QUALITY ASSURANCE MANUAL

Transcription

1 MMFX STEEL CORPORATION OF AMERICA 2415 CAMPUS DRIVE SUITE 100 IRVINE, CA TELEPHONE (949) FACSIMILE (949) QUALITY ASSURANCE MANUAL 5 th Edition August 2011 This document is property of MMFX Steel Corporation of America. All rights reserved, including the right to reproduce this book or portion thereof in any form or on any media whatsoever.

2 Table of Contents 1. Statements General Policy Statements Review of Quality Assurance Manual Signatures References and Definitions Reference Standards Definitions Product Description of Product Manufacturing Tolerances Product Traceability Acceptance Quality Control Procurement of MMFX Product from Qualified Suppliers Production of Product Delivery of Product from Steel Mills to MMFX facilities Product Acceptance MMFX Product Certification Segregation of Inventory and Non-Conforming Finished Product Material Storage and Shipping Inspection Records Records Review of Records Tables Table 1 - MMFX Steel Bars Standard Sizes, Dimensions and Deformations... 9 (Same as ASTM A615 Table 1 and ASTM A1035 Table 1)... 9 Table 2 MMFX Steel Bars - Mechanical Properties Requirements Figures Figure 1. Schematic of MMFX Bar Markings with Equivalency to ASTM A Figure 2. Typical Mill Label/Tag Figure 3. Typical MMFX Mill Certificate - A615 Grade 75 / A1035 Grade 100 /AASHTO MP18 (Buy America/Buy American Compliant) Page 2 of 12

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4 2. References and Definitions 2.1. Reference Standards AASHTO (American Association of State Highway and Transportation Officials) Standard Specifications AASHTO MP 18M/MP Standard Specification for Uncoated, Corrosion-Resistant, Deformed and Plain Alloy, Billet-Steel Bars for Concrete Reinforcement and Dowels ASTM International Standard Specifications 2.2. Definitions ASTM A615/A615M 09b Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement ASTM A1035/A1035M 09 Standard Specification for Deformed and Plain, Low-carbon, Chromium, Steel Bars for Concrete Reinforcement Heat Number Steel mill identification of steel melt information identifying steel chemistry, date and location of melt Mill Label/Tag Label attached to finished steel bars identifying - point of origin, production/rolling date, product size, type, grade of product, length, weight and heat and roll numbers MMFX Mill Certificate - identification label of bar materials certified to ASTM A615 Gr 75/80, and A1035 and/or AASHTO MP 18, which include product: point of origin, production/rolling date, product size, type, grade of product, length, weight and Heat and Roll Numbers (See Section 7 - Figure 3) MMFX Steel - means MMFX Steel Corporation of America subsidiary of MMFX Technologies Corporation Non-Conforming Bars Steel bars, which have been delivered from qualified suppliers that require thermal treatment Non-Conforming Finished Product Steel bars, which have received thermal treatment and cannot be issued mill certifications that failed testing to meet either: ASTM A615 Gr 75/80 and/or ASTM A1035 Gr 100 and or AASHTO MP 18 Gr Qualified Supplier Steel melting and rolling mills which MMFX Steel has determined have the capabilities to produce steel reinforcing and smooth bars, which can be certified to Standard Specifications ASTM A1035 and/or AASHTO MP Quality Assurance Manual document detailing the corporate quality policy and structure of the company, referencing operating procedures to assure product to customers Quality Control Manager company representative responsible for carrying out the policies and procedures of the Quality Assurance Manual Red Tag identification label placed on Non-Conforming Finished Product. Red tagged bars are segregated from conforming bars with steel mill certifications Roll Number Steel mill identification of steel bar rolling information identifying date and location of rolling, bar (size, type, grade and length) Thermal Treatment bar heating used to improve mechanical properties of Non-Conforming Bar materials in order to certify them to Standard Specifications ASTM A1035 and/or AASHTO MP 18. Page 4 of 12

5 3. Product 3.1. Description of Product MMFX Steel bars, both deformed bars (rebars) and smooth bars complying to ASTM A615 Grade 75/80 specification and/or ASTM A1035/A1035M specification and/or AASHTO MP 18M/MP 18 Grade 100 specification are available in various cut lengths. The standard sizes and dimensions of MMFX bars and their number designations are given in Section 6 Table 1 MMFX Steel Bars Standard Sizes, Dimensions and Deformations. MMFX bars shall have minimum yield strength and tensile properties in accordance with Section 6 Table 2 - MMFX Steel Bars - Mechanical Properties Requirements. ( MMFX Steel Bars ) For the case of deformed bars (rebars) for concrete reinforcement, the schematics of MMFX Bar markings are shown in Figure Smooth bars do not have bar markings Manufacturing Tolerances Surface Characteristics: Bars received at the MMFX s facility will be verified against the tolerances of ASTM A 615 Grade 75/80, ASTM A 1035 and/or AASHTO MP 18M Grade Chemical Analysis Testing For Steel conforming to ASTM A1035 the chemistry shall be as specified by the ASTM A1035 standard, article For Steel conforming to AASHTO MP18 the chemistry shall be as specified by the AASHTO MP18 standard, article Mechanical Properties: The Mechanical Properties reported on the mill certification should conform to the properties outlined in Section 6 Table 2 - MMFX Steel Bars - Mechanical Properties Requirements Markings: All bars should be marked by a distinguishing set of marks legibly rolled onto the surface of one side of the bar. Typical MMFX Steel bars complying with ASTM A1035 requirements are shown in Section 7 Figure 1 Schematic of MMFX Bar Markings with Equivalency to ASTM A Product Traceability The MMFX product delivered to the warehouse will have a mill label/tag similar to the one as shown in Section 7 Figure 2 Typical Mill Label/Tag. All product mill labels will be checked against the Qualified Supplier s Chemistry Record for Heat Number and are to include: point of origin, production/rolling date, product size, type, grade of product, length, weight and Heat and Roll Numbers. The mill certification will be kept on file after it has been checked against the mill labels/tags. A MMFX Mill Certificate (see Section 7 Figure 3) will be issued for every bundle shipped from the MMFX Steel s Fabrication and Distribution Center Traceability through Mill Label/Tag A combination of a unique heat and roll numbers are sufficient to trace the finished product back to relevant quality records. The Mill Tag also includes product details such as grade, product size, bar length etc Heat number is a unique fingerprint, which identifies the chemical composition of the product; the date the heat was melted and chemical composition certification Roll number is traced to rolling schedule of the steel and mechanical properties certification. Page 5 of 12

6 4. Acceptance Quality Control The following flow list illustrates the steps of accepting a product delivered to MMFX customers Procurement of MMFX Product from Qualified Suppliers MMFX bar is manufactured at Qualified Steel Mills. These Steel Mills are designated as Qualified Suppliers based on their capabilities to provide a consistent steel chemistry, and suitable finished steel quality. The selection of the Qualified Supplier must include: Compatibility of supplier's steel making practices with the specifications of MMFX Steel Review of supplier's quality control practices and other relevant documents Effective document exchange and review Production inspection and testing Audits of supplier's facilities The certification and approval of MMFX suppliers is the responsibility of MMFX Steel. The quality assurance manuals and certifications of the current suppliers of MMFX products are to be supplied to MMFX Steel MMFX Purchase orders to suppliers need to include: Technical requirements in the form of product specification and industry standards Additional quality requirements, if any Production of Product MMFX s Chief Operating Officer (COO) is responsible for the production of MMFX Products. MMFX Steel s Quality Control personnel are to be given full access to the facility during production of MMFX steel products and are provided with all production and quality records relating to the production of MMFX steel products MMFX bar product raw materials (i.e. steel scrap, ferro-chrome etc.) used in the production of its semi-finished steel billets are supplied through industry recognized raw material providers MMFX billets are converted into bar materials at the rolling mill, which are indentified by Heat and Rolling Numbers (see also Section 3.3). Lot sizes of MMFX materials are based on quantity of material rolled from a specific heat Delivery of Product from Steel Mills to MMFX facilities The instructions for operating MMFX storage, fabrication and distribution facilities are given to those facility mangers and operators to assure proper inventory and traceability of MMFX rebar. Inventory records are shared with MMFX Logistics and are verified by MMFX Quality Control personnel Product Acceptance MMFX Product is delivered from Qualified Suppliers with mill Bill of Lading (BOL) including Heat and Rolling Numbers. MMFX performs its own receiving inspection of purchased MMFX bar. The received Product is checked against the supplier s BOL for conformity with the following requirements of ASTM A615, ASTM A1035, and/or AASHTO MP 18, and/or additional MMFX internal technical product specifications, if any (i.e. chemical composition requirements, mill markings and mechanical properties) If the Product conforms to all requirements of ASTM A615, ASTM A1035, and or AASHTO MP 18 the product is certified and moved into the MMFX inventory as per Section If the Product and the Mill Certificate are conforming to all requirements of MMFX Steel, except for mechanical properties, Product is separated and moved for Thermal-Treatment Thermal-Treatment of MMFX rebar: When thermal-treatment operation is required, heat treatment is done according with MMFX s Thermal Treatment protocol. The thermal treatment process logs are prepared by the heat treatment operators and electronically stored by the MMFX Logistics. Page 6 of 12

7 4.5. MMFX Product Certification Product conforming to MMFX product acceptance criteria is labeled with MMFX Mill Label/Tag (Section 7 - Figure 2) and the Product is entered into the inventory maintained by shipping. A MMFX Mill Certificate is issued as shown in Section 7 - Figure 3. The MMFX certified heats must meet the specification for dimension, chemistry and mechanical properties according to ASTM A615, ASTM A1035 and or AASHTO MP The certification process of heat-treated bar, consists of sampling and mechanical testing according to ASTM A615, ASTM A1035 and or AASHTO MP18 and other industry standards. The mechanical testing is performed by the Qualified Supplier and/or independent qualified testing labs. Thermal treated bars, which meet ASTM A615, ASTM A1035 and or AASHTO MP18 requirements, are then available to be issued a MMFX Mill Certificate (Section 7 - Figure 3) In accordance with AASHTO MP18 Section 11, comparative corrosion performance data shall be furnished, based on mutual agreement between the manufacturer and the purchaser Segregation of Inventory and Non-Conforming Finished Product Product determined to be in compliance with ASTM A615, A1035 and or AASHTO MP 18 criteria, is entered into inventory. A MMFX Mill Certificate will be issued for products in inventory at the time of shipping Red tagged bars (Non-Conforming Finished Product) are placed in a segregated area of the MMFX facility MMFX Steel has the option of: returning the Non-Conforming Finished Product to the producer, selling it as a no-grade material or scrapping the product. 4.7 Material Storage and Shipping Material Storage Product storage to open elements should be avoided when practical. Preference is given to internal hard surface storage with proper standard storage practices such as appropriate dunnage to insure that MMFX bars are not exposed to accidental spillage of fluids etc. When storage conditions necessitate exposure to the elements either inside or outside of MMFX storage facilities, provide appropriate cover (i.e. tarpaulins, plastic etc.) from the elements as needed to prevent deterioration of the material Material Shipping Product shipped to fabricators and/or to the job site may need cover (i.e. tarpaulins, plastic etc.) to prevent exposure to the elements. Special shipping instructions shall be at the material owner s direction (i.e. special dunnage, coverings etc.) Page 7 of 12

8 5. Inspection Records 5.1. Records The following records are kept in order to track the incoming materials and the acceptance procedures Qualified Supplier Chemistry Record of the incoming product with the supplier s Bill of Lading Thermal Treatment Firing Logs Mechanical Test Records MMFX Mill Certificates 5.2. Review of Records In order to maintain the highest quality and expectations for the MMFX products, the records are available and periodically reviewed Maintenance of Records Records will be kept at the offices of MMFX Steel, 2415 Campus Drive, Suite 100, Irvine, CA It is be the responsibility of the Quality Control Manager, to keep such records current and accurate. Page 8 of 12

9 6. Tables. Bar Designation No. Table 1 - MMFX Steel Bars Standard Sizes, Dimensions and Deformations (Same as ASTM A615 Table 1 and ASTM A1035 Table 1) Nominal Dimensions A Deformation Requirements, in. [mm] Cross- Diameter, Sectional Perimeter Maximum Minimum In. [mm] Area, In. [mm] Average Average In 2 Spacing Height [mm2] Nominal Weight, LB/ft [Nominal Mass, kg/m] Maximum Gap (Chord of 12.5% of Nominal Perimeter) 3 [10] [0.560] [9.5] 0.11 [71] [29.9] [6.7] [0.38] [3.6] 4 [13] [0.994] [12.7] 0.20 [129] [39.9] [8.9] [0.51] [4.9] 5 [16] [1.552] [15.9] 0.31 [199] [49.9] [11.1] [0.71] [6.1] 6 [19] [2.235] [19.1] 0.44 [284] [59.8] [13.3] [0.97] [7.3] 7 [22] [3.042] [22.2] 0.60 [387] [69.8] [15.5] [1.12] [8.5] 8 [25] [3.973] [25.4] 0.79 [510] [79.8] [17.8] [1.27] [9.7] 9 [29] [5.060] [28.7] 1.00 [645] [90.0] [20.1] [1.42] [10.9] 10 [32] [6.404] [32.3] 1.27 [819] [101.3] [22.6] [1.63] [12.4] 11 [36] [7.907] [35.8] 1.56 [1006] [112.5] [25.1] [1.80] [13.7] 14 [43] 7.65 [11.38] [43.0] 2.25 [1452] [135.1] [30.1] [2.16] [16.5] 18 [57] [20.24] [57.3] 4.00 [2581] [180.1] [40.1] [2.59] [21.9] A The nominal dimensions of a deformed bar are equivalent to those of a plain round bar having the same weight [mass] per foot [meter] as the deformed Table 2 MMFX Steel Bars - Mechanical Properties Requirements ASTM A615 Grade 75/80 ASTM A1035 and AASHTO MP 18 Grade 100 ASTM A1035 Grade 120 Tensile Strength, min, psi 100, , ,000 Yield Strength, min, psi 75, , ,000 Elongation in 8 in., min, % Bar No. 3, 4, , , 10, , Page 9 of 12

10 7. Figures Figure 1. Schematic of MMFX Bar Markings with Equivalency to ASTM A1035. Page 10 of 12

11 Figure 2. Typical Mill Label/Tag Page 11 of 12

12 Sold To: [Company Name] [Address] [City, State, Mail Code Country] Issue Date: January 03, 2011 Mechanical Testing - ASTM A370, E8 Chemical Composition - ASTM A751 PRODUCT HEAT# GRADE SIZE ASTM A1035 GR 75/80 ASTM A1035 #8/25m R611A13 GR100 AASHTO MP m 0 18 GR R611A R511A12 4 ASTM A1035 GR 75 ASTM A1035 GR100 #8/25m AASHTO MP 18 m GR100 ASTM A615At GR75 #7/22m ASTM A1035 GR100 m Yield Strengt Tensile h Strength (0.2% offset) Stress at 0.35% EUL Elongati on in 200 mm Bend Test C Cr Mn Si S P Cu Ni Mo Al V N MPa MPa MPa % P/F % % % % % % % % % % % PPM P * Y** P * Y** P Y** USA / R511A124 Notes: This heat does not show typical ASTM A 615, GR 75/80 markings. Bars are branded with ASTM A 1035, GR 100 markings and meet all other requirements of both ASTM A 615, GR 75 and ASTM A 1035, GR 100 specifications / R611A130 Notes: This heat does not show typical ASTM A 615, GR 75/80 markings. Bars are branded with ASTM A 1035, GR 100 markings and meet all other requirements of both ASTM A 615, GR 75 and ASTM A 1035, GR 100 specifications / R611A129 Notes: This heat does not show typical ASTM A 615, GR 75/80 markings. Bars are branded with ASTM A 1035, GR 100 markings and meet all other requirements of both ASTM A 615, GR 75 and ASTM A 1035, GR 100 specifications. Certification for stock length mill bundled material. 1. This material conforms to the specification described on this document and may not be reproduced. 2. The slight rust apparent on some bars is the oxidation of the mill scale produced during heating and rolling process. This condition will in no way adversely affect the quality of or use of the product. 3. This product is not weldable according to AISI/AWS D1.4 code. 4. MMFX Rebar is certified for use as a concrete reinforcement only. I hereby certify that the above figures are correct according to the records of MMFX Steel Corporation of America. Quality Control Manager * AASHTO MP 18 min. 9.2% Cr ** Melted, Manufactured and Rolled in the U.S.A. Figure 3. Typical MMFX Mill Certificate - A615 Grade 75 / A1035 Grade 100 /AASHTO MP18 (Buy America/Buy American Compliant) Page 12 of 12