Standard Recommended Practice for Establishing and Implementing A Quality System for Construction 1. SCOPE This document contains criteria and guidelines for establishing and imple- menting a quality system for use by @ ‘construction materials laboratory (CML), ‘These criteria may also be used by labo- ratory evaluating agencies, ‘The criteria in this document only apply to the following testing areas: soils, aggregates, bituminous materials and portland cement concrete 2. REFERENCED DOCUMENTS Materials Testing Laboratories! AASHTO DESIGNATION: R 18-93 3.3 Quality System Establishment — Activites associated with the develop- ‘ment of policies, standard operating pro- ‘cedures, standard forms, chars, listings and record keeping plans designed to achieve quality objectives. 34 Quality System Implementa- rion— Actions taken by employees of the (CML in order to comply with established quality system policies, standard op: crating procedures and record keeping requirements 31 Quality System (for a CML) ‘The organizational structure, staff re- sponsibilties, policies, standard op- crating procedures and processes which when implemented assist the CML in achieving its quality objectives. 32 Quality Manuel (QM) (for a CML)—A set of documents describing a CML’s quality system, Ths dorama i onder he ton of he “Amercan Associaton of State Hipeay td Tap ‘Stew Offeias (AASHTO) Hghesy Sbcommtee (n Matrae and the eet rapes of he ‘Rdoinseaive Tsk Group of is AMIR Comet 734 TERMINOLOGY 4. SIGNIFICANCE AND USE. 4.1 This document provides. guid- ance to CMLs in the establishment and implementation of an intemal quality system, By use of the concepts in this document, a laboratory may prepare a quality manual (QM) that describes the ‘elements and functions ofits quality sys- tem. This document also provides criteria for use by laboratory evaluating agen- 42. This document is not intended to prescribe the methods by which a CML achieves the desired level of qual- ity, but does provide acceptable ap- proaches. 43 The user is cautioned that a QM prepared by following this document can only serve a useful purpose ifit describes fo references procedures that are prac- ticed on a routine basis by the CML. A QM only describes the elements of the system and how they are intended to be implemented. It is not the existence of 4 QM but the implementation of an effec- tive quality system that is important. S. QUALITY SYSTEM CRITERIA ‘The CML shall establish and imple- ‘ment a quality system which meets the following criteria: Sl Quality System Manual—The (CML shall establish and maintain a QM. ‘that conforms tothe requirements in Sec tuon 6. Each document in the QM shall indicate its preparation date, If a docu- ‘ment is revised, the date of revision shall be indicated on the document. The QM shall be available for use by labora: tory staff 82. Technical Manager—The CML shall have a technical manager (however named) who has overall responsibil forthe technical operations of the abora- tory, 5.3 Quality System Management— ‘The CML shall designate a person(s) having responsibility for determining if 4uality system implementation activites are being conducted by CML staff in the ‘manner specified in the CML’s quality system manual. This individual(s) shall have direct access to top management (ote 1. NOTE 1—This individuals) may have ‘other responsibilities (,e. laboratory man agen)Rig 5A Equipment Calibration and Veri- Fication—The CML shall calibrate ot verify all significant testing equipment associated with tests covered by the scope of this standard which the CML performs. As a minimum, the equipment listed in Tables 1, 2, 3, and 4 shall be included if it is ‘associated with tests Performed by the CML. Applicable ‘equipment shall be calibrated or verified at the intervals specified in the CML’s QM. The intervals specified in the QM shall be no greater than those indicated in Tables 1, 2, 3, and 4 (Note 2). Newly acquired equipment without manufactur- cers cenification and equipment that has rot been calibrated or verified because it has been removed from service shall bbe calibrated or verified before being placed in service. The CML shall have etailed writen procedures for all in- house calibration and verification activ ties not addressed in standards (see Fig- ures X13 to X25). These procedures shall indicate the equipment required to per- form the calibration or verification. NOTE 2—When a maximum calibration or verification interval fora specific piece of test equipment is specified in a standard, the ‘maximum interval specified by this document is intended to be the same as the maximum imerval specified by the stindard. 5.8 Proficiency Sample Testing— ‘The CML shall participate in applicable AMRL and CCRL proficiency sample programs, NOTE 3—The AASHTO Materials Refer- fence Laboratory (AMRL) and the Cement and Concrete Reference Laboratory (CCRL). located atthe National Insitute of Standards and Technology in Gaithersburg, Maryland, Aistribute proficiency simples for soils, ag. stegates, bituminous materials and portland ‘cement concrete testing, 5.6 Test Reconds—The CML shall ‘maintain test records which contain suffi- cient information to permit verification of any test reports. Records pertaining to testing shall include original observa: tions, calculations, derived data and an identification of personnel involved in sampling and testing. The CML shall prepare test reports which clearly, accu- rately and unambiguously present the in- formation specified in Table 5. (The in- formation required in Items a, c, e, f, ‘SPECIFICATIONS FOR MATERIALS 2S TABLE 1 Bituminous Materials Test Equipment Trier Equipment—Test Method Requirement (one Suybolt Vicometers—T 59, D Das Calibae 36 Mechanical Shakers Ck. Sieviog Thorouphness | 12 (Gen, Pupose Balances. Seales & Weigh | Verily 2 ‘est Thermometers—T 201, T 202, 7209, | Calieae 6 7228. 749.7 51, D§, D70.D 113, D 2041 2170, D371, D 3182 ‘Azalea! Balances & Weights Vent, 2 Gomp. Test. Mach —¥ 165. T 169, T 24S, | Verify Lod Indications 2 7246, D 1074, D 1075, D 1559. D 1560 Mechanical Compactor —T 245. D 1559 Caitre 36 [CA Kneading Compactor 47, D 1561 | Calibae 26 Tiners—T 201. 7 202, D 2170, D211 | Ca. Accormy 6 ‘Ovens ‘Verify Temp Senge 4 Peveometer and Accessores—T49,D§ | Ck, Dil & Timer Awa] 6 Needle Cone Duclty Machine 51, DS Ck. Molas & Speed of | 12 Tene! TRO & RTFO Oven—T 179, T240,D 1758, | Shell/Caniage Ck Row | 1? 2s sion Speed & Temp ‘Vacuum Syrem—T 200, D 2041 Ck, Pressure 2 Sieves (Ck. Paysiat Condon 6 Molds, Followers, Calb Cylinders —T 246, | Ck Catal Dimensions ry 1247, D156), D Is6t Molds. Manual Comp. Hammers, Breaking | Ck Chea Dimension & Heads T 245, D 1559 ‘Mass of Hammer 12 ‘Molds & Plngen—T 167. D 107 ‘Ck. Creal Dimensions 2 Brass Rings & Assembly—T 53, D 36 | Ck. Ceteal Dimensions 2 Pyenometers—P 228, B70 ‘Ck. Creal Dimensions & | 12 Phys. Cond Cols & Foas—T 9, 159 (Ck. Creal Dimensions owmeten-—T 170. T 240, D 1856, D 2872 _| Calivate Flash Cope —T 8, 779, D 92, D 3143 (Ck, Crce) Dimensions and g of Table 5 does not have to appear tion and verification, test reports. internal fon the test report as long as itis included in test records and is traceable to the test report) The procedure for amending reports shall require that the previously existing report be clearly referenced ‘when an amendment is made. The refer- ences shall establish a clear audit wail from the latest issuance or deletion to the original report and its supporting data. NOTE 4—The requirements in Table 5 apply to the record that is used to present {he laboratory's test results i ther final form, In some cases, atest eport or test dta sheet 's the final form of the data 5.7 Records Retention—Records pertaining to testing, equipment calibra: Quality system reviews, proficiency sam- ple testing, test technician training and evaluation, and personnel shall be re- tained by the laboratory in a secure loca- tion for a minimum of 3 years. NOTE S—Although 3 3.year retention schedule is adequate in some instances, there ave many circumstances when a longer refen- ion may te advantageous 10 the CML Records concerning the calibration and veri ‘ation of equipment are an example, Rete: tion schedules of this type usually require Such records t be held throughout the useful life of the equipment. 58 Equipment Calibration and Veri- Jication Records—The CML shall main-736 ‘SPECIFICATIONS FOR MATERIALS Rig TABLE? Soils Test Equipment Imerval Equipment—Test Method Requirement (Monn) “Mechanical Shakers ‘Ck. Sieving Thoroughnese | __12 Gen. Purpose Balances, Seales & Weighs | Verily 2 ‘Compression or Loading Device—T 193, 208, | Verify Load Indications 2 216, 7 236, 7296, 7297, D 1883, D 2166, 2435, D 2850, D 3080, 4767, ‘Mechanical Compactor—T 99, T 180, D 698, | Calibrate 2 D 1537 (CA Keeading Compacior—T 190, D 2848 | Calibrate 7% ‘Ovens Verify Temperature Sex| & ings) Vacuum System—T 100, D 854 Ck. Pressure 24 Molis—T 99, T 134, T 135, T 136, 7180, | Ck, Critical Dimensions 2 T 190, T 193. D 698, D 538, D 559, D S60, D 1557, D 1883, D 2844 Manual Hanuner—T 99, T 180, D698. 1557 | Ck Wi & Catical Dimew | 12 Sieves (Ck Physical Condition @ | Liquid Limit Deviee—T #9, D s3i8 Ck. Wear & Chteal Di | 2 Grooving Tool 89, D 4318 ‘Ck, Critical Dimensions 2 Hydrometers —T 88, D 422 ‘Ck. Critical Dimensions 2 Straightedge—T 99, T 134, 135, 136, | Ck. planeness of edge 6 T 180, D 698, D 558. D 559. D 560, D 1557 ‘Weighted Foot Assembly —T 176, D 2419 | Ck weight 2 ‘CBR Annular and Slowed Weighis—T 193, | Ch. weigh 2 D ies3 (CBR Penetation Piston—T 193, D 1883 Ce diameter 2 ‘Standard Metal Specimen—T 190.D 2848 | Ck ouside dameter 2 ‘Metal Foliower—T 190, D 2608 Ck. diameter 2 TABLES Aggregate Test Equipment Thserval Equipment—Test Method Requirement (Month) Unit Weight Measures —T 19, © 29 ‘Calibrate 2 ‘Mechanical Shakers ‘Ck. Sieving Thoroughness | _12 Gen. Purpose Balances, Seales & Weights | Verity 2 Sieves ‘Ck. Physieal Condition 6 Ovens Verify Temp Seuings 4 Sulfate Oven—T 108, C88 ‘Ck. Rite of Evaporation 2 LA. Machine —T 96, C131 Ck RPM & Cnt Dimen | 24 ‘Conical Mold, Tamper —T 84, © 128 ‘Ck, Crideal Dimensions 2a ‘Steel Balls—T 96, C 131 Ck Indiv We & Charge We | 34 ‘Sodium Sulfate Containers —T 108, ¢ 88 Ck. Physical Condition tain calibration and verification records for all equipment specified in the QM, Such records shall include: a) detailed results of the work per- formed (dimensions, mass, force, frequency, temperature, time, etc), ») description of the equipment cali brated or verified including model and serial number or other accept- able identification (Note 10), ©) date the work was done, 4) identification of the individual per- forming the work, €) identification of the calibration or verification procedure used, 1) the previous calibration or verifica- tion date and the next due date, and 8) identification of any in-house cali- bration o verification device used (including serial numbers, lab rhumbers, or other identification used to establish traceability of items such as standard masses, proving rings, standard thermome- ters, balances, calipers, etc.) Figures X27, X28, and X29 are exam- ples of typical forms which may be used 59 Technician Training and Evalua- tion Records—The CML shall train and evaluate laboratory personnel associated with tests covered by the scope of this standard which the CML performs, in the ‘manner specified in the CML's quality manual, Results of these activities shall be recorded and records shall be main- tained in the manner specified in the QM, 5:10 Proficiency Sample Records— ‘The CML shal retain results of participa- tion in proficiency sample programs in- cluding data sheets, summary reports, ‘and documentation describing steps taken to determine the cause of poor results and corrective actions taken, SAIL Test Methods and Procedures— ‘The CML shall maintain copies of stan dard and nonstandard procedures for test- ing performed which is covered by the scope of this standard and shall ensure that the procedures are the most current and are readily accessible to employees performing the work 6. QUALITY SYSTEM MANUAL (QSM) REQUIREMENTS, ‘The CML shall establish and maintainR18 ‘SPECIFICATIONS FOR MATERIALS TABLE 4 Portland Cement Concrete Test Equipment 231 TABLES Test Report Requirements 4 QM meeting the following require: meats NOTE 6—Typical examples of documents meeting QM requirements ate provided in the Appendix. The CML may establish methods ‘other than those shown in tke Appendix to meet QM requirements NOTE 7—Figuee X1 lists typical elements which may be included in a QM. 6.1 Organization tional Policies 6.1.1 The QM shall contain the legal ‘name and address of the CML—and that of the main office or company, if differ- cent—and any other information needed to identify the organization (See Fig- ure X2), 6.1.2 The QM shall contain the own- ership and management structure of the CML. Names, affiliations and positions of principal officers and directors shall be listed (See Figures X2, X3, and X4). 6.13 The QM shall contain an orga- nization chart showing relevant internal ‘organizational components (See Figures X3 and X4). 62 Staff 6.21 The QM shall contain an out. line or chart showing operational person: nel positions and their lines of authority and responsibility (see Figures X3 and x4). 6.2.2 The QM shall contain position descriptions for each technical opera- tional position shown on the CML's orga- nization chart in testing areas covered and Organiza- by the scope of this standard. Required operational position descriptions shall identify the position and include 2 de- scription of the duties associated with the position, required skills, education and experience, and supervision exer- cised and received (See Figure XS), A reference to where the required position descriptions may be found is acceptable if they are not included in the QM. 62.3. The QM shall contain a brief biographical sketch, noting the educa- tion, work experience, licensure, certfi- cations, and current position of supervi- sory technical staff involved in testing areas covered by the scope of this stan dard (See Figure X6). Alternatively, the (QM may contain a reference to the loca ton of the biographical sketches 62.4. The QM shall contain 2 docu- ‘ment which describes the method{s) used to ensure that CML personnel are trained to perform tests covered by the scope of this standard in accordance with standard procedures. In addition to the description of training methods the document shall indicate what position(s) or employee(s) is responsible for the CML training pro- gram and maintenance of taining records (ee Figure X7. NOTE 8—There may be sever! different ‘methods employed for difering conditions of staff experience and background including (1) ‘on-the-job apprentice waining (one-on-one) {or new employees with ite or no experience in laboratory or inspection work; (2) formal Inhouse wraining sessions for certification, ting, oF competency evaluation, and (3) = Note 4) Equipment —Test Method Requirement (ston) | [2 Name and address of the testing lab | ‘Unit Weight Measures—T 121, © 138 Calta 2 semery ‘Air Meters—T 152, T196, C173, C231 Calibrate 3 Eee erat, ‘Comp. Testing Machine —T 22, € 39 ‘Verify Load Indications 2 © Name aad address of the client of ‘Capping Maverial Check Strength 3 demifiation of the project ‘Shummp Cones—T 119, € 143 ‘Check Critical Dimensions | 12 | |G, Description and identification of Ue ‘Meulic Reusable Molds—T 22, 723, C31, | Check Critical Dimensions | 12 test sample cx Date of receipt of the text sample Single Use Molds—T 22, T 23.31.39 | Check Dimensions of Each | — TH bieuiay OF eat pauses 1 Shipment [i Tdentification of the standard text ‘Moist Room/Storage Tanks—C 31,39 | Temp. Vesiied with Records] — adhiet {uae flad eases of al ing Thermometer known deviations from the test metox ‘Gen, Purpose Balances, Scales & Weights | Verify 2 ra en aha val ober paciuear ae required by the standard test method 1 Mentification of any test resalts 0b: tained from tests performed By 2 sub- J. A name of the persons) accepting technical responsibility forthe test r= por taining by extemal organizations. An indi- Vidual with prior experience performing a specific test need only have competency con: firmed by the CML, 62.5 The QM shal! contain a docu: ‘ment describing the method(s) used to evaluate staff competency to ensure that each test covered by the scope of this standard is performed in accordance with standard procedures. This description shall include the frequency of evalua- tions for each technician and indicate what position(s) or employee(s) is re- sponsible for evaluating staff compe- tency and maintaining records. These procedures shall ensure that each techni cian performing the test method is evalu- ated (see Figure XB), NOTE 9—Proficieney sample testing may ‘be useful in evaluating staff competency, how ever, it should be used in conjunction with ‘observation of actual testing performed. 62.6 The QM shall contain a form(s) for recording training and com- petency evaluation activities summarized under Sections 6.2.4 and 6.2.5 including the name of the trainee, name of the738. evaluator, test method evaluated, the dates and results. (See Figure X9), 63. Equipment 63.1 Inventory—The QM shall con- tain an inventory of major sampling, test- ing, calibration and verification equip- ‘ment associated with the test methods covered by the scope of this standard A reference to where the inventory is located is acceptable if itis not included in the QM. The inventory shall include, for each piece of major equipment, the fname, manufacturer, model and serial umber. (See Figure X10). NOTE 10—An identification number as. signed by the CML of other unigue identi fying information may be substituted for the ‘model and serial number if his isthe practice ‘normally followed by the CML. NOTE 11—Major equipment includes all equipment that is normally amortized by 4 CML, such as shakers, physical or chemi testing machines, balances, baths, ovens, mi- roscopes, and computing equipment dedi- cated (0 testing. Equipment such as chairs, desks and file cabinets may be excladed Major equipment does not usually include expendable items such as miscellaneous lassware, sieves, molds and viscometer, 63.2 Equipment Verification: 63.2.1 The QM shall contain a lists) giving general description of ‘equipment for performing tests covered by the scope of this standard which re- uite calibration or verification. For each item listed the list shall include the incer- val of calibration or verification, a refer- ence to the calibration of verification procedure used (Note 12), and the loca- tion of calibration and verification re- cords (see Figure X11). Calibration and [NOTE 12—When sandard calibration pro- ‘cedures are ued, the standard shall be refer- ‘enced (eg. unt weight bucket, AASHTO T 19; compression machine, AASHTO T 67). ‘When the procedure used has been prepared by the CML, the in-house designation hall be referenced. It shall be indicated if the work is performed by an ouside agency. NOTE 13—In addition to being in the QM {his information may also be included in the SPECIFICATIONS FOR MATERIALS calibration and verification recorde on each piece of equipment, 63.22 The QM shall contain a doc: lument which describes the CML's ‘method for ensuring that the calibration and verification procedures are per- formed for all required equipment at the specified intervals. This document shall include the name of individval(s) respon- sible for ensuring that calibration and verification activities are carted out, and procedures for handling equipment ‘which is new, removed from service, out of calibration or defective (see Figure X12), 6323 The QM shall contain in- house equipment calibration and verifi- cation procedures, when they cannot be referenced in applicable standards, or have @ reference to their location in the CML (see Figures X13 to X25), 6324 The QM shall contain certifi ‘cates or other documents that establish the traceability of in-house equipment or reference standards used for calibration and verification, or have a reference to their location in the CML. (See Figure X26) 64 Test Records and Reports: 64.1 The QM shall contain a docu- ‘ment which describes methods used by the CML to produce test records and t0 prepare, check and amend vest reports, (See Figure X30) 64.2. The QM shall contain typical fest report forms which illustrate the ‘manner in which tests results and sup- Porting information (See Section 5.6) are documented. (See Figure X31), NOTE 14—A printout showing a typical test record is acceptable ifthe laboratory uses clectonie media for report storage 65. Sample Management—The QM shall contain a document describing pro- ccedure(s) for sample identification, stor- age, retention, and disposal of samples (Gee Figure X32), NOTE 15—In this context, the term “stor age” refers to what is done before testing, ‘The term “retention” refers to what is done after testing Rig 6.6 Diagnostic and Corrective Ac. 6.6.1 The QM shall contain a docu. ‘ment(s) describing participation in prof ciency sample and on-site inspection pro- grams (Note 16), methods used to iden- tify poor results and procedures followed when poor results oecur or deficiencies occur. (see Figure X33). NOTE 16—AMRL and CCRL conduct on- site inspection and proficiency sample pro- grams which the CML may use 6.6.2. The QM shall contain a docu- ‘ment outlining the method(s) used in responding to external technical com plaints (see Figure X34), 6.7 Internal Quality System Re- view—The QM shall contain a document escribing the scope of internal quality system reviews, establishing the fre- quency of these reviews, identifying indi viduals responsible for the review, de- scribing the distribution of reports to management and identifying the location of resulting records (see Figure X35), 68. Subcontracting—The QM shall contain a document describing the poli- cies which the CML follows relative to subcontracting, if it engages in such ac- tivities, A reference to where the policies may be found is acceptable if they are ‘ot included in the QM. These policies shall include procedures followed by the CML in selecting competent subcontrac- tors and reporting the results of testing performed by subcontractors. If the CML does not engage in such activities, the (QM shall contain a statement t0 that ef= fect. KEY WORDS ‘Construction Materials Testing, Quality System Manual, Quality System.RIB SPECIFICATIONS FOR MATERIALS 29 FIGURE X1—Typical QM Table of Contents Dae) APPENDIX ca ‘QUALITY MANUAL FOR (Non-mandatory Information) (Laboratory Name) TABLE OF CONTENTS ‘Typical examples of documents meets | Fac Sealant ae ing QM requisements are provided in : : this Appendix. The CML may establish | a0 of : : ‘methods other than those shown in this | Greanization and Organizational Policies 3 5 appendix to meet the QM requirements | sir a H of Sections $ and 6. Equipment 5 mx ‘Test Data Control and Reporss 6 Diagnostic and Comective Action 7 x Internal Quality System Review ® & Subcontracting 3 mx740. (xe Legat Name and adsress Main Ofce Addex: ‘SPECIFICATIONS FOR MATERIALS FIGURE X2—Typical List Showing Ownership and AfTiiation of Principal Officers and Directors Rig Owner Poston Tame ike Afiiaion ‘Chet Exeouive Officer President Vice-President Viee Present Board Member Board Member Board Member FIGURE. X3——Typical Chart Showing Management Structure (Commercial Laboratory) Name and Adstss of Labrtory Laboratory Name Cabeenory Assess Bowdof Dieser Preders ‘Name Lib Manager ‘ame Se na Gener Conse Biomizous Comme Taborsioy Superior Titers Superior Name ‘Name {tortor Tectia ‘retoy Tecan ane) ‘Sane ‘are Name Note—The figures m ths appendix iustrate npcal examples ef documents forms and standard operating procedures which sass the requrements of this practice, A CML mas emplon other methods which saif the nen: of this practiceRIB. ‘SPECIFICATIONS FOR MATERIALS 741 FIGURE X4—Typleal Chart Showing Management Structure (State Laboratery) Name and Adress of Laboratory ‘Usboairy Name) abortry Asaree) ‘Comistioer Secretary ‘State Engineer (Name) Waar mad Reseaen Eapieet (Name) Fortang Comer Geasecial Aaphal Testing omer Ten | c Testag Ta Sopersar Tab Supersar Ta Supennar —] (mel Name) me) Lab Tecnica Lab Technine | Tab Tecnica Sinema ao in Nae Nowe—The figures in his appends ilttraterpcal examples of document, forms and tandord operating procedures which sash he requirement of ‘his practice. A CML may employ other methods which argh the Ite ofthis pesence742 ‘SPECIFICATIONS FOR MATERIALS Ris FIGURE X5—Typical Operational Postion Description tae SENIOR MATERIALS TESTING ENGINEER (GENERAL DESCRIPTION ‘The SENIOR MATERIALS TESTING ENGINEER leds 2 group of enniciass an performs aéanced echnical wrk invlvng te tesig of metas, ape Es cements, pum, sis, peoeum prods nd oer aerial, an ndindallypeclorms eis fs Whi avanced nate Employee sites woke be done ad outings rcedurs expecially wet aw mato tt aft be wed Wark abo ile he wring of mat specesns tnd he Serng of new tests ad etn apart SUPERVISION EXERCISEDRECEIVED: otk performed with cosierable dependence withthe review of est and prcedoes made by the rupert fo desied ress ad eeformance to estab lished pots. Eetiessopervaon over sdminiiaine ta echnea personel | pues: veiecs he chemical aio physi testing of metas agpregaes. cements, pains, wil, peu procs and shee material. Easres compliance with the quay system for hee area of esting ewses and apes forma forthe ierpeution an alsin of es resus and makes ecommenstons repasing compliance | Advts oer einer he preparation of material specifictins fr metal product Agee. cements. paints. sel peuoleum pouch te ‘Assis work nd ouines procedures ew by employes inthe grup Perf elated wrk 5 ese MINIMUM QUALIFICATIONS Eeventon: Bachelors Degree Experene Five years of technical experce inthe areas of éesign engineering survey, mater testing ansporaion a higheay paring. trl constuction, ta highway maintenance FIGURE X6— Typical Biographical Sketch xe) BIOGRAPHICAL SKETCH ames — Laboratory Manager FORMAL EDUCATION: Degree! Tope. (Discipline). College Name) ._ (Dues PROFESSIONAL RECOGNITION: Registered Engineer Sia of State) | exrentence: (Dues rome) —Jb Responsbiies Dae revi) — Wb Responses: ‘CERTIFICATIONS AND RATINGS. | TRamsine: ‘Note —The figures in ds eppeni lsat ypcal examples of documents forms and sandard operating procedures which saisy the requirements ofthis practice. A CML may employ other methods which say the ten of th proctoeRig SPECIFICATIONS FOR MATERIALS 743, FIGURE X7—Typical Desriti Testing Technician Training Program a STAFF TRAINING PROGRAM FOR TESTING TECHNICIANS ‘Ah eater technica stl be aed prior performine tet peedure no reo pereced. The lowing ring pocedre hl be fellowes for 1, The race sal ob copy of he applicable et proce and report for, 2 The rice sal rudy the test procedure and test rpor orm to beam familia withthe egipment,ermigy test proce, elisa es rept 3. A qualified echician shal demonstrate te et procadere fr tence 44 Thetrine shall epee perform te est proceder nce ie puidanc of Gig ecniian ot poiency is btned. 5 The laboratory supervisor hall serve the Wane demonsening the proce so dum har the age has demoed te sity to prfom the ‘est rocedur. if is performed propery. by makiog aa ey i the ines ining record FIGURE X8—Typical Method for Reviewing Test Technician’s Competency xe) METHOD FOR REVIEWING TECHNICIAN'S COMPETENCY Each laboratory supervisors responsible for evaluating thir test echnician's competency a east once every sin months by reguining each ecaican ‘0 demonstrate the AASHTO and/or ASTM tes procedures fr which he/she ha ben trained to perform, [a ecrician dos ot routinely perform 2 tet, it may not be ecessary to evaluate his or her competency 10 perform the test every sn months. However, the tectncian’s competes shall be evalusted porto pertorming the tes For each testing techrician, the supervisor shall record the est demonstrated, the date of the demonstration, and the results of he evaluation (: jsfacton or unstsfactoy) In adition, te supervise sal sign each entry on the evaluation record Wan unsatsaciony result is recorded fora specific est the superior sll seview all observed deviations trom the stindas AASHTO oe ASTM procedure wit te esting techrician, observe the technician fedemonsrat the test procedure and recor the ess as indeed above FIGURE X9—Typieal Record of Testing Technician Training and Evaluation (xe, ‘TECHNICIAN TRAINING AND EVALUATION RECORD ‘Grech One Tes Mtoe ial ‘Month ‘CommentiRers Teiaing eat ‘Note—The figures in this appendix itacrote typical examples of documents, forme and standard operating procedures which ratify the requirements, ‘ofthis practice. A CML may employ other methods which aay the ise ts practice744 SPECIFICATIONS FOR MATERIALS FIGURE X10—Typical Page from an laventry of Major Equipment [SVENTORY OF MAJOR EQUIPMENT EQUIPMENT, ‘MANUFACTURER MOBELNO | SERIAL # 10S ANGELES RATTLER S00 825 ‘OvEN H 0 ‘sa2an05) OVEN, [ 188 RPS? BALANCE i Ke 05196 BALANCE t Pa ous BALANCE, I 1S 2076s SHAKER 6 DK 73 SHAKER TS 10360 SHAKER = a 2a SHAKER i [ree ns FIGURE X11—Typical List Showing Calibration and Verification tnformation Ris ny EQUIPMENT CALIBRATION AND VERIFICATION INFORMATION icon Calbeiaeral aioe Reds Gaianed Pose et ies nia LD iB ioe SIMD Bale (eis Lt 12M {seine [ast oss Mesh. Compson TEN Tsoiae ASTM BEIGE LA Abn Eine t rm T anrerse ae Inne Recdie #E Cres Ase. 0 er arene ab Ine Peete # ‘emp. Mach BM Ceri ab ‘se cons rir Mol aM Sous ab Inone cere A Maral Mats “so Min Brive ab [none Peeters #6 Uni We askew (agp Lay ao garg Lab T AASHTO T 19 nic Wi Buctes (Cone Lat) Mo Conse ib AASHTO 19 = oo Ba La ASTM ET ‘Note—The fares in his appendix dlusirate typical examples ofthis practice A CML may employ other methods hich sai of documents, forms and standard operating procedures which satisfy the requirements iat the intent ofthis practiceRig SPECIFICATIONS FOR MATERIALS 745 FIGURE X12—Typical Policies and Procedures for Conducting and Recording the Results of Equipment Calibration and Verification [Note—The figures inthis append erate typical examples of documents. forms (ut EQUIPMENT CALIBRATION AND VERIFICATION POLICIES AND PROCEDURES (Genera Pte 1. Reguied equipment sal be clbate specified cera allowing the general prcedues indicated below 2. Newt aquited equipment witout mansfacttr’s certain aa eupmeba hs ot been calibre ce erfied becae it as ben eee fom se ‘ce sal be ealbraed or verified before bee pce i sere 3. When any ofthe Unit's est equipments overloaded. mishanded,pvng ess tha ae suspect, rs por meting specication leans. the wnt Supers se tll remove i fom service ance mark it by atachng afd bos cape The equip sal be returned to see ely ater sppropine ‘ein are made and calla ad verification stows te equipment to faneon saison oo meet specifies werances General Procedures |. The Supervisor is each etiog Us sal maintain 2 ile or each eof equigment in i oe: requiring eabraon or vector, The ile for each Piece of equipment hl contain dete records of aliraten of werifiction work performed in chonsiogia oe hal be ep in he Supesar othce 2. The Supervisor each Tsing Unt shall manana st of 12 labeled fers in is ober ece~ one fr each moni ofthe yeas Each mont fle hall ena» panally completed calibra or verifcaton record frm for eich pace tegument requiring calibra er weeesien daring the eh ans (ted on the fer abe 23. Daring the ist week ach math the supers of each test ui sal eove the parily completed record forms frm he ure mons oder an tnsrut appropriate stat perio he necessary eatbraion or ection work within inten week anette ne compte een fores ‘4 The Supers sall prepare pari filled out record forms for ach pee of equpmea cai or verified ha month—iéerifvine he equipment and ‘he nex ie caliaon er verizon wots equted (Month apd ea) —ané i each paral led ou fem ine topteprate months ace ‘5. The Soperisor sal ile ach of te complete reco forms nthe appropri equipment recor fils. chronological ode ofthis practice. A CML max empl exer methods which sais the mien of ths practice and standard operating procedures which sus the requirements746 SPECIFICATIONS FOR MATERIALS R18 FIGURE X13—Typical Procedure for Verifying Ovens auipent Check DavING oveN This method provides aseuctins or verifying the di sens on general purpose drying oven i aR 1A calibrated themareter graduated in |.0°C increments hang ange wich ices he temperate range fo be checked 2. A bras thermometer velo retin heat while he even dori open Tht extemal fora constant enpersare reading, 3. Acotes pinto ol the thermometer ia sch a anne aso eable the operator io ead ihe vnc easily ftom Use onside he en sacs. ‘Drying ovens sal be eapabe of maitining «conta empernre range ted athe appropet est methods Procedve Face he dermometer inside thebeats wel withthe clothes pin ached othe thermometer Poston the shemomete on the bef wher the samples ae rommally ance ‘Take the fst reading a east 1 hou after losing the oven oven howd remain undisturbed ‘Take as many readings as necessary to determine if the temperature range i within he specified olerance (vee consecutive readings taken ‘no les than 1/2 hr apa, witha We tolerance allowed are mlequte), 4 Adjust the temperature’ of the oven if an observed temperature reading is outside the tolerance specified (allow at least 1/2 befor the temperature to sabitize between etch adjusment). Retr to Step 3. 2 2 FIGURE X14—Typleal Procedure for Veriying Sieves [ aa Equipment Checked sieves | Papas ‘Ts metho provides instoctions for checking the physical condita of laboratory tess ves ranging in ie fom 7S mm (3 im) 00.075 (Ne 2003 pecton Equipment Reauied 1A caliper readable 19 0.01 mm. (Use for No. 4.75: seve and coarser.) 2A eye comparator wih a0. mm sae (or te with sieves fine tan 475), Tolerance ‘Sleves shall meet the physical requirement spevified in AASHTO M 92 (ASTM E 11), rosedure {Steps 1& 2 appt ol to ives ving openings gree than 75 mm) 1 “Select an adequate numberof nevis sive openings (or slog 245" line. Mensre an record the seve openings vet tht he ite opening Indieated on he labels core, Repeat step 1 oan the sv 9°. Inspec the general condition of he sve Check the fame and ole jt foreach rte eheck fo pin oles Make sue the seve Basan appropiate abel (Check frites fhe wires on each inde the fine eves LNote—The figures inthis append ilusrate pica examples of documents, forms and standard operating procedures which sai the requirements of ‘this practice A CML may employ other methods which sey the inten af ns practiceR18. ‘SPECIFICATIONS FOR MATERIALS. 747 FIGURE X15—Typical Procedure for Verifying Manual Compaction Hammers Oa auipent Check MANUAL HAMMER (AASHTO T 99, T 180) (ASTM D 658, D 1557) Popo: "hit method provides insetion for checking the rita dimensions of he proctor Mme. Inspection Eauipmen Require Tr Calipers readable 02mm 2 Tape measre readable to im 3. lance, capciy 5g. readable tog Eauipcat tll meet the dimensional cance specified ia he apple tt mend Pract 1 Measure and record the diameter of the ramet fae éetemiae by taking wo reading 0 apart sing the cali Pullup de bande, measvre ad record the drop bight of he hammer. Deezmine hs ih tnd he pide seve Vg the tae MERE ‘Remove the Bammer rom the pudeleve. Deter ad ecard i rao the wees I ‘Meas abdtecord he hares fhe Yet oles sear een ft hans, FIGURE X16—Typicl Procedure for Verifying Conical Molds and Tampers Ox xsipment Checked CONICAL MOLD, TAMPER (AASHTO T 84) (ASTM C 128) Popes “This metho pres insraton for checking the crite mensions ofthe tn aoe an teperued 1 the bon seth nsgecoon Egipment Rega: 1 Calipers readable | mm, 2. Balance, 500g capaci. readable 00 tg 3. Raer readable oI mn. Tease ‘Eun shal meet the mensional talerance pei i hte metho, Procedure: (Conn ‘Measure the inside timer tthe to of econo he nates mm by thing Ss readings 90 apart sing the rulers and record the resus, Invert the cone a een Step Ie Pace the cone oni lass surface. Measure and record ep of he cne Using he Calpers. measur the thickness of he coe tthe nears 0. thm by taking 2 readings 90" apart ate tp of he coe an 2 readings 90" apr athe bstom of the cone a8 recor the eu. Crampess TT Measore and record the giametr ofthe tumpig (0c tothe eae 1mm by aking two readings 9° apart sng healer 2 Devermine and record the mas of the tamper othe pearesO1 Note—The figures inthis append lusrae pica examples of documents, forms and standard operating procedures whch satify the repurements of ‘is praciceA CML may employ other methods whch sts the inten of is practice,748 ‘SPECIFICATIONS FOR MATERIALS Ris FIGURE X17—Typlcal Procedure for Verifying Vacuum Systems (xsi avipnet Cocke ‘VACUUM SYSTEM USED IN (AASHTO T 100, T 200) (ASTM D 854, D 2081) Pumas "This meth provides nse for ebecang the vacvue pes, Inspection Eaupmen Reguied ‘Bierce Equipe shal be capable of ppsine the acim pei inthe applicable test method Procedure: Tr Connect the guge wo the yste wit th rap intine Between he system athe ae 2. Mae sre all conection sesh, 53. Open be number fines normal ke ttn aod tea and record the presse indie onthe Eee, FIGURE X18—Typical Procedure for Verifying L.A. Abrasion Machines (Dus Eguinment Chechet LAA. ABRASION MACHINE (AASHTO T 96) (ASTM C 131) Porpose: ‘This method provides instruction for checking the crcl dimensions ad general opernting conden ofthe L.A abrasion machine aud the mth ofthe spheres wed 3 est charges Inspection Eines Regist: 1 Selle eat} me. 2. Soopwathreaaabeve 01 se. | 3 Balance witha skp eapacy. eadbleto t= oerace ‘The LA. machine shall meet the ensiooa i:ances specie in the applictble et method lied above ad shal bei ood operating condition, The te) eres wed to tage te LA. machine hall mest tb mass clerances sperified ia the spplable tex metho ised abo Procedre: (CA. Machine) “Measure and record the inside diamcter ofthe drum atthe Ie and righ edges othe nearest Measure and record the width and height ofthe opening t the nearest 1 mm Measure and record the wall dickness a he left and right sge tothe newest 1m Determine ifthe cylinder i orizootal using a ste allo check lef orrigh rol ‘Measure and record the self with inte the dam fo the newest 1m ‘Measure and record the distance from the shelf to the opening in the ection of tation. Using te stopwatch, determine the nia. th nearest whole umber over « bite period. Record the Rin, (Check thatthe number of revalecons is 500 by locking a the counter onthe machine (Stel sper) 1D" Determine an record he mass of ach indies! spre ote nearest i. 2 Devermine and record the mas ofthe collective caret) the eas 5 [Note—The firures i this append tsa rypcel examples of document. forms and standard operating procedures which sats th requirements of ‘his practice. A CML may employ other methods which sais the inten of ts practiceRIB. SPECIFICATIONS FOR MATERIALS "9 FIGURE X19—Typical Procedure for Verifying Bituminous Concrete Specimen Molds (Duet Equpnent Oreck MOLDS (AASHTO T 167, T 265, T 248) (ASTM D 1074, D 1559, D 1561) | Pumas "Tas procedure provides isto fr checking the nica dimension of compressive sagt, Masta and Hveem mols ‘nspection Bgipment Reavied Tr Calpers. capable of merurng an inside ameter of 100mm ad eadale to 002 ieee The diameter of he molds checked shall met the dieasiona erances specie i the applicable test meth sted above, Procedure 1 Measure and record the ssid diameter of he moto the nearest 0.02 mm. Roae the mld O(a) and measure and record he inde diameter aps 2, Turn he mold over andsepe Sep FIGURE X20— Typical Procedure for Verifying Sols Test Mods Du Eguipent Checked MOLDS (AASHTO T 99, T 136, 1 135, T 136, T 180, T 190, T 193) (ASTM D 69, B S58, D559, D S60 DISs7, B 2848, D 1883) epee This procedure provies instructions fer checking the cial dimensions of 100,150 and 200 mam (4 6 an 8 ) mold sensi testing. spectin Equpmen Revie 1» Calpers. capable of measuring he bleh ar inside dmc ofthe mols and readable 0002 Procedure 1 Measure an econ heise diameter of he wld othe nearest 0.02 mm. Rotate he mod 90 (Ii urn ad measure ad econ the inside acer 2. Turn the mold over and ep Sep 5. Measure anc record the hegh he molé othe sere 02 sm, Rota the td 90H en) and meshes econ he Aegh apni Note—The figures im his append ilsrate typical examples of document orms and standard operating procedures which satsy the requirements this practice. A CML may employ otner methods which sash the en ofthis practice750 ‘SPECIFICATIONS FOR MATERIALS Ris FIGURE X21—Typical Procedure for Verifying Timing Devices (Da Eauipmeat Coeted: TIMERS (AASHTO T 72, T 201, T 202) (ASTM D 88, D 2170, D 2171) Purpose: “This procedure provides isto: for checking the accuracy of timing dees 1 Tuer, readable 10.1 ec. having verified accuracy within he oerance ised in stove tet ethos lence Timers sal met the accuracy egireress spc inthe aplatle et methods ited above Procedure: Tr Hold he calibra tines ia exe hand an tbe timer ob checked i the oppose had 2. State tiers smltancously by presing the sar” etns tthe same time 3. Allow th mers orn for at east 1 a he stop te timer stultancouty Record theme indicted by both timer 4 Record he iferencebetwoen te (xo imers Calle a record the pee aceureey accuracy = (AB) « 100 2 ‘A = Reading oo nb ime (Se) B = Reading on sundae ine (Se) FIGURE X22—Typical Procedure for Verifying Penetration Test Apparatus (Ou) auipmens Check PENETRATION APPARATUS (AASHTO T 49) (ASTM D 5) Popo: ‘Ths procedure provides istration: fr checking the equipment wed to perform the penis es, lnspecion Egipmen Reaure 1 Balance redable 190.01 2. Microscope oeepite, 10K 53. Meta ck, 10,0 mm igh Meta Mock, 25.4 mi in) heh 4 Soppor Block, 75-675 mm hgh 5 Rule readabietol mim, 6. Cahtrate Stopwatch enable t 0.1 sez “Toerance: "The eupment shall met the tolerances speciid in tet methods T 49 and D 5 Procedure TE Remove the spindle, SO and 100 g weighs frm the penenteter, Record the mats f cach othe nearest 0! ‘Weigh each needle othe nearest 001 g. Visually examine each nce with microscope or eyepiece. Each nedle shouldbe sight and ‘eee of bars, The bate ofeach needle thould be fat. 3. an automatic timing mechanism is used on the penetometer, start the calibrated stopwatch when the plunge i eased and stop the ‘alia stopwaich when th plunger stops. Record the ime indicated onthe cllratedslopwatch othe neatest ©. sc. anal device is used to release the plunge. check the accuracy of the liming device used over a G-secimerval. Record the elzped time tothe Nene Ot see | 4 Place the suppor: bck on the base of the penetrometer. Place th 10 mim block on the suppor block, Adjust the needle eight so thats ‘ip st touches the ‘op ofthe 10 mm block. Remove the 10 mum block and release the needle tothe suppor block Adj he sonrument {0 measure the distance moved. Repeat Step 4using the 25.4 mm (I in) Block, Determine dial aceuracy by comparing readings with the hela ofthe Blocks '5. Measure and record ine estance from te perforate shelf to the bottom ofthe waterbath, Measre and record the distance from the pesorsted Shelf othe surace ofthe water. Measure and record the distance the thermometr is immersed inthe water, 6._Observe and record the temperatre ofthe water in the Bath othe nearest OT (0.05C) ‘Nate—The figures in this appendix lustrate typical examples of documents, forms and vandard operaing procedures which satis te requirements (of tis pracice.A CML mas employ other methods which say the inten of tis pracice,