905 PIPE

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905.01 CERTIFICATION
Furnish certification for pipe as specified in TC-1.03.
MATERIAL SPECIFICATION REMARKS
Nonreinforced Concrete Pipe M 86, Class 3
Reinforced Concrete Pipe (RCP) M 170, Class 4 and 5 60 in. and smaller diameter, Load bearing option. Larger than 60 in. diameter, Material option.
Reinforced Concrete Elliptical Pipe (HERCP) M 207, Class 4,

Horizontal installation only

60 in. and smaller equivalent diameter, Load bearing option. Larger than 60 in. equivalent diameter, Material option.
Concrete End Sections M 170 Class 3 pipe reinforcement required
Reinforced Concrete Arch Culvert M 206
Concrete Drain Tile M 178
Non-Asbestos Fiber-Cement Storm Drain Pipe C1450
Reinforced Concrete Low-Head Pressure Pipe C361
Corrugated Polyethylene Pipe (CPP) M 294
Corrugated Polyethylene Drainage Pipe M 252 Perforated underdrain and underdrain outlet pipe.
Corrugated Polypropylene Drainage Pipe M 330
Polyvinyl Chloride Profile Wall Pipe (PPWP) M 304
Polyvinyl Chloride (PVC) Pipe M 278 Underdrain outlet pipe
M 278 (a) Perforated underdrain
Joints for Concrete Pipe and Manholes Using Rubber Gaskets C443
Joints for Concrete Pipe, Manholes and Precast Box Sections Using Preformed Flexible Joint Sealants C990 Not for use with circular pipe
Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals D3212
Corrugated Steel Pipe (CSP), Pipe Arches and Underdrain M 36 (b), (c) End finish shall be annular corrugations
Corrugated Aluminum Alloy Pipe M 196 (b) End finish shall be annular corrugations
Structural Plate for Pipe, Pipe Arches and Arches (SPPA) M 167
Copper Pipe Fed Spec WW – T–799, Type K
Polyethylene (PE) Precoated Corrugated Steel Pipe M 245 and M 246 Minimum thickness 10 mil on each of the surfaces.
(a) Perforations shall conform to the requirements of F758.
(b) Bands with dimples are prohibited.
(c) All Corrugated Steel Pipe shall be aluminum-coated Type 2 conforming to M 274 unless otherwise specified.
905.02 CERTIFIED REINFORCED CONCRETE PIPE PLANTS
Reinforced concrete pipe (RCP) will be accepted on certification based on TC-1.03 and the requirements outlined below. This includes the sampling, testing, documentation, and certification of the product by the manufacturer in combination with an Administration monitoring program.
Annual Inspections. Plants producing material for the Administration, or an Administration inspected contract, for the first time or after a break in production longer than one calendar year will be subject to a comprehensive inspection of its production, testing, storage facilities, materials used and applicable documentation prior to production. Each plant will be subject to another comprehensive inspection at the beginning of each calendar year thereafter. The Administration will determine whether plant equipment and personnel conform to all applicable specifications and that suitable testing facilities are available. Submit a Quality Control Plan (QCP) for review and approval prior to inspection. The producer is responsible for ensuring timely delivery of the QCP. The QCP shall include the following:
(a) The manner in which the materials will be handled including.
(1) Locations of stockpiles.
(2) Methods of weighing and batching material into mixers.
(3) Sources of materials and certifications that those materials meet these Specifications.
(4) Methods to be used to heat or cool materials during periods of extreme temperature.
(b) The following Quality Control (QC) procedures.
(1) The names, qualifications, responsibilities and a unique identification number for each of the QC personnel and the designation of a QC manager.
(2) Sampling and testing methods and frequencies.
(3) Method used for inspecting reinforcement cages prior to and during production.
(4) Method of curing.
(5) Method of maintaining accurate QC records.
(6) Samples of forms approved by the Administration.
(7) Patching procedure.
(8) Method of preparation of units for shipping.
(9) Method of identification of each unit as tested and approved.
Certification by a Professional Engineer registered in the State of Maryland attesting the plant’s facilities conform to all applicable specifications will be accepted in lieu of Administration inspection. However, final determination of conformance will be as determined.
905.02.01 Responsibilities of the Concrete Pipe Producer. Perform Quality Control operations at the plant to ensure that the material conforms to specifications. The QC process will be subject to unannounced periodic Quality Assurance (QA) verification and the plant’s QC personnel shall fully participate in the verification process. Submit any change in personnel, production, testing facility and policy as a supplement to the QCP in writing within 10 days.
905.02.02 Lot Size. A pipe lot is defined as a maximum 14-day production run of concrete pipe of like size, material, strength designation, and manufacturing process. The 14 days need not be consecutive, as long as they occur within a period of 30 consecutive days and the manufacturing process is not altered in any way between production days. Lot size may include up to 1000 pieces for 12 in. to 36 in. pipe and 18 in. to 36 in. equivalent elliptical diameter pipe, or 500 pieces for 42 in. and larger pipe and 42 in. and larger equivalent elliptical diameter pipe.
905.02.03 Acceptance Testing. Perform a three-edge bearing test to produce a 0.01 in. crack for each lot in conformance with M 170, Section 5.1.1 except as modified for pipe diameter per Table 905. Pipe that have been tested only to the formation of a 0.01 in. crack and that meet the 0.01 in. or lesser load requirement will be considered acceptable for use.
905.02.04 Quality Control Testing. Perform one three-edge bearing test to ultimate load at least once every 12 months in conformance with M 170, Section 5.1.1 for each size and class of pipe shipped to Administration inspected Contracts. Also, perform an absorption test on each size and class of pipe manufactured and shipped to Administration projects at least once every 12 months. Specify in the QCP the method selected to test the lots for ultimate load and absorption.
905.02.05 Test Facilities. The producer’s facilities, equipment, and quality control personnel shall be capable of conducting the tests specified in T 280 and will be approved as part of the Annual Inspection. Identify all QC personnel in accordance with 905.02(b)(1) with a unique number used for testing and stamping or stenciling pipe for shipping. Record that number in the QCP and include the individual’s printed name and signature. Maintain yearly calibration certificates on all equipment used for testing. The producer may elect to use the services of an independent commercial testing laboratory as approved in lieu of conducting their own tests.
905.02.06 Shipment. Pipe may be shipped to Administration projects only after the required testing for all pipe in the lot have been completed with acceptable results and all pipe to be shipped is at least the age of the test specimens at testing. Visual inspection of the pipe and the accompanying documentation will be made when pipe is received on the project to verify compliance with certification requirements.
Prior to shipping, mark the following information on the inside of each pipe.
(a) Plant name.
(b) Plant location.
(c) Size of pipe.
(d) Class of pipe.
(e) Date of manufacture.
(f) Quality control stamp.
(g) Quality control personnel number.
905.02.07 Certification. Manufacturer’s certification shall accompany each shipment of pipe. Deliver a copy of the certification to the Engineer, the Administration’s laboratory, the Contractor, and maintain a copy at the plant. Certification shall include the following:
(a) The plant name, address, and location.
(b) Size and class of the pipe.
(c) Date of manufacture and shipment.
(d) Number of pieces.
(e) Administration Contract number.
(f) Statement of Specification compliance.
(g) Signature and number of the quality control personnel that inspected the shipment.
905.02.08 Records. Maintain all testing and inspection documents at the production plant for at least three years from the manufacture date and make available upon request. Collect and maintain conformance certificates and mill test reports for aggregates, cement, fly ash, joint material, reinforcing steel, and other materials intended for use in products used on Administration projects.
905.02.09 QC Forms. Maintain an Administration approved quality control form for all pipe produced for use on Administration projects. Include the following on the forms for each lot:
GENERAL INFORMATION PIPE DIMENSIONS REINFORCEMENT TESTS
Plant Name

Lot Identification

Production Dates

Pipe Class

Units Per Lot

Technician Signature

Material Sources

Cement

Fine Aggregate

Reinforcement

Diameter

Length

Wall Thickness

Joint Style

Size Spacing Area: Specification and Test Results

Adequacy and Quality of Welds and Splices

Visual Inspection

Absorption: Specification and Test Results: Once per year

THREE EDGE BEARING
0.01 in. Crack Strength: Specification and Test Results
Ultimate Strength: Specification and Test Results: Once per year
905.02.10 Responsibilities of the Administration. The Administration will notify each plant when to present its QCP. 30 days will be provided to make arrangements for delivery after the Administration is notified of the plan’s completion. Verification of certification by Quality Assurance Audit will be performed a minimum of once per year, as determined.
The Administration reserves the right to discontinue acceptance of RCP if the verification process indicates that materials, test procedures, or finished pipe do not conform to the specifications, Contract Documents or QCP. Producers will be notified of any type of non-compliance revealed during Quality Assurance Audits and provided with a resolution procedure to resolve any deficiencies.
905.03 CERTIFIED CORRUGATED POLYETHYLENE PIPE PLANTS
Polyethylene pipe conforming to specifications will be accepted on the manufacturer’s certification based on the requirements outlined below. This includes the sampling, testing documentation, and certification of the product by the manufacturer in combination with an Administration Monitoring Program.
905.03.01 Responsibilities of the Corrugated Polyethylene Pipe Manufacturer. All manufacturers of Corrugated Polyethylene Pipe must be enrolled in the National Transportation Product Evaluation Program (NTPEP) to provide Corrugated Polyethylene Pipe to Administration projects. If a new manufacturer has applied to NTPEP and is awaiting the NTPEP process, the manufacturer may submit to OMT proof of application, a copy of the QCP, and results of an audit and comparison testing by an independent third-party firm which has been signed by a Professional Engineer. Upon review, a pending letter of approval will be issued until such time as the NTPEP audit process is completed.
905.03.02 Test Facilities. The NTPEP Certification Program requires all tests to be conducted at laboratories that are accredited by AASHTO or approved by the Administration. Each source may establish and maintain its own laboratory for the performance of quality control testing or may request to utilize an approved independent laboratory. The manufacturer shall make a written request and have written approval from the Administration prior to having material tested off site. The equipment required for all approved laboratories shall be qualified to perform the required test procedures as required by the applicable specification and standards.
905.03.03 Certification. The manufacturer shall certify as specified in TC-1.03, each shipment of material. The certification shall be submitted to the Structural Materials Lab for review and stamping upon shipment of material. The certification shall include the following:
(a) Plant name, address, and location.
(b) Lot or production identification.
(c) Date of manufacture and shipment.
(d) Number of units of each size pipe or total linear ft of each size pipe.
(e) Contract number.
(f) Statement of specification compliance.
(g) Signature of the quality control manager, or authorized company representative (name shall be designated in the QCP).
(h) Perforation dimensions.
(i) Identification Markings.
(j) Test data as applicable.
(1) Density
(2) Melt Index
(3) NCLS
(4) UCLS
(5) Carbon Black Content
(6) Water Inlet Data
(7) Pipe Stiffness
(8) Pipe Flattening
(9) Brittleness
(10) OIT
(11) Elongation at Break


905.03.04 Records. The manufacturer shall maintain quality control records according to their Quality Control Plan. All testing and inspection documents shall be maintained at the manufacturing facility for at least seven years from the manufactured date and made available upon request.
905.03.05 Responsibilities of the Administration. The Administration may independently verify the manufacturer’s certification results by taking random samples of the finished pipe for testing from plant inspections or from project site samples and review all testing results for conformance to specifications.
The Administration will perform a visual inspection on pipe received at the project and will collect the manufacturer’s certification at the time of delivery.