. (1.90 mm ±0.08 mm)?

Notching

4) Specimens notched across centerline of the reduced section cut perpendicularly to

the plane defined by length and width?

5) Cut at a rate maximum rate of 0.1 in./min (2.5 mm/min) to a depth of [0.2 x measure

thickness of specimen]?

6) Notch measured by microscope to ensure depth is ±0.001 in. (±0.025mm)?

7) Single razor blade not used for more than ten test specimens?

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• NCLS – Pipe Liner Specimen Preparation

NCLS (Pipe Liner - Test Specimen Preparation) Yes No

C) NCLS Pipe Liner Specimen Preparation ( AASHTO Std. Practice) (ASTM F2136 Sec. 7.0)

Obtaining Test Specimens:

1) Enough material cut from the pipe sample to make five tensile test specimens?

2) Five specimens 2.36 in ±0.01 in. (60.00 mm ±0.25 mm) long and 0.125 in ±0.001 in.

(3.20 mm ±0.02 mm) wide punched longitudinally from pipe liner such that the

notch will be perpendicular to the direction of flow?

OR

3) A sample of pipe liner ground and made into plaques according to ASTM D4703,

Procedure C at a cooling rate of 15°C/min (27°F/min.)? (Usually required for pipe

15 inch diameter or less.)

4) Five test specimens 2.36 in ±0.01 in. (60.00 mm ±0.25 mm) long and 0.125 in

±0.001 in. (3.20 mm ±0.02 mm) wide punched from the plaque(s)?

Notching:

5) All specimens notched across centerline of the reduced section cut perpendicularly

to the plane defined by length and width? Specimens from pipe liner notched on

the outside of the liner?

6) Notch cut at a rate maximum rate of 0.1 in./min (2.5 mm/min) to a depth of 20

percent of the measured thickness of the specimen?

7) Reduced section width measured to the nearest 0.001 in. and ligament thickness

measured to the nearest 0.0001 in.?

8) Single razor blade not used for more than ten test specimens?

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• NCLS - Procedure NCLS (Pipe Liner) Yes No

D) Procedure (Continued) (AASHTO M 294 Sec. 6.1.1; 9.4) (ASTM F2136 Sec. 7)

NCLS Testing:

1) Temperature in bath maintained at 122°F ±2°F (50°C ±1°C)?

2) Five specimens tested?

3) For tests on pipe liner - Weight of shot needed to apply a stress level of 4100

kPa (600psi) to each specimen determined? (Attaching the shot tube at this time

is prohibited.)

4) Specimens attached to the loading frame taking care to not bend the specimen?

5) For tests on pipe liner specimens lowered into the bath within 1 hour after

notching?

6) Specimens conditioned in bath for at least 30 minutes?

7) After conditioning, timer set to zero?

8) Weight tube carefully connected to the appropriate lever arm for each specimen?

9) Load applied gradually within a period 5 sec to 10 sec without any impact on the

specimen?

10) Timer started immediately after loading has begun?

11) Time to failure of each specimen recorded to the nearest 0.1 h (6 min)?

12) The average failure time of five pipe liner specimens not less than 18 hours?

13) The average failure time of five pipe liner plaque specimens not less than 24

hours?

14) Calculations performed correctly?

15) Test temperature recorded?

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• Carbon Black Content

Color Content (D4218) Yes No

A) Apparatus (AASHTO M 294 Sec. 6.1.1) (ASTM D4218 Sec. 6.0)

1) Muffle furnace with internal dimensions of approximately 100m in length, width, and

height? (Furnaces with larger dimensions are considered unsuitable.)

2) Screen of 20-mesh approximately 120 by 100 mm folded down approximately 10 mm

of the long dimension?

3) Thermocouple-probe temperature controller or equivalent?

4) Desiccator, with desiccant?

5) Laboratory interval timer, with alarm?

6) Disposable aluminum weighing dish, with crimped sides and tabs on the rim?

7) Tongs or Tweezers, approximately 250 to 300 mm?

8) Analytical Balance, readable to the nearest 0.0001g?

B) Procedure (AASHTO M 294 Sec. 6.1.1) (ASTM D4218 Sec. 10.0)

1) Temperature set to 605°C ± 5ºC?

2) Weighing dish marked with an identifying impression on tab?

3) One dish placed on screen in muffle furnace and surface oil burned off for 2 min?

4) Dish transferred to desiccator and allowed to cool for at least 2 min?

5) Dish weighed to nearest 0.0001 g?

6) Approximately 1 g of specimen added to dish and dish reweighed?

7) Dish and contents placed into muffle furnace for 3 min?

8) Dish removed and allowed to cool in desiccator for at least 2 min?

9) Dish reweighed to 0.0001 g?

10) If ashable mineral fillers are suspected to be present, is the dish with contents replaced

in furnace for at least 10 min or until light-colored ash remains?

11) Dish allowed to cool in desiccator for at least 2 min and then reweighed to 0.0001 g?

12) Two determinations averaged to obtain a test result (ref: Sec. 10.14 & 12.1.3)?




Audit Report

Plant Name:





of 54

• Wall Thickness

Wall Thickness - Micrometer Yes No

A) Apparatus (ASTM D2122 Sec. 7.1)

1) A cylindrical or ball anvil tubing micrometer readable to ± 0.001 in. (± 0.02 mm)?

B) Procedure (ASTM D2122 Sec. 6 & 7)

1) Pipes cut cleanly and burrs removed?

2) If tested for NTPEP quality assurance purposes are specimens conditioned and tested

at:

a. 73.4°F ± 3.6°F (23°C ± 2°C)?

b. 50% ± 5% relative humidity?

c. for not less than 24 hr (where required, in accordance with D618)?

3) A minimum of eight measurements taken at closely spaced intervals and averaged?

4) Wall Thickness range (in percentage) calculated?

Comments: None

Wall Thickness via Alternative Apparatus Yes No

A) Apparatus (D2122 Sec. 4.0) NTPEP (Work Plan Approved Alternate Procedure)

1) Device Used? Ultrasonic Laser Electronic Nuclear

2) Has the apparatus used been validated in accordance with D2122?

3) Is each gauge and transducer identified?

B) Procedure for Wall Thickness via Ultrasonic gauge

1) Two sets (8 measurements/set) of liner thickness readings taken per shift?

2) One of the sets taken with a micrometer in accordance with D2122?

4) Each set of measurements comprised of at least eight readings?

5) Are the numbers from each reading recorded?

6) Does the record indicate whether a micrometer or ultrasonic gauge was used?

Comments: None

NTPEP



Audit Report

Plant Name:





of 54

• Inside Diameter and Length

Inside Diameter Yes No

A) Apparatus (M 294 Sec. 9.6.1, M 252 Sec. 9.5.1) (ASTM D2122 Sec. 8.0)

1) Metal rule, tape, or caliper accurate to 0.03 mm and having at least 0.01 in. (0.2 mm)

graduations?

OR

2) Tapered plug gage, having a taper ratio of 1:100 and accurate to ± 1% of its taper and

± 0.001 in. (± 0.02 mm) of its diameter and a 45° by 1/8 in (3 mm) face bevel located

on the entrance of the end of the gage?

B) Procedure (M 294 Sec. 9.6.1, M 252 Sec. 9.5.1) (ASTM D2122 Sec. 8.2)

1) A metal rule, steel tape, or caliper used to determine the average inside diameter from

two diameter measurements, the first at the seam (0°) and the second 90° from the

seam?

OR

2) A plug gage inserted into the pipe, causing round out but no expansion used to

determine the inside diameter?

Comments: None

Length of Pipe Yes No

C) Apparatus (M 294 Sec. 9.6.2, M 252 Sec. 9.5.2) (ASTM D2122 Sec. 12.1)

1) Steel tape or rule with marked graduations of ¼”or less (240”x 0.01 x 0.1) accurate to

± 6 mm in 3 m?

D) Procedure (AASHTO M 294 Sec. 9.6.2, M 252 Sec. 9.5.2) (ASTM D2122 Sec. 12.2)

1) Pipe stress free and at rest on a flat surface and in a straight line?

2) Length measured?

Comments: None

NTPEP



Audit Report

Plant Name:





of 54

• Unit Weight

Unit Weight Yes No

A) Apparatus

1) Steel tape or rule with marked graduations having a tolerance of 10% of the nominal

length?

2) Balance or scale, accurate to 1% of the load applied?

B) Procedure

1) Pipe length determined according to D2122?

2) Pipe length weighed?

3) Calculations performed correctly to produce result in units of weight per foot?

Comments: None

NTPEP



Audit Report

Plant Name:





of 54

• Perforation Locations & Dimensions

(M 294 & M 330) Yes No

A) Apparatus

1) Caliper or other measuring device, readable and accurate to at least 0.008 in (0.2

mm)?

B) Class 1, Locations & Dimensions

Class 1, Locations:

1) Spacing of rows uniform and distance between centerline of rows not less than 25mm

(1 in.)?

2) Rows of perforations, height of centerline of the uppermost rows above the invert, a

chord length of unperforated segment meets the requirements of Table 1 in the

specification?

3) For single-wall and dual-wall pipe, perforations located in rows parallel to the axis of

the pipe, in the external valleys in each row of corrugations, and not cut into the

corrugation sidewalls?

4) For DP pipe, perforations located in the center of the cells arranged in two equal

groups placed symmetrically on either side of the lower unperforated segment

corresponding to the flow line of the pipe?

Class 1, Dimensions:

1) Perforations approximately circular and have a diameter of not less than 5 mm (0.2

in.) and not greater than 10 mm (0.4 in.)?

C) Class 2, Locations & Dimensions

Class 2, Locations:

1) Perforations spaced uniformly along the length of the pipe?

2) For single-wall and dual-wall pipe, perforations located in the external valleys?

3) For DP pipe, perforations located in center of the cells?


1) Perforations circular having a diameter of not less than 5 mm (0.2 in.) and not greater

than 10 mm (0.4 in.)?

2) Width of slots do not exceed 3 mm (0.12 in.)?

3) Length of slots don’t exceed 70 mm (2.75 in.) for 12 in. (300 mm) and 15 in. (375

mm) pipe and 75 mm (3 in.) for 18 in. (450 mm) and larger?




Audit Report

Plant Name:





of 54

• Perforation Locations & Dimensions (M 252) Yes No

A) Apparatus (AASHTO M 252 Sec. 9.5.3)


mm)?

B) Class 1, Locations & Dimensions (AASHTO M 252 Sec. 7.4.1)

Class 1, Locations:

1) Perforations located in rows parallel to the axis of the pipe, in the external valleys in

each row of corrugations, and not cut into the corrugation sidewalls?

2) Spacing of rows uniform and distance between centerline of rows not less than 25mm

(1 in.)?

3) Rows of perforations, height of centerline of the uppermost rows above the invert, a

chord length of un-perforated segment meets the requirements of Table 1 in the

specification, M 252?


1) Perforations approximately circular and have a diameter of not more than 5 mm (0.2

in.) for 4 to 6 in. (100 to 150 mm) pipe and not greater than 10 mm (0.4 in.) for 8 to

10 in. (200 to 250 mm) pipe?

C) Class 2, Locations & Dimensions (AASHTO M 252 Sec. 7.4.2)

Class 2, Locations:

1) For single-wall and dual-wall pipe, perforations located in the external valleys and

spaced uniformly along the length of the pipe?


1) Perforations circular having a diameter of not exceeding the values of Annex A2 and

are located in the outside valleys of the corrugations?

2) Width of slots do not exceed 3 mm (0.12 in.)?

3) Length of slots don’t exceed 25 mm (1.0 in.) for 4 in (100 mm) and 6 in. (150 mm)

pipe and 30 mm (1.2 in.) for 8 in. (200 mm) and larger?




Audit Report

Plant Name:





of 54

• Water Inlet Area - M 252, M 294 & M 330

Yes No

A) Apparatus


mm)?

B) M 252 (Class 2)

1) Water inlet area is a minimum of 20 cm2/m (1 in²/ft)?

C) M 294 & M 330 (Class 2)

1) Water inlet area is a minimum of 30 cm2/m (1.5 in²/ft) for 12 in to 18 in (300 mm to

450 mm) pipe and 40 cm2/m (2 in²/ft) for pipes larger than 18 in. (450 mm)?

Comments: None

NTPEP



Audit Report

Plant Name:





of 54

• Brittleness – M 294 & M 330

Brittleness (TUP) (M 294 & M 330) Yes No

A) Apparatus

1) Tup: conforming to ASTM Tup Type B having a mass of 4.5 kg (9.9 lb.), a nose

radius of 2.00 in. (51mm), and a minimum outer diameter of 2.00 in. (50.8mm)?

2) Drop tube: approximately 12 ft long, provides a fall of at least 10 ft (3.0 m), mounted

such that the lengthwise direction is essentially vertical, allows the tup to fall freely

(does not chatter), and has means of holding up the tup at steps of 2 in. (50.8 mm) and

can release the tup in a reproducible manner, allowing the tup to free fall and catch on

the first rebound?

3) Specimen Holder, Flat plate approximately 8 x 12 x 1 in. (203 x 305 x 25.4 mm)

mounted on a rigid base fastened to concrete slab, with a 0.12 in. (3 mm) groove with

rounded edges about 0.06 in (1.5 mm) to allow the positioning the pipe and a flat steel

plate or shim to support specimen at impact?

4) Freezer: For conditioning the specimen at -4 ± 2°C (M 294 only)

B) Procedure

1) Six specimens tested (one impact per specimen) or one specimen impacted six times

(separated by 120 ± 10° angular)?

2) For M 294: Specimen(s) conditioned at -4 ± 2°C for a minimum of 24 hours?

3) For M 330: Specimen(s) conditioned at 23 ± 2°C (73.4 ± 3.6°F) for a minimum of

24 hours?

4) Impact points at least 150 mm (6 in.) from end of the specimen?

5) Specimen positioned such that point of impact is at the top of the vertical diameter

and tup strikes on a corrugation crown?

6) Tup dropped 3 m (10 ft.) onto the specimen?

7) Impact(s) occurs within 60 seconds from removal from conditioning environment?

8) Test accepted if no cracks appear after visual inspection?




Audit Report

Plant Name:





of 54

• Brittleness – M 252

Brittleness (TUP) (M 252) Yes No

A) Apparatus (AASHTO M 252 Sec. 9.4)

1) Parallel plate device that conforms to Figure 3 of M 252?

2) Top plate weighs 9.5-kg (21 lbs.)?

B) Procedure (AASHTO M 252 Sec. 9.4)

1) Test specimen 150 mm (6 in.) long and cut from one continuous length?

2) Specimen conditioned at -4 ± 2°C for a minimum of one hour?

3) Top plate set for free fall of 500 mm (19.7 in.) measured to the top of the uppermost

surface of the specimen?

4) Upper plate dropped?

5) Impact occurs within 30 seconds of removal from the conditioning environment?

6) Specimen removed and inspected for cracking?

7) Specimen accepted if no cracking occurs?

Comments: None

• Pipe Stiffness/Flattening (Apparatus)

Pipe Stiffness/Flattening Yes No

A) Apparatus

1) A calibrated Compression Testing Machine of the constant rate of cross head

movement-type, meeting the requirements of ASTM D695, and capable of variable

head speeds accurate to 0.02 in. /min. ( 0.5 mm/min.)

2) Flat, smooth, and clean Loading Plates: of sufficient thickness [ ≥0.25 in. (6.0 mm)]

so that no bending or deformation occurs during the test; having a length equal to or

exceeding the specimen length, and a width which exceeds the specimen contact width

by at least 6 in. (150 mm) at maximum deflection?

3) A Deflection Indicator readable and accurate to 0.001 in. (0.02 mm) which does not

support the test specimen or the plate and does not affect the load deflection

measurements?

Comments: None

NTPEP



Audit Report

Plant Name:





of 54

• Pipe Stiffness/Flattening (Procedure)

Pipe Stiffness/Flattening Yes No

B) Procedure

Stiffness

1) Specimen conditioned in accordance with section 8 of the method? (Specimens are conditioned

prior to test at 21 to 25°C (70 to 77°F) for not less than 24 hours. Also, all tests are to be

conducted at a laboratory temperature of 25°C (70 to 77°F) unless otherwise specified.)

2) At least two specimens tested for M 330 and M 294, one at 0° and one at 90° (only one

specimen is required for M 252 with seam lines parallel to testing plates)?

3) For M 330 and M 294, specimen length at least one diameter length for pipe 300-600 mm (12-

24in.) in diameter, and ½ diameter length for pipe greater than 600mm (24in.) in diameter? For

M 252 specimen length equal to 300 ±10mm (12 ±0.4in) long, cut to include full corrugations?

4) Ends of specimen cut square and free of burrs and jagged edges?

5) Length of each specimen determined to at least 1/32 in. (1 mm) by averaging at least four

equally spaced measurements around the perimeter?

6) Average inside diameter determined from two diameter measurements, the first at the seam and

the second 90° from the seam?

7) The outside diameter determined to the nearest 0.1 in. (0.2 mm) using a circumferential wrap

tape or by averaging the maximum and minimum outside diameters as measured with a

micrometer or caliper.

8) Test specimen lies flat on the plate and is centered laterally such that the longitudinal axis is

parallel to the bearing plates?

9) Deflection indicator set in place?

10) Upper plate brought into contact with the specimen with no more load than is necessary to hold

it in place?

11) Specimen compressed at a constant rate of :

0.50 0.02 in./min. (12.5 0.5 mm/min.) if 3 to 24 inches in diameter ?

0.60 0.02 in./min. (15.2 0.5 mm/min.) if 30 inches in diameter ?





12) A load of 20 5 N (4.5 lbf ± 1.1 lbf) shall be considered as the origin of the load-deflection

curve if curvature in the specimen results in erratic initial loading?

13) Load-deflection recorded continuously or recorded intermittently at increments of no more than

5 percent of the average inside diameter of the specimen?

14) Load-deflection curve carried beyond 20% deflection so that the shape of the curve at 20%

deflection can be determined?

15) Specimen has the minimum stiffness specified in M 294, Section 7.4 at 5% deflection? NTPEP



Audit Report

Plant Name:





of 54

16) No evidence of wall buckling (Any decrease or downward deviation in the pipe stiffness test

curve at or below the calculated buckling deflection limit shall be considered a buckling point.

Additionally, any irrecoverable longitudinal crease or similar irrecoverable artifact that spans

three or more corrugations and is present after 30 minutes following removal of the test

specimen from the parallel plate test machine shall be considered as buckling. Deformation in

the corrugations due to direct contact of the test specimen with the parallel plates shall not be

considered as buckling.).

Flattening

17) Continuation of testing for flatness using the same two specimens for stiffness?

18) Continuation of testing for flatness using two new specimens?

19) Buckling deflection limit calculated as stated in M 294, Section 9.2.1?

How are the values for “hp” and

percentage derived?

20) Is the rate of loading the same as used for stiffness?

21) Checks for any visual evidence of cracking, splitting, delamination, or buckling?

22) Check specimen for a decrease or downward deviation in the load-deflection curve during the

pipe flattening test when the pipe is tested?

Comments: None

NTPEP



Audit Report

Plant Name:





of 54

• Oxidative Induction Time (Procedure)

Oxidative Induction Time (Polypropylene Resin) Yes No

Procedure (AASHTO M 330 Sec. 6.1.1) (ASTM D 3895)

1) Samples taken from pipe and tested using a DSC machine

2) Samples to be compression molded into film with a thickness of 0.0093 to

0.0104”.

3) Cut disks from film that are 0.245” t0 0.255” in diameter and weighs 5 – 10

mg.

4) Use empty pan as a reference pan?

5) Test duplicate samples and average the two for reporting purposes?

6) Nitrogen gas is ultra-high purity? Oxygen gas is ultra-high purity?

7) Place samples into DSC test chamber and start test. Allow 5 minutes for

samples to come to 200C under a Nitrogen atmosphere.

8) Nitrogen flow is 50 mL/min

9) Temperature rate is 20C /minute.

10) Once 200C is reached allow 5 minute equilibrium with Nitrogen?

11) After 5 minutes switch gas to 50mL/minute Oxygen?

12) Continue timed testing until the exotherm curve has a definitive upward rise?

13) Once this is reached stop the test and determine the OIT by drawing tangent

lines along the x curve and the upward rising curve and where they intersect

subtract that time from the time the Oxygen was turned on.

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• Un-notched, Constant Ligament Stress Crack Test (UCLS)

UCLS (Apparatus) Yes No

A) Apparatus (ASTM F3181) (ASTM D4703)

1)Blanking Die, suitable for cutting test specimens?

2)Stress Cracking Testing Apparatus

a. accurate to 0.5% of the calculated or applied load?

b. lever loaded machine having lever arm ratio up to 10:1?

c. dead weights?

d. any other method for producing a constant ligament stress?

3) Constant Temperature Bath, capable of maintaining 176°F ± 2°F (80°C ± 1°C)?

4) Compression-Molding Press and Suitable Chase for Compression-Molding

specimens at least 7 in (178 mm0 by 7 in. (178 mm) and cooling it at 15°C/min

(27°F/min.)?

5) Metal Shot?

6) Timing device, readable to the nearest 0.1 hr (6 minutes)?

Reagents

7) Deionized water?

B) Pipe Liner Specimen Preparation

Obtaining Specimens

8) Enough material cut from the pipe sample to make five tensile test specimens?

9) The mold must be capable of producing plaques that are 0.04 ± 0.005 in. (1.0 ±

0.1 mm) thick for a width of 2.25 in (57.1 mm), then transitioning to a thickness

between 0.090 in. (2.3 mm) and 0.095 in (2.4 mm). The transition must occur

across 1.125 in. (28.6 mm) on either side of the narrow section and stay constant

for the full length of the test specimen 6.5 in. (170 mm)?

10) The narrow area of the test specimen is 0.50 in. (12.7 mm) wide and 2.25 in.

(57.1 mm) long and 0.04 ± 0.005 in. (1.0 ± 0.1 mm) thick. The end tabs must be

between 0.090 and 0.095 in. (2.3 and 2.4 mm) thick. The thickness will

transition from the narrow section to the ends across 1.125 in. (28.6 mm) on

either side?

11) The test specimen is cut from the plaque according to D638?

12) A hole, 0.219 in. (5.6 mm) is placed in each tab with a 7/32 in. drill bit?

NTPEP



Audit Report

Plant Name:





of 54

13) Reduced section width measured to the nearest 0.001 in. and ligament thickness

measured to the nearest 0.0001 in.?

Comments:

• Un-notched, Constant Ligament Stress Crack Test (UCLS)

UCLS (Procedure) Yes No

C) Test Procedure (ASTM F3181)

UCLS Testing:

1) Measure the width and thickness of each specimen to an accuracy of 0.001 in.

(0.03 mm) in accordance with D5397?

2) Calculate the load necessary to apply a tensile stress of 650 psi (4.48 MPa)?

3) Five specimens tested?

4) Specimens attached to the loading frame taking care to not bend the specimen?

5) Set timer set to zero?

6) Time to failure of each specimen recorded to the nearest 0.1 h (6 min)?

7) Failure of specimens near the grips classified as a non-test and not considered in

data analysis?

8) The average failure time of five specimens not less than 34 hours?

9) The minimum failure time of any liner specimens not less than 18 hours?

Comments:

NTPEP



Audit Report

Plant Name:





of 54

• Tensile Properties of Plastics

Tensile Properties of Plastics Yes No

A) Apparatus (ASTM D 638 sec. 5.0)

Testing Machine

1) Fixed grips rigidly attached to the fixed and the movable members of the testing

machine?

2) Self-aligning grips with free movement into alignment as soon as any load is applied

so that the long axis of the test specimen will coincide with the direction of the

applied pull together the center line of the grip assembly?

3) The slippage relative to the grips of the specimen is prevented insofar as possible?

4) Drive Mechanism—A drive mechanism for imparting to the movable member a

uniform, controlled velocity with respect to the stationary member, with this velocity

to be regulated as specified in Section 8?

5) Load Indicator—A suitable load-indicating mechanism capable of showing the total

tensile load carried by the test specimen when held by the grips?

6) The total elastic longitudinal strain of the system constituted by these parts does not

exceed 1 % of the total longitudinal strain between the two gage marks on the test

specimen at any time during the test and at any load up to the rated capacity of the

machine for the fixed member, movable member, drive mechanism, and grips?

7) Crosshead Extension Indicator—A suitable extension indicating mechanism capable

of showing the amount of change in the separation of the grips, that is, crosshead

movement?

Extension Indicator (extensometer)

8) A suitable instrument for determining the distance between two designated points

within the gage length of the test specimen as the specimen is stretched?

9) Setting of the extensometer at the full gage length of the specimen?

10) Instrument with free of inertia at the specified speed of testing?

NTPEP



Audit Report

Plant Name:





of 54

11) Modulus-of-Elasticity Measurements—for modulus-of-elasticity measurements, an

extensometer with a maximum strain error of 0.0002 mm/mm that automatically and

continuously records?

12) Low-Extension Measurements—the extensometer system must meet at least Class C

(Practice E83) requirements, which include a fixed strain error of 0.001 strain or

61.0 % of the indicated strain, whichever is greater?

13) High-Extension Measurements—for making measurements at elongations greater

than 20 %, measuring techniques with error no greater than ±10 % of the measured

value?

14) Micrometers—Apparatus for measuring the width and thickness of the test specimen

complied with the requirements of Test Method D5947?

Comments:

• Tensile Properties of Plastics

Tensile Properties of Plastics Yes No

B) Procedure (ASTM D 638 Sec. 10.0)

1) Measurement of the width and thickness of each specimen to the nearest 0.025mm

using the applicable test methods in D5947?

2) Measurements of the width of specimens produced by a Type IV die as the distance

between the cutting edges of the die in the narrow section?

3) Measurement of the diameter of rod specimens, and the inside and outside diameters of

tube specimens, to the nearest 0.025 mm (0.001 in.) at a minimum of two points 90°

apart?

4) Alignment of the long axis of the specimen and the grips with an imaginary line joining

the points of attachment of the grips to the machine?

5) Check of proper distance in case of flat/tub and rod specimens?

6) Evenly and firmly tightened grips?

7) Attachment of the extension indicator?

8) Setting the speed of testing at the proper rate as required in Section 8?

9) Recording of the load-extension curve of the specimen?

10) Recording of the load and extension at the yield point?

11) For a pipe sample with Recycle PE, recording of the load and extension at the

moment of rupture?

Comments:

NTPEP



Audit Report

Plant Name:





of 54

NTPEP


Plastic Pipe (HDPE and Polypropylene) Report Signature

Audit Report

Plant Name:





of 54

Section 10: Report Signature

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

Auditor Name: name

Signature:

NTPEP


Plastic Pipe (HDPE and Polypropylene) Miscellaneous

Documents

Audit Report

Plant Name:





of 54

Section 11: Miscellaneous Documents

Audit Meeting Attendance Sheet:

Pipe Wrap:

NTPEP


Plastic Pipe (HDPE and Polypropylene) Miscellaneous

Documents

Audit Report

Plant Name:





of 54

Certificates of Analysis collected during audit:

NTPEP