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

PlantName:

Physical Address:

Mailing Address:(if different from above)

Proprietary OwnershipCompany Name:

Physical Address:

Primary ContactName:Title:

Telephone:Email:

Fax:

ManagementQC Manager:

Plant Manager:

Auditor ContactName:

Telephone:Address:

Email:

Auditor Name: _______________Audit Report Number: ____________

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

DOT Official ContactName:

Title / Organization:Telephone:

Address:

Email:



Address:

Email:



Address:

Email:

Other Attendee ContactName:


Address:

Email:


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

Evaluation Program for Geosynthetic Reinforcement

Summary Report For_____________________________________________

IntroductionThe 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 facilities producing geotextiles provides a comprehensive review of the production and testing of geotextiles 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.

The desktop review and the on-site review were conducted by lead auditor ___________________. Geosynthetic manufacturer ________ was represented by ___________ (Plant Manager) and ____________ (Quality Assurance Manager), during the on-site audit which was completed on _____________.

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

Summarize audit findings here.


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Table of Contents

Desk Audit Based on Manufacturer QMS Manual and other Documents..................6Section 1: Geotextile Product Line Summary and Production Line Overview...........................6Section 2: Product Raw Materials Information...........................................................................8Section 3: QMS QC/QA Requirements.......................................................................................9Section 4: QMS Requirements for Resolution of Non-Conforming Product or Test Results...13Section 5: QMS Requirements for Manufacturer Testing Facilities and Associated Personnel...................................................................................................................................................14Section 6: QMS Requirements for Records Retention and Traceability...................................15Section 7: QMS Requirements for Internal Audits....................................................................16Section 8: QMS Requirements for Marking, Storage, Shipping, and Handling of Finished Geotextile...................................................................................................................................16

On-Site Manufacturing Plant Evaluation by Auditor..................................................17Section 1: Training and Competency Evaluation of Testing Personnel – Audit of Records.. . .17Section 2: Sample / Yard Inspection and Traceability of Product and Testing Records...........20Section 3: Sample Reports for Raw Materials and Geotextile Testing.....................................24Section 4: Manufacturing Process Walk-Through....................................................................24Section 5: Geotextile Identification Markings...........................................................................25Section 6: Report Signature.......................................................................................................25

Appendix A: Audit of QC Testing Procedures and Tester Competency....................26Melt Index (AASHTO M294, ASTM D1238)..........................................................................26Carbon BlackContent (ASTM D4218)......................................................................................28Mass per Unit Area (ASTM D 5261)........................................................................................29Permittivity (ASTM D 4491 – Falling Head Test)....................................................................29Permittivity (ASTM D 4491 – Constant Head Test).................................................................30Apparent Opening Size (ASTM D 4751)..................................................................................31Grab Tensile Properties (ASTM D 4632)..................................................................................32Trapezoidal Tear Strength (ASTM D 4533)..............................................................................33CBR Puncture Strength (ASTM D 6241)..................................................................................34

Appendix B: Equipment Calibration............................................................................36Appendix C: Geotextile Sampling Report....................................................................37Appendix D: Sample Manufacturer QC/QA Test Reports.........................................39


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Desk Audit Based on Manufacturer QMS Manual and other Documents

Section 1: Geotextile Product Line Summary and Production Line Overview

Product Line Product Designation

a) Manufacturing Plants Used to Produce Product Line:

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

If yes, does each plant have its own unique geotextile marking? YES NO

List other locations:

Auditor Note: Obtain information to identify the production lines used to produce products for the product line under consideration, and describe any differences between production lines that produce products for the same product line as defined in the NTPEP GTX work plan. If more than one production line used to produce a geotextile product (e.g., a different production line may be used to produce the yarn that is used to manufacture the final


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product), identify each production line used and what part of the product manufacturing process is conducted on each production line.

b) Production Line Details:Auditor Note: Auditor may need to supplement information and description provided in manufacturer supplied documents and input with observations from on-site review of manufacturing facility.

Manufacturing Plant Production Line Identification/Description

Products Manufactured on the

Production Line


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Section 2: Product Raw Materials Information

YES

NO N/A

1) Identify raw materials received at the plant to form the products in the product line: Resin – describe resin used: ____________________________________________________________________ Additives – identify type of additives: _____________________________________________________________________ Coatings – identify type of coatings: ______________________________________________________________________ Fibers – Describe fibers used: _____________________________________________________________________ Yarns – identify types: _______________________________________________________________________

2) Describe Raw Material Lot definition and Numbering System: Resin: ________________________________________________________ Additives: _____________________________________________________ Coatings: ____________________________________ Fibers: ________________________________________________________ Yarns: _____________________________________________

3) Are Certificates of Analysis furnished by the raw materials manufacturers for each lot?Resin: ________________________________________________________Additives: _____________________________________________________Coatings_____________________________________________________Fibers: ________________________________________________________Yarns: _____________________________________________________

4) Is regrind (reworked material) used as a source of resin for the products produced? If the answer to Question #4 is yes, what % of the product source is regrind? _________If the answer to Question #4 is yes, how is the quality of the final product maintained with consideration to the possibility that some losses in the raw material properties due to the regrind process could occur? ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

5) Are post-consumer recycled materials used as a resin source for the raw materials used in the final products or to otherwise form the final products? If the answer to Question #5 is yes, how are these products segregated from the products that meet AASHTO M288 and the NTPEP work plan? ______________________________________________________________________________________________________________________________________________________________________

Comments:


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Section 3: QMS QC/QA Requirements

A) QMS Manual Information and Organizational Policies YES NO N/A1) QMS Manual Identification:

2) Date of Latest Revision of Approved QMS:

3) Facility has this manual available?

4) Does the QMS cover page contain:a) The company name?b) The company logo?c) The date of latest revision?

5) Does the QMS include a document indicating the line of authority from the quality control testing technicians to the quality control manager?

6) Does the QMS indicate who in the quality organization has authority to reject produced materials or shut down production?

Identify Person: _________________________________________7) Does the QMS include a quality mission statement endorsed by the company’s Chief

Executive Officer?Comments:

B) Manufacturer QC/QA for Raw Materials YES NO N/A1) Does the manufacturer have property specifications for raw materials used in their

geotextile products:d) For resin?e) For fibers?f) For Yarns?g) For coatings?h) Other ______________________________________________

2) Identify properties used in the manufacturer’s raw materials specifications:a) For resin:

a. Melt indexb. Carbon black contentc. Other _____________________d. Are lot specific values for all these properties included in the COA? If

not, which ones are not included? __________________________________________________________________

b) For fibers:a. Denierb. Tenacityc. Tensile strengthd. Molecular weighte. CEGf. Other _____________________g. Are lot specific values for all these properties included in the COA? If

not, which ones are not included? _______________Auditor Name: _______________Audit Report Number: ____________

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B) Manufacturer QC/QA for Raw Materials YES NO N/A___________________________________________________

c) For yarns:a. Denierb. Tenacityc. Tensile strengthd. Molecular weighte. CEGf. Other _____________________g. Are lot specific values for all these properties included in the COA? If


d) For coatings:a. Brookfield viscosityb. Densityc. Gel temperatured. Durometer (Shore A) Initiale. Other: ________________________f. Are lot specific values for all these properties included in the COA? If


e) For other raw materials (e.g., additives such as carbon black, antioxidants, coloring, etc.):

a. Properties used: ____________________________________________________________________________________________

b. Are lot specific values for all these properties included in the COA? If not, which ones are not included? __________________________________________________________________________

3) Do the manufacturer’s raw material specifications meet AASHTO M288 requirements?

4) Manufacturer raw material QC/QA approach used:a) Visual check of raw material supplier Certificate of Analysis (COA) in

comparison to geosynthetic manufacturer raw material specificationsb) QC/QA tests conducted by manufacturer or contracted outside lab

5) Do the raw material QC/QA procedures as described in the QMS:a) Specify the QC/QA process and procedures for the raw materials?b) The timing and frequency of random sampling, and sample size, considering lot

size?c) Require raw materials QC/QA testing prior to using them in production?

If the answer to 5(c) is no, how is final product identified/traced that contains raw material(s) that did not meet specification requirements, and is this clearly described in the QMS manual?


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Auditor Note – Verify that the QMS manual contains the information/requirements identified in the table below.Summarize the raw materials QC/QA program, including sampling frequency relative to raw materials lot size/definition, sample size, when/where the material is sampled, QC/QA tests conducted on each raw material type, and corrective action taken when the QC/QA tests fail to meet one or more geosynthetic manufacturer raw material(s) property specifications:

a) When/where sampling of raw materials is conducted:

b) Raw materials sampling frequency and size:

c) QC/QA tests conducted on (if not applicable, insert “N/A”):1) Resin:

2) Fibers:

3) Yarns:

4) Coatings:

5) Other raw materials (e.g., additives such as carbon black, antioxidants, coloring, etc.):

d) Corrective action taken when QC/QA test results don’t meet property specifications:

e) Other raw materials evaluation activities done by the geosynthetic manufacturer:

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

C) Quality Control Inspection and Testing (Geotextile Product) YES NO N/A1) Does the QMS include procedures for the inspection and testing of geotextiles

during and at the completion of the production of the geotextile products? 2) Do the procedures in the QMS:

a) Require visual inspections of the final product?b) Specify the QC/QA process and proceduresc) Describe a method for random sampling?d) Describe the timing and frequency of geosynthetic random sampling, and

sample size, considering lot size?e) Specify the lot numbering system for the geosynthetic products?

Provide the definition of a lot used for the geotextile products:________________________________________________________________________________________________________________________

3) Does the QMS include an example of a quality control test report form?

4) Does the QMS document procedures and measurements used to verify the consistency of the manufacturing process (e.g., processing temperatures, fiber forming processes, etc.) and condition of the manufacturing equipment?

5) Does the QMS describe quality control procedures for the coating used (PET


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geosynthetics only) and how it is applied to the polyester yarns to form the final product, considering both application rate and quality of the coating?

Comments:

D) Statistical Analysis of Test Results YES NO N/A1) Does the QMS include a document describing the statistical process control plan?

2) Does the plan include methods such as control charts to monitor production facility quality control test results to identify trends and make production adjustments as necessary?

E) QC/QA Testing Plan and Procedures

Test NameTesting Performed by:

Test Interval No Testing Performed or N/AIn House Outside lab

Tests for Raw Materials:- Melt Index (ASTM D1238)- Carbon black content- Denier- Tenacity- Tensile strength- Molecular weight- Carboxyl end group content- Brookfield viscosity (coatings only)- Other tests _______

Geosynthetic Tests:

- Mass per Unit Weight (ASTM D 5261)- Permittivity (ASTM D 4491)- Apparent Opening Size, AOS (ASTM D 4751)- Grab Tensile Properties (ASTM D 4632)- Trapezoid Tearing Strength (ASTM D 4533)- Puncture Resistance (ASTM D 6241)- UV Degradation (ASTM D4355)- Asphalt Retention of Paving Fabrics (ASTM D6140- Melting Point (ASTM D276)1Names, addresses, and contact information for outside laboratory facility(ies) used:


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Other testing done on production geotextile products that is not lot specific:

Section 4: QMS Requirements for Resolution of Non-Conforming Product or Test Results

YES NO N/A1) Does the QMS include provisions for resolving non-conforming product or test results?

2) Do the provisions require that a test report clearly identify the deficiencies? 3) Do the provisions require that product produced subsequent to the deficiency will be

quarantined pending an investigation of the failure? 4) Do the provisions specify how to identify the finished product that is to be quarantined

as a result of the non-conforming test result(s), e.g., specific roll numbers?5) 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?

e) Corrective action noted on test report?

f) A second sample taken to verify the deficiency has been corrected?

g) If second sample fails, is the process (a – f) repeated until the deficiency is corrected? 6) Does the QMS require that test reports indicate the action taken to resolve raw material

or product failures?


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

Audit Report

Section 5: QMS Requirements for Manufacturer Testing Facilities and Associated Personnel

A) Quality Control Testing Facilities YES NO N/A1) Does the QMS include requirements for the quality control testing facilities? 2) Does the QMS require that the quality control testing facility maintain accreditation

through GAI-LAP, and is that accreditation current?3) Do the requirements indicate that: a) There is a description of how QC responsibilities are covered at all times, including

when the QC manager is away from the plant for any reason? b) The quality control manager be responsible for quality control testing at all

facilities and shall assure that all sampling and testing is done by technicians meeting the requirements of manufacturer’s technician qualification program as described in the quality system manual?

c) The facilities shall maintain current versions of all AASHTO, ASTM, and Company Test Procedures for all tests performed and a current version of the company’s quality system manual?

d) The testing equipment shall be calibrated/verified in accordance with the equipment manufacturer’s recommendations at least once every 12 months by personnel customarily involved in such work as documented in the quality system manual?

e) All testing facility equipment shall be properly maintained and maintenance activities shall be documented?

f) The testing facility shall maintain records of all NTPEP reviews and actions taken to resolve any note deficiencies?

g) Records of equipment calibration, verification, and maintenance will be retained and available to the NTPEP for review upon request?

B) Lab Equipment List YES NO N/A1) Does the QMS include a list(s) giving a general description of physical and chemical

test equipment requiring calibration, standardization, or checks?2) Does the list include:

a) The interval between calibration, standardization, or checks?

b) A reference to calibration, standardization, or check procedures?

c) An identification of the location of calibration, standardization, or check records?

C) Lab Equipment Plan YES NO N/A1) Does the QMS include procedures for ensuring that equipment standardizations and

checks are performed for all required equipment at specified intervals?2) Do the procedures include: a) How to handle equipment which is newly acquired, removed from service, or does

not meet accuracy requirements? b) In-house equipment standardization and check procedures, when they cannot be

referenced in applicable standards?Auditor Name: _______________Audit Report Number: ____________

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Audit Report

c) Certificates or other documents that establish traceability of in-house equipment or reference standards used for standardization and checks?

D) Lab Equipment Maintenance YES NO N/A1) Does the QMS include procedures for ensuring that equipment maintenance is

performed for all required equipment at specified intervals?2) Do the procedures indicate: a) The position(s) or employee(s) responsible for ensuring the maintenance is

performed? b) How the maintenance is documented?

c) The location of maintenance records?

E) Training and Competency Evaluation for Quality Control Personnel YES NO N/ATraining1) Does the QMS include procedures used to ensure that the plant’s personnel are

trained to perform all quality control tests? 2) Do the procedures indicate that the quality control manager is responsible for the

training program and maintenance of records? Competency Evaluations3) Does the QMS include procedures used to evaluate staff competency to ensure that

each quality control test is performed in accordance with standard procedures? 4) Do the procedures: a) indicate that the evaluations are conducted at least annually and / or whenever

there is a change in procedures? b) indicate that the quality control manager is responsible for evaluating staff

competency and maintaining records?

Comments:

Section 6: QMS Requirements for Records Retention and Traceability

YES NO N/A1) Does the QMS include a process for storing quality control test reports for raw

materials and the finished geosynthetic products, as well as raw material COA’s?2) Does the process:

a) Provide a way for the test results for any geotextile to be located, including the test results for the raw materials used to manufacture the geotextile?

b) Provide easy identification of the location of the quality control test reports?

3) Does the plant follow their procedures for the following:a) Test results and product traceability (storing and locating test reports)?b) Resolving non-conforming test results?c) Equipment maintenance?d) Internal quality audits?e) Management reviews?


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Audit Report

f) Contract reviews?g) Customer feedback?

4) Does the QMS establish traceability from the final geotextile product back to the raw material lot used?

5) Are the documents that establish traceability of the final geosynthetic product maintained along with the inventory?

6) Do the requirements indicate the following documents be retained for at least 5 years:a) NTPEP audit documentation?b) Resin and/or Fiber test reports (QC of Raw Material)?c) Geotextile test reports (QC of Product)?d) Training and Competency Recordse) Equipment calibration / standardization / checks?f) Internal Audits?

Comments:

Section 7: QMS Requirements for Internal Audits

Internal Audits YES NO N/A1) Does the QMS include procedures for performing internal quality audits? Note – the audit may be performed by an independent auditor (third party) provided

all the activities listed under 2) are covered.2) Do the procedures include:

a) an evaluation of plant inspection?

b) an inspection of testing equipment and calibrations?

c) an observation of resin sampling and lot control procedures?

d) an observation of geotextile sampling and testing procedures?

e) a review of the product certification procedures

f) a review of nonconforming product documentation and actions taken?

3) Are the results of the audit documented?

4) Is the most recent report included in the quality manual?

Section 8: QMS Requirements for Marking, Storage, Shipping, and Handling of Finished Geotextile

Internal Audits YES NO N/A1) Does the QMS include procedures for marking, storing, shipping, and handling of

finished geotextile?Comments:


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Audit Report

On-Site Manufacturing Plant Evaluation by Auditor

Section 1: Training and Competency Evaluation of Testing Personnel – Audit of RecordsAuditor Note – List the plant personnel approved to perform quality Control tests. Obtain the information during the audit or refer to the plant’s pre-audit documentation or previous audit report.

A) Identification of the personnel approved to run quality control testing at the plant:

Name Position1)

2)

3)

4)

6)

7)

10)

11)

12)

14)

15)

.


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Audit Report

B) Training Information Matrix for Quality Control Testing Conducted In-HousePlease list the names and quality control tests for which they are trained to perform for those individuals conducting quality control testing at the facility: Include a copy of the training record and competency evaluation record for each employee listed below.

Res

in T

ests

CEG

, int

rinsi

c vi

scos

ity

Mel

t Ind

ex

Mel

ting

poin

t

Geo

text

ile T

ests

Mas

s/U

nit W

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t

Perm

ittiv

ity

AO

S

Gra

b te

nsile

Trap

ezoi

d Te

ar S

treng

th

Punc

ture

Res

ista

nce

UV

deg

rada

tion

Asp

halt

rete

ntio

n

Fibe

r Ten

acity

Fibe

r Den

ier

Personnel


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AASHTO’s National Transportation Product Evaluation Program (NTPEP) Section 6Evaluation of Audit of Training

Audit Report

C) 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.Name: Name:

Training Record

Adequate?

Competency Eval. Recd’s Adequate?

Training Record

Adequate?

Competency Eval. Recd’s Adequate?

Resin Tests YES NO YES NO N/A Resin Tests YES NO YES NO N/ACEG Content CEG ContentMolecular Wt. Molecular Wt.Melt Flow Index Melt Flow IndexMelting Point Melting PointCarbon black Carbon black

Geotextile Tests Geotextile TestsMass/unit wt. Mass/unit wt.Permittivity PermittivityApparent Opening Size

Apparent Opening Size

Grab Tensile Properties

Grab Tensile Properties

Trapezoid Tearing Strength

Trapezoid Tearing Strength

Puncture Resistance

Puncture Resistance

UV degradation UV degradationAsphalt retention

Asphalt retention

1) Do the training records indicate that at least one person is trained for each quality control test performed in house?

YES NO

Comments:


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Section 2: Sample / Yard Inspection and Traceability of Product and Testing Records

A) Traceability of product raw material and finished product QC/QA data YES NO N/A

7) Regarding the raw materials supplier COA and manufacturer QC/QA data/test results:a) Are they traceable to the final geosynthetic products produced?b) Was auditor able to verify traceability on site?

Indicate method used by manufacturer to maintain traceability (e.g., raw material lot number included in final product identification, computer database maintained by manufacturer quality staff):

8) Regarding manufacturer QC/QA data/test results for geosynthetic product:a) Are they traceable to the final geosynthetic products produced?b) Was auditor able to verify traceability on site?

Indicate method used by manufacturer to maintain traceability (e.g., finished product lot number included in final product identification, computer database maintained by manufacturer quality staff, etc.):

B) Split Sample SelectionProduct Line Designation:

Product Name: Product Name: Product Name: Product Name:

Is a resin/fiber/yarn sample available for split sample testing?Yes No Yes No Yes No Yes No

Split sample testing is requested for:Geotextile only Raw materials and geotextile

Geotextile only Raw materials and geotextile



C) Raw MaterialsAre resin/fiber/yarn lot test results available?

Yes No Yes No Yes No Yes No

Are test results for other raw materials used in the geotextiles available?Yes No Yes No Yes No Yes No

D) Finished Product TestsAre production facility test reports available for the same lot of geotextile?

Yes No Yes No Yes No Yes No

Auditor Name: _______________________ of 39Audit Report Number: _________________


Resin/fiber/yarn Lot # Resin/fiber/yarn Lot # Resin/fiber/yarn Lot # Resin/fiber/yarn Lot #

Geotextile Lot # Geotextile Lot # Geotextile Lot # Geotextile Lot #

E) Split Sample Markings Verifications (Conducted by auditor) YES NO1) Do geotextile markings: a) exist along the geotextile roll at intervals not exceeding ___ ft [___ m]? b) include the Manufacturer’s name or code number?2) Regarding the labels placed on the geotextile roll: a) Are they properly located and firmly affixed in accordance with the NTPEP work

plan? b) Do they include the roll number? c) Do they include the lot number? d) Do they include the AASHTO M288 class(es)? e) Do they include the property MARV’s?

Comments:

Auditor Note – After the split sample sizes and specs are decided on, the auditor should conduct the yard inspection of the geotextile in the yard noting any physical defects. In addition the auditor should select three random samples of geotextile to verify proper quality control records.

F) Visual Inspection of Geotextile in the Yard (Conducted by auditor) YES NOGeotextile Inspections

1) The auditor shall inspect GTX rolls to ensure that they are:

a. free from rips, tears, or holes?

b. free from thin spots/areas?

c. free of foreign inclusion and visible defects?d. Other observations: ________________________________________________

_________________________________________________________________2) The auditor shall inspect geotextile to ensure that it is properly marked3) The auditor shall inspect to ensure that damaged or flawed geotextile has been marked

according to the manufacturer’s Quality Manual?Comments:

Auditor Note – To gather the proper information for the record traceability (using three randomly selected samples from the yard) complete the following chart titled Test Record Audit.



G) 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 3YES NO N/A YES NO N/A YES NO N/A

Resin/Fiber/Yarn TestsFiber tenacity Each LotFiber denier Each LotCEG Content Each LotMolecular Wt. Each LotMelt Flow Index Initially/QuarterlyMelting Point Each LotCarbon black Each LotOther tests: _____________________ Each Lot

Geotextile TestsMass/unit wt. 2 / ShiftPermittivity 1 / DayApparent Opening Size 1 / ShiftGrab Tensile Properties 2 / ShiftTrapezoid Tearing Strength 1 / ShiftPuncture Resistance 1 / ShiftUV degradation 1 / ShiftAsphalt retention 1 / ShiftOther Tests: ______________________ 2 / Week

Comments:Product Name/Designations for:

Sample 1: ______________________Sample 2: ______________________Sample 3: ______________________



H) Additional Test Record Audit In addition to a review of the test records for the yard samples selected, test records are reviewed for geotextile 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 geotextile. Additional Test Records Reviewed: Records available, records indicate tests are performed at required

frequency and results meet spec. requirements for:All Tests

PerformedAll Tests

Performed

Product Name Date Produced

Raw Material Lot # YES NO

Finished Product Lot

#

Rolls Properly Identified and

Traceable?YES NO

Week 1

Week 2

Week 3

Comments:

Section 3: Sample Reports for Raw Materials and Geotextile TestingAuditor Note – Maintain example hard copies of the test records, certificates of analysis, and reports gathered during the audit.



Sample Test Reports: Please provide sample reports representing quality control testing for raw materials and in accordance with the AASHTO M288 Specification:

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

Geosynthetic – Mass/unit weight, AOS, permittivity, Grab tensile strength, trapezoidal tear strength, CBR puncture, etc.

Test reports for raw materials available to state DOT personnel upon request. Auditor reviewed test reports for geotextile samples obtained at the manufacturing facility in __________, including test reports for the raw materials used in the specific product samples obtained. Test results were consistent with expectations. Test reports representing the manufacturer’s QC/QA testing are included in Appendix D of this report.

Section 4: Manufacturing Process Walk-ThroughAuditor Note – Complete the following after the yard inspection and the selection of the split samples. The raw material samples shall be taken at this point. Note: If not applicable, enter “N/A” in box.

A) Process from resin to fiber/yarn

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

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

Consistency of yarn weaving process:

B) Process from fiber/yarn to final product

Consistency of geotextile formation process:

Consistency of product preparation for storage and shipment, including labeling:



Section 5: Geotextile Identification MarkingsAuditor Note - Insert a picture(s) of the plant’s unique geotextile identification markings. Refer to the plant’s pre-audit documentation or previous audit report.

Section 6: Report SignatureThe Preceding Report has been reviewed and assured to be accurate by the Lead Auditor.

Auditor Name:Signature:





Appendix A: Audit of QC Testing Procedures and Tester Competency

Auditor Note – Based on the information gathered for training, conduct the audit of the applicable test methods:

Melt Index (ASTM D1238)

A) Apparatus (AASHTO M 294 Sec. 6.1.1) (ASTM D 1238 Sec. 5.0) Yes No1) 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:

B) Melt Index (Resin) Procedure (AASHTO M 294 Sec. 6.1.1) (ASTM D 1238 Sec. 9.0) Yes No

1) Complete test standard, including SOP for test, available to tester?

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

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



diameter checked?4) Temperature stability verified and within ±0.2°C?

5) Die and Piston inserted?6) Temperature of cylinder, with piston and die in place, stable 15 minutes before

testing begins?7) Piston removed and placed on insulated surface?8) Cylinder charged within 1 minute with weighed portion of resin and piston

reinserted?9) Appropriate weight added to make a total load of 2.16 kg?

10) Time allowed for the resin to soften and begin to melt. 11) 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.

12) Purge completed at least 2 minutes prior to start of test?13) Test begins, and collection of timed extrudate starts, within 7.0 min ± 0.5 min of

completion of the charge and when the lower scribe mark is in the cylinder?14) At the same time, the timer is reset to zero and the initial cut-off is made?

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

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

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

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

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

Comments:



Carbon BlackContent (ASTM D4218)

A) Apparatus (AASHTO M 294 Sec. 6.1.1) (ASTM D 4218 Sec. 6.0) Yes No1) Fume Hood or Vent Hood?2) Muffle furnace with internal dimensions of approximately 100m in length, width, and

height? (Furnaces with larger dimensions are considered unsuitable.)3) Screen of 20-mesh approximately 120 by 100 mm folded down approximately 10 mm

of the long dimension?4) Thermocouple-probe temperature controller or equivalent?5) Desiccator, with desiccant?6) Laboratory interval timer, with alarm?7) Disposable aluminum weighing dish, with crimped sides and tabs on the rim?8) Tongs or Tweezers, approximately 250 to 300 mm?9) Analytical Balance, readable to the nearest 0.0001g?

Comments:B) Procedure (AASHTO M 294 Sec. 6.1.1) (ASTM D 4218 Sec. 10.0) Yes No

1) Complete test standard, including SOP for test, available to tester?2) Complete test procedure available to tester3) Muffle furnace located under fume hood or vent hood?4) Temperature set to 605°C ± 5ºC?5) Weighing dish marked with an identifying impression on tab?6) Dish placed on screen in muffle furnace and surface oil burned off for 2 min?7) Dish transferred to desiccator and allowed to cool for at least 2 min?8) Dish weighed to nearest 0.0001 g?9) Approximately 1 g of specimen added to dish and dish reweighed?

10) Dish and contents placed into muffle furnace for 3 min?11) Dish removed and allowed to cool in desiccator for at least 2 min?12) Dish reweighed to 0.0001 g?13) 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? 14) Dish allowed to cool in desiccator for at least 2 min and then reweighed to 0.0001 g?15) Two determinations averaged to obtain a test result (ref: Sec. 10.14 & 12.1.3)?

Comments:



Mass per Unit Area (ASTM D 5261)

A) Apparatus (ASTM D 5261, Sec. 6.1) Yes No1) Balance, calibrated, capable of weighing to 5000 g, with an accuracy of 0.01 g.

Comments:B) Procedure (ASTM D 5261, Sec. 7, 8, 9 and 10) Yes No

1) Complete test standard, including SOP for test, available to tester?2) Minimum of five specimens – cut from across roll width – away from selvage?3) Minimum specimens size of not less than 10 000 mm2 (15.5 in2)?4) Test specimen conditioned (moisture equilibrium)?5) Weigh each of the conditioned specimens separately on calibrated balance to the

nearest 0.01 g?6) Average and standard deviation of the population?

Comments:

Permittivity (ASTM D 4491 – Falling Head Test)

A) Apparatus (ASTM D 4491, Sec. 6.1) Yes No1) Calibration curve of volumetric flow rate versus head for the apparatus alone in

order to establish that apparatus is not controlling flow?2) De-aired water? < 6 ppm? Commerical O2 meter or dissolved oxygen meter?3) Head measurement accuracy – manometers and/or pressure sensors present?4) Water temperature control?5) Specimen prep – soaked for _____ hours, sealed and “zero-headspace”

containers?6) Specimen securing fixture (in the permittivity apparatus) – are there potential

leakage paths due to folding or crimping specimens due to improper fit or is there any twisting of specimens to affect the seal?

7) Inside diameter (d) of the upper unit, the diameter (D) of the exposed portion of the specimen, and the water temperature (T) – all recorded?

Comments:B) Procedure (ASTM D 4491, Sec. 13, 14) Yes No

1) Complete test standard, including SOP for test, available to tester?

2) Complete test standard, including SOP for test, available to tester?3) Four specimens equally spaced along a diagonal line extending from the lower

left hand corner to the upper right hand corner of the laboratory sample.4) Specimens minimum 2 inch diameter?5) Do specimens have proper fit in test apparatus?

Caution: The falling head procedure should not be performed for geotextiles with a permittivity greater than 0.05 sec –1 unless the system is equipped with an automated data acquisition system that would measure elapsed time for the drop in head from 80 to 20 mm on the manometer.

6) Discharge pipe so that its outlet is slightly above the level of the specimen?7) Water level falling from 150 mm (6 in.) to 80 mm (3.2 in.) where timing is

started to fall to 20-mm ( 4.5-in.) level?



8) Five measurements per specimen?9) Calculation verified?

10) Average permittivity reported?

Comments:

Permittivity (ASTM D 4491 – Constant Head Test)

A) Apparatus (ASTM D 4491, Sec. 6.1) Yes No1) Calibration curve of volumetric flow rate versus head for the apparatus alone in

order to establish that apparatus is not controlling flow?2) De-aired water? < 6 ppm? Commercial O2 meter or dissolved oxygen meter?3) Head measurement accuracy – manometers and/or pressure sensors present?4) Water temperature control?5) Specimen prep – soaked for _____ hours, sealed and “zero-headspace”

containers?6) Specimen securing fixture (in the permittivity apparatus) – are there potential

leakage paths due to folding or crimping specimens due to improper fit or is there any twisting of specimens to affect the seal?

7) Inside diameter (d) of the upper unit, the diameter (D) of the exposed portion of the specimen, and the water temperature (T) – all recorded?

Comments:B) Procedure (ASTM D 4491, Sec. 13, 14) Yes No

1) Complete test standard, including SOP for test, available to tester?2) Four specimens equally spaced along a diagonal line extending from the lower

left hand corner to the upper right hand corner of the laboratory sample.3) Specimens minimum 2 inch diameter?4) Do specimens have proper fit in test apparatus?5) Backfilling with deaired water to remove trapped air? 6) Discharge pipe adjusted along with the rate of water flowing into the apparatus to

obtain a 50-mm (2-in.) head of water on the geotextile. This is the head (h) under which the test will be performed.

7) A vacuum tube located just above (10 mm (0.5 in.)) the surface of the geotextile in order to remove trapped air in specimen? Readjustment of head to 50 mm (2 in.) necessary?

8) Record of the values of time (t), quantity of flow (Q) as collected from the discharge pipe, and water temperature (T), holding the head at 50 mm (2 in.).

9) Five measurements per specimen?10) Calculation verified?11) Average permittivity reported?

Comments:

Apparent Opening Size (ASTM D 4751)

A) Apparatus (ASTM D 4751, Sec. 6.1) Yes No1) Mechanical sieve shaker, imparting Both lateral and vertical motion to the

sieve(s)?



2) Constant frequency device utilizing a tapping arm to impart the proper motion to the glass beads? Cork or rubber contact point in good condition?

3) Spherical Glass Beads in size fractions in accordance with Table 1 shown below?

4) Beads pre-sieved (checked) prior to use in testing?5) Balance with capacity adequate for the mass of samples anticipated and accurate

to ± 0.05 g?6) Static Elimination, to prevent the accumulation of static electricity when the

beads are shaken on the surface of geotextile? Commercially available devices or anti-static sprays are acceptable.

7) Pan, for collecting sieved beads?8) Are beads used again? Post test sizing check?

Comments:B) Procedure (ASTM D 4751, Sec. 7, 8 and 9) Yes No

1) Complete test standard, including SOP for test, available to tester?2) Five specimens equally spaced along a diagonal line extending from the lower

left hand corner to the upper right hand corner of the laboratory sample.3) Specimens soaked in distilled water for 1 hour then dried in standard

atmosphere?4) Geotextile secured in such a way that it is taut, without wrinkles or bulges, not

stretched or deformed such that it changes or distorts the openings in the fabric. 5) Specimen support fixture – is the perimeter seal effective during the test?6) Test started with the smallest diameter glass beads that will be tested. Place 50 g

of one size glass beads on the center of the geotextile?7) Ten minute shake? 8) Top of specimen beads captured in pan with (including beads falling off when

specimen turned over and sieves tapped)? Weighed?9) Weigh beads that pass through specimen?

10) Repeat tests using increasing sized beads?11) Five measurements per specimen?12) Calculation verified (average of five AOS measurements)?13) AOS calculation algorithm – interpolate between two bead sizes?

Comments:



Grab Tensile Properties (ASTM D 4632)

Grab Tensile (D 4632) A) Apparatus (ASTM D 4632, Sec. 6.1) Yes No

1) Mechanic Tensile Testing Machine, of the constant-rate-of extension (CRE) or constant-rate-of-traverse (CRT) type with autographic recorder?

2) Clamps - each clamp shall have one jaw face measuring 25.4 by 50.8 mm (1 by 2 in.), with the longer dimension parallel to the direction of application of the load. The other jaw face of each clamp shall be at least as large as its mate. Each jaw face shall be in line, both with respect to its mate in the same clamp and to the corresponding jaw of the other clamp?

3) Specimen cutting die (101.6 by 203.2 mm (4 by 8 in.)? 4) Are beads used again? Post test sizing check?

Comments:B) Procedure (ASTM D 4632, Sec. 10) Yes No

1) Complete test standard, including SOP for test, available to tester?2) 10 specimens MD and 10 specimens TD? Or – reliable estimate based on COV?3) Specimens tested wet or dry? _________________4) Distance between the clamps at the start of the test at 75 ± 1 mm (3 ± 0.05 in.). 5) Strain rate at a speed of 300 ± 10 mm/min (12 ± 0.5 in./min)? 6) Jaws located centrally in width of specimen? 7) Elongation at Max Load or Rupture?…check computer acquisition? 8) Calculation verified (average of ten measurements per direction tested?

Comments:



Trapezoidal Tear Strength (ASTM D 4533)

A) Apparatus (ASTM D 4533, Sec. 6.1) Yes No1) Mechanic Tensile Testing Machine, of the constant-rate-of extension (CRE) or

constant-rate-of-traverse (CRT) type with autographic recorder?2) Clamps - having all gripping surfaces parallel, flat, and capable of preventing

slipping of the specimen during a test, and measuring 50.8 by no less than 76.2 mm (2 by no less than 3 in.), with the longer dimension perpendicular to the direction of application of the load?

3) Trapezoidal Template specimen cutting die - isosceles trapezoid template - rectangular specimens 76.2 by 201.6 mm (3 by 8 in.)? Make a preliminary cut 15.9 mm (0.625 in.) long at the center of the 25.4 mm (1 in.)?

4) Upper clamp supported on free swivel or universal joint.

Comments:B) Procedure (ASTM D 4632, Sec. 9 and 10) Yes No

1) Complete test standard, including SOP for test, available to tester?2) 10 specimens MD and 10 specimens TD? Or – reliable estimate based on COV?3) Specimens tested wet or dry? _________________4) Distance between the clamps at the start of the test at 25 ± 1 mm (1 ± 0.05 in.). 5) MD tear strength – long dimension in MD? TD tear strength – long dimension in

TD?6) Strain rate at a speed of 300 ± 10 mm/min (12 ± 0.5 in./min)? 7) Clamps located along nonparallel sides of trapezoid in line with 25 mm (1 in.)

long side of the trapezoid? 8) Maximum load recorded? 9) > 25% outlier discarded?

10) Calculation verified (average of ten measurements per direction tested?

Comments:



CBR Puncture Strength (ASTM D 6241)

A) Apparatus (ASTM D 6241, Sec. 6.1) Yes No1) Mechanic Tensile Testing Machine, of the constant-rate-of extension (CRE) with

autographic recorder?2) Clamping Apparatus - consisting of concentric plates with an internal diameter of

150 mm (5.9 in.), capable of clamping the test specimen without slippage (limit slippage of test specimen to 5 mm)? The external diameter is suggested to be 250 mm (9.8 in.). The diameter of the holes used for securing the ring clamp assemblage is suggested to be 11 mm (7/16 in.) and equally spaced at a diameter of 220 mm (8.7 in.). The surfaces of these plates can consist of grooves with rubber O-rings or coarse sandpaper bonded onto opposing surfaces. It is suggested that 9.5-mm (3/8-in.) bolts be welded to the bottom plate so that the top plate can be placed over the bolts and nuts easily tightened. A guide block may be used to help seat the material being clamped. Other clamps that eliminate slippage are acceptable.

3) Plunger, with a flat diameter of 50 mm ± 1 mm with a radial edge of 2.5 mm ± 0.5 mm (see below?)

Comments:B) Procedure (ASTM D 6241, Sec. 10) Yes No

1) Complete test standard, including SOP for test, available to tester?2) 10 specimens? Or – reliable estimate based on COV?3) Specimens tested wet or dry? _________________4) Clamp and mark the test specimen along the inside circumference of the holding

container? This allows for a measurement of potential slippage of the specimen5) Strain rate at a speed of 50 mm/min (2 in./min)? 6) Plunger to puncture all the way through before terminating test? 7) Maximum load recorded? 8) < 5% slippage? Or discarded? 9) Calculation verified (average of ten measurements?

Comments:



Add other geotextile tests for evaluation here.



Appendix B: Equipment Calibration

Equipment Calibration, Standardizations, and ChecksAuditor Note – Use the following table to perform the record audit of quality control testing equipment

calibration, standardization, and checks.

Equipment Calibration, Standardization & Checking

ITEM

Cal/Verify (C/V)

Written Procedure Do the records contain the following?

Plan

tsp

ec.

inte

rval

C/V

Cur

rent

?

C/V

Per-

form

edin

spec

.

In Q

Mor

ref.

to lo

c.?

C/V

equi

p.lis

ted

Mod

el&

Seria

l No.

Nam

eof

Wor

ker

ID o

f C/V

equi

p. u

sed

Dat

e W

ork

done

Det

aile

dre

sults

Ref

eren

ceto

pro

cedu

reus

ed

Balances, Scales and Weights (standardize every 12 months, 0.5% accuracy)

Calipers (calibrate at least every 12 month)

Micrometers (calibrate at least every 12 month)

Melt Index Heater (check at least every 12 months) D1238

Temperature Measuring Device (calibrate at least every 12 months)

Comments:O.A. means calibration was completed by an Outside Agency.

None



Appendix C: Geotextile Sampling Report

IN-PLANT SAMPLING REPORT NTPEP Program: GTX

NTPEP Number: (20___)-0__

Manufacturer Name:

Page _1_ of _1_

Type of Facility where Sampling Conducted:_____ Manufacturing (production line); Describe______________________________________________________________________________ Warehouse (storage of finished product): Describe_________________________________________________________________

Location of Facility where Sampling Conducted:

Location within Production Line/Process where Sampling Conducted:

Date Material(s) Sampled:

Manufacturer Representative(s) Present: Pre-arrangements Made with Manufacturer to Sample: _______Surprise inspection ________Advance warning given (______ days) but not specific sampling appointment date

Material(s) Sampled and Description: (Please specify product designation and structure (IE. NP-NW, HB-NW, MF-W, etc for each style submitted below:)Sample ______:

Roll No. __________________________



Lot/Batch No.______________________

Sample ______:

Roll No. __________________________ Lot/Batch No.______________________

Sample ______:


Sample ______:


Sample ______:


Sample ______:


Sample ______:


Sampling Event Notes: (plant condition, roll storage/inventory, traceability of raw materials to products, sampling issues, etc.) Sample Shipment Preparation Observations: (sample identification approach, sample placement in the shipping container, who did shipment preparation, how shipped, etc.) Sampler Name and Affiliation: (please print):



Signature Date

Include a copy of this sampling report with samples.



Appendix D: Sample Manufacturer QC/QA Test Reports


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