1、Standard Practice for Quality Assurance of Standard Manufactured Materials AASHTO Designation: R 38-10 (2013) American Association of State Highway and Transportation Officials 444 North Capitol Street N.W., Suite 249 Washington, D.C. 20001 TS-5c R 38-1 AASHTO Standard Practice for Quality Assurance
2、 of Standard Manufactured Materials AASHTO Designation: R 38-10 (2013) 1. SCOPE 1.1. This standard practice contains minimum criteria and guidelines for establishing and implementing quality assurance (QA) procedures for standard manufactured materials used in highway construction. The purpose of th
3、is document is to establish minimum quality control (QC) requirements for manufacturers and to provide guidelines for acceptance of standard manufactured materials by transportation agencies. 1.2. Standard Manufactured MaterialsMaterials used in transportation construction are broadly categorized ac
4、cording to their source and corresponding methods of production. The three principal materials categories are as follows: Project-produced materials, Fabricated structural materials, and Standard manufactured materials. 1.3. In order to explain the difference between these materials categories and p
5、rovide a basic understanding of how QA is applied to them, each of the three primary material categories is defined below (see Section 3). Although QA procedures should be addressed for each of these material categories, the scope of this standard practice is the application of QA to standard manufa
6、ctured materials. 1.4. Standard manufactured materials are standard items that are produced routinely (i.e., not for a specific project) by a manufacturer. They are generally characterized by one or more of the following conditions: 1.4.1. The materials are normally mass-produced under highly contro
7、lled and largely automated manufacturing conditions. 1.4.2. The material properties are stable and have no potential for alteration under proper transportation from the manufacturer to the project site. 1.4.3. The materials arrive at the project site in a solid, finished state and require only insta
8、llation. 1.5. Relevant ItemsThis standard practice addresses those items used in transportation construction that meet the above description of standard manufactured materials. Some examples of standard manufactured materials used in transportation construction are presented in Table 1 below. The li
9、st of items in Table 1 is not all-inclusive but is intended to provide examples of typical items within each of the three principal materials categories. 2016 by the American Association of State Highway and Transportation Officials. All rights reserved. Duplication is a violation of applicable law.
10、TS-5c R 38-2 AASHTO Table 1Typical Items by Materials Category Materials Category Example Items Project-Produced Materials Earthwork Subbase and Base Courses Geotechnical Items* Hot Mix Asphalt (HMA)* Portland Cement Concrete (PCC)* Field Applied Structural Coatings* Pavement Markings* Fabricated St
11、ructural Materials Fabricated Structural Steel and Coatings* Precast/Prestressed Concrete Structural Elements* (e.g., Precast Box Culverts, Prestressed Bridge Beams) Standard Manufactured Materials Binders and Cements (e.g., PG Binder, Portland Cement) Drainage or Water Systems (e.g., Ductile Iron P
12、ipe, Corrugated Metal Pipe, PVC Pipe, Hydrants, Gates and Valves, etc.) Geotextile Fabrics Landscaping Items (e.g., Lime, Fertilizer, Seed, Mulch, Chain Link Fence, etc.) Paints and Coatings (e.g., Traffic Paints, Glass Beads, Preformed Markings, Epoxy, Zinc Galvanizing, etc.) Roadside Safety Device
13、s (e.g., Impact Attenuators, Steel Beam Guardrail, Wood Posts, etc.) Standard Precast Concrete Items (e.g., Concrete Pipe, Concrete Manholes and Junction Boxes, Concrete Barrier, Concrete MSE Wall Panels, etc.) Standard Steel Shapes or Products (e.g., Anchor Bolts, Frames and Grates, Rebar, Stay-in-
14、Place Forms, Sheeting and Piles, etc.) Traffic Control Devices (e.g., Electrical Conduit, Signal Heads, Signal Poles, Controllers, Signs, etc.) * Some constituent materials incorporated are evaluated as standard manufactured materials. 2. REFERENCED DOCUMENTS 2.1. AASHTO Standard: R 18, Establishing
15、 and Implementing a Quality Management System for Construction Materials Testing Laboratories 2.2. ASTM Standards: D3665, Standard Practice for Random Sampling of Construction Materials E4, Standard Practices for Force Verification of Testing Machines E105, Standard Practice for Probability Sampling
16、 of Materials 2.3. Other Document: ISO 10013:2001, Guidelines for Quality Management System Documentation 3. TERMINOLOGY 3.1. Relevant Terms and DefinitionsThe terms and definitions included below are provided to ensure standard application of terminology relevant to the QA of transportation constru
17、ction materials, including standard manufactured materials. Where terms or definitions in this standard practice differ from the above-referenced documents, the terms included herein shall replace those contained in the above-referenced documents. 3.1.1. acceptanceall factors used by the agency (i.e
18、., sampling, testing, and inspection) to evaluate the degree of compliance with contract requirements and to determine the corresponding value for a given product. 2016 by the American Association of State Highway and Transportation Officials. All rights reserved. Duplication is a violation of appli
19、cable law.TS-5c R 38-3 AASHTO 3.1.2. accredited laboratorieslaboratories that are recognized by a formal accrediting body as meeting quality system requirements, including demonstrated competence to perform standard test procedures. 3.1.3. agencyany organization, constituted under federal, state, or
20、 municipal laws, that is responsible for administering contracts for highway or transportation construction. 3.1.4. calibrationa systematic process used to standardize measurement instruments or test equipment by determining any deviation from an established reference or standard. A correction or ad
21、justment of the instrument or equipment may be required based on the amount of deviation from the standard. 3.1.5. certified personnelpersonnel who are recognized by a formal certifying body as qualified to perform sampling, testing, inspection, or related procedures. 3.1.6. control chartalso called
22、 “statistical control chart.” A graphical plot of QC measurements or test values used to identify variation in a production or placement process due to either chance causes or assignable causes. 3.1.7. control chart limitsalso called “action limits.” Statistically derived boundaries applied to a con
23、trol chart for controlling material production or placement. Control chart limits are expressed as the upper control limit (UCL) and the lower control limit (LCL). When values of the material characteristics fall within these limits, the process is “under control.” When values fall outside the limit
24、s, there is an indication that some assignable cause is present causing the process to be “out of control.” 3.1.8. dispute resolutionthe procedure used to resolve conflicts resulting from discrepancies between the agencys and contractors results of sufficient magnitude to impact payment. 3.1.9. engi
25、neering limitsthe absolute limiting value(s) placed on a quality characteristic beyond which the test result for an individual sample is considered to be unacceptable. Engineering limits are established to identify material that does not provide the minimum required engineering properties. They usua
26、lly have an upper engineering limit (UEL), a lower engineering limit (LEL), or both. The engineering limits may be the same as the specification limits. 3.1.10. fabricated structural materialsmajor structural items produced specifically for an individual construction project by a material fabricator
27、. They are generally characterized by one or more of the following conditions: (a) The production process for the material occurs under controlled conditions at an established fabricator plant typically located within state or in another state; (b) The material properties are stable and have no pote
28、ntial for alteration under proper transportation from the fabricator to the project site; (c) The materials arrive at the project site in a solid state and require little or no additional work after installation. 3.1.11. fabricatora company that produces fabricated structural materials (e.g., precas
29、t/prestressed concrete structural elements, fabricated structural steel) for either the prime contractor or a subcontractor. 3.1.12. lota specific quantity of material from a single source that is assumed to be produced or placed by the same controlled process. 3.1.13. manufacturera company that man
30、ufactures and supplies standard manufactured materials for either the prime contractor, a subcontractor, or a fabricator. 3.1.14. populationa collection of all possible individuals, objects, or items that possess some common specified characteristic(s) that can be measured. 2016 by the American Asso
31、ciation of State Highway and Transportation Officials. All rights reserved. Duplication is a violation of applicable law.TS-5c R 38-4 AASHTO 3.1.15. prime (general) contractorthe company that has the primary construction contract for an agency project and that assumes overall responsibility for comp
32、leting the work. 3.1.16. producera company that produces and supplies project-produced materials (e.g., aggregates, HMA, PCC) for either the prime contractor or a subcontractor. 3.1.17. project-produced materialsmajor items produced directly for an individual construction project either by a contrac
33、tor or by a material producer. They are generally characterized by one or more of the following conditions: (a) The production process for the material occurs either at the project site or at a production plant located in close proximity to the project site; (b) The material properties are subject t
34、o potential contamination or segregation during transportation from the plant to the project site; (c) The materials arrive and are placed at the project site in a nonsolid or loose mixture state requiring subsequent mixing, compaction, finishing, or curing. 3.1.18. qualified laboratorieslaboratorie
35、s that are capable as defined by appropriate programs established or recognized by each agency. Accredited laboratories are considered “qualified.” However, a “qualified laboratory” need not be accredited. 3.1.19. qualified personnelpersonnel who are capable as defined by appropriate programs establ
36、ished or recognized by each agency. 3.1.20. quality(1) the degree of excellence of a product or service; (2) the degree to which a product or service satisfies the needs of a specific customer; (3) the degree to which a product or service conforms with a given requirement; or (4) conformance to requ
37、irements. 3.1.21. quality assurance (QA)(1) all those planned and systematic actions necessary to provide confidence that a product or facility will perform satisfactorily in service; or (2) ensuring the quality of a product is what it should be. The two primary elements of a QA program for standard
38、 manufactured materials include QC by the manufacturer and acceptance by the agency. Additional elements of a QA program for standard manufactured materials include qualified personnel, qualified laboratories, and dispute resolution procedures. 3.1.22. quality characteristicsa product characteristic
39、 that is measured through testing, either for QC purposes or for conformance with acceptance requirements. Quality characteristics are specific material properties or product requirements that are evaluated by QC and acceptance testing. Quality characteristics are normally selected because they: (a)
40、 relate to initial and long-term performance; (b) are quantifiable or measurable; and (c) can be measured with good repeatability. 3.1.23. quality control (QC)the system used by a contractor party to monitor, assess, and adjust its production or placement processes to ensure that the final product w
41、ill meet the specified level of quality. QC includes sampling, testing, inspection, evaluation, and corrective action (when required) to maintain continuous control of a production or placement process. 3.1.24. quality measureany one of several mathematical tools used to quantify the level of qualit
42、y of an individual quality characteristic. Application of a quality measure to a set of test data provides an overall numeric representation of quality for a specific quality characteristic. Typical quality measures used in QA are selected because they quantify the average quality, the variability,
43、or both. Examples of quality measures that may be used include: mean, standard deviation, percent defective (PD), percent within limits (PWL), average absolute deviation (AAD), moving average, and conformal index (CI). PWL and PD are the quality measures recommended for use in QA specifications. 3.1
44、.25. quality system manual (QSM)a written document that describes the overall QC operating procedures of a contractor party (e.g., prime contractor, subcontractor, producer, fabricator, manufacturer). A manufacturers QSM documents the internal policies for achieving quality and 2016 by the American
45、Association of State Highway and Transportation Officials. All rights reserved. Duplication is a violation of applicable law.TS-5c R 38-5 AASHTO the assignment of responsibility and accountability for QC within the manufacturers organization. It may also describe the minimum QC requirements expected
46、 of upper- or lower-tier contractor parties who supply constituent materials or who are involved in handling or processing of the manufacturers products. 3.1.26. random samplinga sampling procedure whereby each sample obtained from the lot has an equal probability of being selected. 3.1.27. run char
47、talso called “music bar chart.” A control chart that presents individual measurements or test values for a specific quality characteristic on a vertical axis and the individual sample numbers (in consecutive order) on a horizontal axis. Run charts plot individual sample values (n = 1) and usually ch
48、eck the measurements or test results against the specification limits or engineering limits. 3.1.28. sample(1) also called “material sample.” A small quantity of material or measurement obtained from a sublot or lot. A sample can refer to either a point of inspection (i.e., visual examination or phy
49、sical measurement) or an individual material sample obtained for testing. A sample may be composed of one or more increments of equal size that have been obtained from the sampling location and combined; or (2) also called “statistical sample.” All of the samples obtained from a lot that provide information that may be used to quantify the quality of the entire lot. The context in which the word “sample” is used determines its meaning. For example, “obtain a sample here” would mean obtain a physical quantity
