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Authorisation
………………………………………………….
MANAGER MATERIALS ENGINEERING
Date ….../….../…..
1. PURPOSE .................................................................................................... 3
2. SCOPE
3. REFERENCES ............................................................................................. 3
4. DEFINITIONS .............................................................................................. 3
5. PROCEDURE .............................................................................................. 6
5.1 Recommended Auditing Frequency ........................................................ 7
Embankment ....................................................................................... 7
Pavements .......................................................................................... 7
Bituminous Surfacings ...................................................................... 10
Drainage ........................................................................................... 13
Bridge Works .................................................................................... 13
Pavement Markings .......................................................................... 15
6. Audit Request Forms .............................................................................. 16
The Main Roads Management System requires that Quality Assurance procedures be
implemented, to ensure that all products supplied to road or bridge construction projects
are of suitable quality for acceptance. In addition to the Contractor’s quality control
testing and on-site inspection by Main Roads personnel, audit testing (or “additional
testing” as defined in the General Conditions of Contract) is a further means of
establishing that the products supplied conform to specification. Such auditing also
provides assurance that the processes being followed are suitable. The audit levels
recommended in this document are targeted to suit the management of risk and set the
minimum levels required to give the Superintendent or Principal the necessary assurance
that the product is satisfactory.
The Superintendent should be aware of the risks involved in reducing the frequency of
auditing for a particular project and should exercise his/her judgement and experience in
doing so.
2. SCOPE
The audit testing frequency in this standard applies to all aspects of pavement
construction and concrete materials. Audit levels are given for the following:
2. REFERENCES
4. DEFINITIONS
Inspection
Inspection is an activity such as measuring, examining, testing or gauging one or more
characteristics of a product and comparing the results with specified requirements in
order to establish whether conformity is achieved for each characteristic.
Road Categories:
Type F FREEWAYS and URBAN HIGHWAYS
Type H HIGHWAYS
Type M MAIN ROADS
Note: A road may be varied in category for the purposes of audit to increase or reduce the
frequency of audit to suit the management of risk and quality requirements of a particular project.
Note: Lots in the initial audits will count towards the required number of lots under the
normal auditing scheme.
Tightened
The number of audits to be carried out on consecutive lots when a Non Conformance
Report (NCR) has been raised on the process or product.
Note: The Superintendent should take into account the reason for the NCR and the risk
involved when initiating the tightened audit schedule.
Normal
The percentage of lots to be audited when the process is in control and has been
validated through the initial or tightened audit process.
Note: The Superintendent may initiate an audit at any time to check the process and
product or to check a suspect process or product.
Corporately Tested
Testing, to determine the characteristics of materials such as bitumen, bituminous
emulsions, crushed rock etc. may require lead times of several weeks for the completion
of testing. In these circumstances it is often not viable to perform audit testing during the
award period of a Contract and deliver results within a time frame that will enable
appropriate action to be taken if a non compliance is detected. As these materials are
often manufactured under controlled processes, by a relatively small number of
producers, it is preferable to test these materials under a Corporate audit regime.
Materials Engineering Branch will manage the sampling and testing of these materials
and then disseminate the results to Superintendents. Thereafter, the Superintendents
will be able to request additional tests on these materials if they perceive a risk to a
specific Contract.
Lots
A lot is any quantity of material or portion of construction all of which has been
produced by essentially the same process that is subject only to random variation and
can therefore be accepted as being of a homogeneous quality.
Examples of lots:
1. The size of the lot is usually limited to the material produced in one day or one
shift using the same process, materials and equipment in the same conditions. It is
normally judged on the basis of visual field inspection of the submitted product and on
knowledge of the consistency or otherwise of the production or construction process.
A lot could be defined as the quantity of rock base produced during one shift of a
crushing process, on condition that the source rock or the actual crushing process was
not altered during the shift in any way that would significantly change the quality of the
material.
When different classes of concrete (eg. N40, S50 etc.) are supplied to a job, each
class should be treated as a separate lot.
3. Lot sizes may vary according to circumstances and the reasons for sampling and
testing.
For example a production batch of bitumen may be 2000 tonnes and this may be
sampled as one lot for the purpose of establishing if this material has been produced to
specification. If a tanker load of bitumen is drawn from this batch and transported to a
road site it may be subject to heating and contamination and should be sampled as a
separate lot to establish that this load conforms to specification at the point of delivery to
the works.
Similarly a large production stockpile of aggregate at a quarry may be a single lot from
the viewpoint of establishing conformance with general material properties such as Los
Angeles, Wet and Dry Strength etc.; provided adequate process control has been
exercised. If material is carted from this stockpile to roadside stockpiles for sealing, then
variations due to handling may occur and this material should be sampled as a separate
lot to establish properties such as Particle Size Distribution and Average Least
Dimension.
Superintendents responsible for organizing audits within the Metropolitan area should
contact the Quality Systems Manager, at Materials Engineering and for rural areas the
Regional Materials Manager in the appropriate Region. These personnel will assist in the
audit planning if necessary and will arrange for auditing to be performed as required. To
facilitate this process proforma audit request forms are attached to this Standard.
ROADWORKS
Embankment
FOR CONTROL OF COMPACTION:
Foundation
End Product Specification:
Dry Density Ratio (WA 134.1) 3 2 1 5 3 2
Contractor's Developed Method Spec:
Dry Density Ratio (WA 134.1) N/A 2 1 N/A 5 3
Moisture Content (WA 110.1 or 110.2) N/A 2 1 N/A 5 3
Optimum Moisture Content N/A 2 1 N/A 5 3
(WA 133.1 or WA 133.2) (The mean value of
these OMCs shall be taken to represent each
material of constant quality)
Principal's Method Spec:
Particle Size Distribution (WA 115.2) N/A 2 1 N/A 3 2
Moisture Content (WA 110.1 or WA
N/A 2 1 N/A 5 3
110.2)
Embankment FOR CONTROL OF IMPORTED MATERIAL
* (UNDER 2M LOW (L), OVER 2M HIGH
(H))
* Note: The risks associated with high embankment failure are greater than those of a low
embankment. The 2m height is only a suggested value for distinguishing between high
and low embankments.
Impurities 3 2 1 7 5 3
BITUMINOUS SURFACING
Prime, Cutter:
Primerseal, Seal,
Rubberised Seal Distillation (ASTM D86) )
and Asphalt CORPORATELY TESTED
(continued) Flashpoint (AS 2106) )
Viscosity (AS 2341.2) )
Density (AS 2341.7) )
CORPORATELY TESTED
Water Content (AS 2341.9) )
Percentage Aromatics (ASTM D1319)
)
Cutback Bitumen
Adhesion Agent:
Bitumen
Laterite Aggregate:
CONTROL OF COMPACTION:
DRAINAGE
BRIDGEWORKS
Cement )
CORPORATELY TESTED
Water (WA 910.1) )
Particle Size Distribution (AS 1141.11) 1 in 5 pours
(Fine and Coarse)
Structural
FOR CONTROL OF STRENGTH
Concrete
(continued)
Consistency (Slump Test) (AS 1012 part 3.1) For on-site batch plants it is
and Strength (AS 1012 part 8.1 & 9) for the recommended that the % of
following: Lots to be tested is increased by
(Testing during initial and tightened testing a factor of 3.
shall include a seven day determination of
compressive strength)
Structural Concrete 4 4 4 10 10 10
PAVEMENT MARKINGS
FACSIMILE TRANSMISSION
TO Attn.
FAX No.:
PAVEMENT MATERIALS
Embankment NMDM Testing
Foundation
Embankment Maximum Dry Density Testing
Construction
Subgrade Material Properties
Sub-base Other
Base Please specify:
………………………………
………………………………
DETAILS
Comments
:
# Tests
Required:
FACSIMILE TRANSMISSION
TO Attn.
FAX No.:
SURFACING MATERIALS
FACSIMILE TRANSMISSION
TO: Attn.
Fax
No.
Job Location:
Structure:
Location In Structure:
CONCRETE