AASHTO’s National Transportation Product Evaluation Program (NTPEP)
Audit Report for Geosynthetic Reinforcement
Plant
Name:
Physical Address:
Mailing Address:
(if different from above)
Proprietary Ownership
Company Name:
Physical Address:
Primary Contact
Name:
Title:
Telephone:
Email:
Fax:
Management
QC Manager:
Plant Manager:
Auditor Contact
Name:
Telephone:
Address:
Email:
Auditor Name:
Audit Report Number: ____________
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Audit Report for Geosynthetic Reinforcement
DOT Official Contact
Name:
Title / Organization:
Telephone:
Address:
Email:
DOT Official Contact
Name:
Title / Organization:
Telephone:
Address:
Email:
DOT Official Contact
Name:
Title / Organization:
Telephone:
Address:
Email:
Other Attendee Contact
Name:
Title / Organization:
Telephone:
Address:
Email:
Auditor Name:
Audit Report Number: ____________
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Evaluation Program for Geosynthetic Reinforcement
Summary Report For
______________________________________________ Product Line
Introduction
The National Transportation Product Evaluation Program (NTPEP) is a program under the sponsorship of
the American Association of State Highway and Transportation Officials (AASHTO). The NTPEP
Evaluation Program for Geosynthetic Reinforcement audit report provides a comprehensive review of the
consistency of the product line, allowing products representative of the line to be tested and the results of
that testing applied to the remaining products in the line not subjected to the full suite of tests, in
accordance with AASHTO PP66-10. The evaluation includes a desktop review of the facility’s quality
manual and 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 jointly by auditors
________________________________________. Geosynthetic manufacturer _____________was
represented by _____________________________, during the on-site audit which was completed on
__________________.
The evaluation findings follow. Deviations from program requirements are noted in red.
The audit was conducted to evaluate the _________ product line, including
_______________________________. Raw materials used include ___________________________.
Raw materials, including COA’s and QC/QA test results, were traceable to the finished product and
found to be consistent throughout the specified product line. The manufacturing process from raw
material to finished product was found to be consistent for all production lines used to produce
products for this product line (_______________________). The QC/QA processes used by the
manufacturer, including raw material specification requirements used by the manufacturer to
procure and evaluate raw materials used in the product line, and quality control for the finished
geogrid products, appear adequate to maintain consistency of the as-manufactured products.
Therefore, the manufacturer was found to be compliant with regard to the definition of a
geosynthetic reinforcement product line in the NTPEP work plan and AASHTO PP66-10, for the
product line as specified herein.
Auditor Name:
Audit Report Number: ____________
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Table of Contents
Section 1: Geosynthetic Reinforcement Product Line Summary and Production Line Overview .. 5
Section 2: Product Raw Materials Information................................................................................ 5
Section 3: QMS QC/QA Requirements ........................................................................................... 6
Section 4: Sample Reports for Resin and Geosynthetic Testing.................................................... 11
Section 5: Manufacturing Process Control ................................................................................ 12
Section 6: Records Retention and Traceability .............................................................................. 13
Section 7: Geosynthetic Reinforcement Identification Markings .................................................. 13
Section 8: Report Signature ........................................................................................................ 15
Section 9: Sampling ....................................................................................................................... 15
Auditor Name:
Audit Report Number: ____________
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Section 1: Geosynthetic Reinforcement 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 geosynthetic marking? YES
Plant Name
Physical Address
Mailing Address
NO
List other locations:
City, State, Country
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 REGEO work plan. If more than one production line used to produce a
geosynthetic reinforcement product (e.g., a different production line may be used to produce the yarn that is used to
manufacture the final product), identify each production line used and what part of the product manufacturing
process is conducted on each production line.
b) Production Line Details:
Manufacturing
Plant
Production Line Identification/Description
Products Manufactured
on the Production Line
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:
Auditor Name:
Audit Report Number: ____________
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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 PP66-10 and the NTPEP work plan?
________________________
Comments:
Section 3: QMS QC/QA Requirements
A) QMS Manual Information
QMS Manual Identification:
Date of Revision of Approved QMS:
Facility has this manual available?
Comments:
B) Manufacturer QC/QA for Raw Materials
Auditor Name:
Audit Report Number: ____________
YES
NO
N/A
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B) Manufacturer QC/QA for Raw Materials
YES
NO
N/A
1) Does the manufacturer have property specifications for raw materials used in
their geosynthetic reinforcement products:
a) For resin?
b) For fibers?
c) For Yarns?
d) For coatings?
e) Other ______________________________________________
2) Identify properties used in the manufacturer’s raw materials specifications:
a) For resin:
a. Melt index
b. Carbon black content
c. 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. Denier
b. Tenacity
c. Tensile strength
d. Molecular weight
e. CEG
f. Other _____________________
g. Are lot specific values for all these properties included in the
COA? If not, which ones are not included? _______________
c) For yarns:
a. Denier
b. Tenacity
c. Tensile strength
d. Molecular weight
e. CEG
f. Other _____________________
g. Are lot specific values for all these properties included in the
COA? If not, which ones are not included? _______________
d) For coatings:
a. Brookfield viscosity
b. Density
c. Gel temperature
d. Durometer (Shore A) Initial
e. Other:
f. Are lot specific values for all these properties included in the
COA? If not, which ones are not included? _______________
e) For other raw materials (e.g., additives such as carbon black,
antioxidants, coloring, etc.):
Auditor Name:
Audit Report Number: ____________
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B) Manufacturer QC/QA for Raw Materials
YES
NO
N/A
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 PP66-10
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 specifications
b) 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?
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 geotextile manufacturer property
specifications (usually, these are the same as the supplier’s specifications):
Auditor Name:
Audit Report Number: ____________
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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 (geosynthetic Product)
1) Does the QMS include procedures for the inspection and testing of
geosynthetics during and at the completion of the production of the
geosynthetic products?
2) Do the procedures in the QMS:
a) Require visual inspections of the final product?
b) Specify the QC/QA process and procedures
c) 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?
YES
NO
N/A
YES
NO
N/A
Provide the definition of a lot used for the geosynthetic 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 and rib forming processes, etc.) and condition of the manufacturing
equipment?
5) Does the QMS describe quality control procedures for the coating used
(PET geosynthetics only) and how it is applied to the polyester yarns/ribs
to form the final product, considering both application rate and quality of
the coating?
6) Does the QMS establish traceability from the final geosynthetic product
back to the resin lot used?
7) Are the documents that establish traceability of the final geosynthetic
product maintained along with the inventory?
Comments:
D) Statistical Analysis of Test Results
1) 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?
Auditor Name:
Audit Report Number: ____________
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Corrective action taken when QC/QA test results don’t meet product property specifications (include
how failing sample is related to specific rolls of product produced and action taken with those
particular rolls):
E) QC/QA Testing Plan and Procedures
Testing Performed by:
Test Name
In House
Outside lab
Test Interval
No Testing
Performed or
N/A
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)
Geosynthetic Tests:
- Mass per Unit Weight
(ASTM D 5261)
- Single rib tensile
strength (ASTM
D6337)
- Wide width tensile
strength (ASTM
D4595 or ASTM
D6337)
- Aperture size and rib
width (hand measure)
- Junction strength (GRIGG2)
1
Names, addresses, and contact information for outside laboratory facility(ies) used:
Other testing done on production products that is not lot specific:
Auditor Name:
Audit Report Number: ____________
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Section 4: Sample Reports for Raw Materials and Geosynthetic Testing
Auditor 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 in accordance with
WSDOT T925/AASHTO PP66-10 Specification:
 Raw materials – Melt Index, molecular weight, carboxyl end group content, tensile strength, denier,
Brookfield viscosity, etc.
 Geosynthetic – Mass/unit weight, aperture/rib width, single rib tensile strength, wide width tensile
strength, junction strength, etc.
Auditor Name:
Audit Report Number: ____________
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Section 5: Manufacturing Process Control
Note: If not applicable, enter “N/A” in box.
A) Process from resin to fiber/yarn/rib
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/rib to final product
Consistency of product weaving process, geogrid junction forming process, or geogrid formation process:
For PET geogrids, consistency of coating process, including processing environment, coating rate, and
final weight per unit area or thickness of coating, including how measured for each aspect of process:
Auditor Name:
Audit Report Number: ____________
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Section 6: Records Retention and Traceability
YES
NO
N/A
1) Does the QMS include a process for storing quality control test reports for
2)
3)
4)
5)
raw materials and the finished geosynthetic products, as well as raw material
COA’s?
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?
Does the QMS establish traceability from the final geotextile product back to
the raw material lot used?
Are the documents that establish traceability of the final geosynthetic
product maintained along with the inventory?
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):
For Auditor – indicate products evaluated for traceability:
6) 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.):
For Auditor – indicate products evaluated for traceability:
.
Comments:
Section 7: Geosynthetic Reinforcement Identification Markings
Auditor Name:
Audit Report Number: ____________
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Auditor Note - Insert a picture(s) of the plant’s unique geosynthetic identification markings. Refer to the
plant’s pre-audit documentation or previous audit report.
Auditor Name:
Audit Report Number: ____________
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Section 8: Report Signature
The Preceding Report has been reviewed and assured to be accurate by the Lead Auditor.
Auditor Name:
Signature:
Auditor Name:
Signature:
Auditor Name:
Signature:
Section 9: Sampling
The sampling report form follows on the next page(s).
Auditor Name: _______________________
Audit Report Number: _________________
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IN-PLANT SAMPLING REPORT
NTPEP Program: REGEO
NTPEP Number: (20___)-0__
Manufacturer Name: TenCate
Page _1_ of _1_
Type of Facility where Sampling Conducted:
_X___ Manufacturing (production line); Describe: Woven geotextiles and geogrids are manufactured at this plant.
_X___ Warehouse (storage of finished product): Describe: Connected to manufacturing facility.
Location of Facility where Sampling Conducted:
Cornelia, GA
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 (30 days) but not specific sampling appt. date
Material(s) Sampled and Description:
(product designation if finished product, or description if sampling unfinished product, e.g., fiber, greige good, coating, etc., for Product)
Sample _ (finished product)
Sample _ (finished product)
Sample __ (finished product)
Sample _ (finished product)
Sample _ (finished product)
Sample _ (finished product)
Sample _ (finished product)
Roll No.
Lot/Batch No._
Roll No.
Lot/Batch No._
Roll No.
Lot/Batch No._
Roll No.
Lot/Batch No._
Roll No.
Lot/Batch No._
Roll No.
Lot/Batch No._
Roll No.
Lot/Batch No._
Sampling Event Notes:
(plant condition, roll storage/inventory, traceab ility 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
Send copy of sampling report to NTPEP Geosynthetics TC Chairperson (Tony Allen, WSDOT, allent@w sdot.w a.gov)
Also include copy of sampling report w ith samples.
Auditor Name: _______________________
Audit Report Number: _________________
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Sample _
Roll No. Lot/Batch No._
Sample
Roll No.
Sample _
Lot/Batch No._
Roll No. _ Lot/Batch No._
Sampling Event Notes:
(plant condition, roll storage/inventory, traceab ility 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
Send copy of sampling report to NTPEP Geosynthetics TC Chairperson (Tony Allen, WSDOT, allent@w sdot.w a.gov)
Also include copy of sampling report w ith samples.
Auditor Name: _______________________
Audit Report Number: _________________
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