Laboratory Inspection Program (LIP)
Laboratory Inspection Process
The program provides a laboratory with a comprehensive account of how its procedures, practices, equipment and facilities compare with ASTM standards requirements. The CCRL laboratory inspector checks critical equipment dimensions and operating characteristics; watches a technician demonstrate test procedures; and reviews the quality system when covered by appropriate ASTM standards. The goal is to provide a consistent and fair evaluation so that the laboratory and its clients may have confidence that testing is of high quality and that ASTM standards are being used correctly.
The sponsors have stipulated that CCRL shall not act as a referee in disputes concerning the quality of materials, the suitability of testing apparatus, or the ability of a laboratory to perform testing work in a satisfactory manner. Because of these prohibitions, all of the services rendered are advisory in nature and laboratories are not rated, certified or accredited by CCRL. However, because of the reputation of CCRL the programs are often used by others in providing accreditation.
CCRL Equipment (click on picture areas to view closeups)
The equipment used is, for all
practical purposes, a mobile measurement
laboratory. We have six sets of equipment and each
set includes load cells; a microammeter test set;
an assortment of custom machinist's tools such as scales,
gauges, and micrometers; a variety of thermometers
and psychrometers; precision weights; hand
tools; and reference literature. Each item was
selected on the basis of its precision and ability
to withstand rough use. All calibrations and verifications of inspection
equipment are traceable to NIST standards.
Inspections Offered:
Cement
The program is based on ASTM standard test methods for determining the physical properties of cements and, the Standard Practice For Evaluation of Laboratories (C1222). The apparatus and procedures in the test methods and the criteria listed in the practice provide the basis for the inspection.
The standard test methods specify requirements for facilities, special apparatus, and general use apparatus. The facilities inspected include the general laboratory work area, the moist room or cabinet, and the water storage tanks. The special apparatus checked includes mechanical mixers, flow tables, compression testing machines, Vicat apparatus, Gillmore needles, autoclaves, bar molds, 2-inch (50-mm) cube molds, air content measures, Blaine air permeability fineness apparatus, Wagner turbidimeters, water retention apparatus, and the 45-µm sieving apparatus . The following general use items are also checked: mix balances and glass graduates. Each item is evaluated to determine if it meets specification requirements and is in satisfactory operating condition.
The selected standard tests are demonstrated by a technician from the laboratory for the CCRL inspector to determine whether the prescribed procedures are being followed. Tests are selected by the laboratory from the following list: Compressive Strength of Hydraulic Cement Mortars (ASTM C109); Fineness of Portland Cement by the Turbidimeter (ASTM C115); Autoclave Expansion of Portland Cement (ASTM C151); Air Content of Hydraulic Cement Mortar (ASTM C185); Normal Consistency of Hydraulic Cement (ASTM C187); Time of Setting of Hydraulic Cement by Vicat Needle (ASTM C191); Fineness of Portland Cement by Air Permeability Apparatus (ASTM C204); Time of Setting of Hydraulic Cement Paste by Gillmore Needles (ASTM C266); Fineness of Hydraulic Cement by the 45-µm Sieve (ASTM C430); and Early Stiffening of Portland Cement (Paste Method) (ASTM C451).
The laboratory's quality system is inspected using the criteria listed in Standard Practice C1222. The standard requires no minimum group of test methods that the laboratory must perform; rather, it requires proficiency in those tests that it performs.
(1) Organization
The laboratory provides the following: the complete legal name and address of the laboratory; a list of other facilities under the technical direction of the laboratory; a list of principal officers of the organization; and a description of the management structure of the laboratory.
(2) Human Resources
A check is made to ensure that the Director of Testing is a full time employee of the laboratory with at least three years supervisory experience in the testing of hydraulic cement, and is also one of the following: a chemist, a materials analyst, an engineer, a person with experience having satisfactorily directed testing of hydraulic cement, or an individual with an equivalent science-oriented education. A review of the laboratory's written descriptions of training and ongoing performance evaluation is conducted; and records for each technician which document their work experience, education, training, and evaluations are examined.
(3) Operations
The laboratory's written procedures for sampling, handling, and testing cement are examined; the final test report or laboratory records is reviewed to determine that these documents include the information required by the specification; a check is made to verify that these records and reports are retained for at least three years; and amended reports are reviewed to ensure that the original report was referenced.
(4) Quality
A review of the laboratory's written procedures for handling technical complaints and assuring the quality of external technical services utilized is conducted; a check is made for participation in the appropriate CCRL Cement Proficiency Sample Program; and the applicable ASTM standard test methods used by the laboratory are reviewed to ensure that the most recent revision is being used.
(5) Equipment
The laboratory's equipment inventory is examined; and calibration or verification procedures and records for this equipment are reviewed.
(6) Qualification of Methods for Chemical Testing (C114)
The manager of the testing laboratory is questioned regarding the scope of their chemical testing. Based on this information, there is an examination of the qualification data for each component to confirm that the accuracy and precision is within the limits set forth in C114. A check is also made to ensure that the qualification has been completed within two years of the review date.
Note: Qualification of chemical tests is required when these tests are used to accept or reject cements. These methods used by the laboratory must be qualified using a NIST Standard Reference Material (SRM) to the limits set forth in C114.
Concrete
The program is based on Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation (ASTM C1077). This standard provides requirements for test methods, laboratory facilities, quality systems, personnel, and organizational structure. These requirements together with the apparatus and procedures prescribed in the referenced test methods provide the scope of the concrete laboratory inspection.
Facilities checked include the laboratory work area and curing facilities (moist room, tanks, or both). Apparatus includes compression testing machines, cylinder molds, capping plates, capping material, slump cones, unit weight measures, platform scales, volumetric air meters, and pressure air meters. General use items such as tamping rods, mallets, and strike-off plates and bars are also checked. Each item is evaluated to determine if it meets standards requirements and is in satisfactory operating condition.
Tests are demonstrated by a technician of the laboratory being inspected for the CCRL inspector to assure that the prescribed procedures are being followed. The tests are selected by the laboratory from the following required list of methods in ASTM C1077: Making and Curing Concrete Test Specimens in the Field (ASTM C31); Compressive Strength of Cylindrical Concrete Specimens (ASTM C39); Unit Weight, Yield, and Air Content (Gravimetric) of Concrete (ASTM C138); Slump of Hydraulic Cement Concrete (ASTM C143); Sampling Freshly Mixed Concrete (ASTM C172); Air Content of Freshly Mixed Concrete by the Volumetric Method (ASTM C173); and Air Content of Freshly Mixed Concrete by the Pressure Method (ASTM C231). The tests demonstrated are compared with the procedures detailed in the standards.
All aspects of the compressive strength test are covered. Compressive strength cylinders need special handling and preparation for a successful test. The cylinders are cured for a specified period, and the cylinder ends are capped before testing. The laboratory curing facilities are evaluated for conformance with the performance requirements set forth in Standard Specification for Moist Cabinets, Moist Rooms, and Water Storage Tanks Used in the Testing of Hydraulic Cements and Concretes (ASTM C511). Cylinder caps are checked to see if they conform to the requirements of Standard Practice for Capping Cylindrical Concrete Specimens (ASTM C617).
Additional test methods may be selected by the laboratory for evaluation during their onsite inspection. In general, these are special purpose tests which are not used as often as the C1077 required tests.
The quality system specifications include requirements for personnel qualifications, test reports, interlaboratory testing, and the availability of standards. In addition, the laboratory is required to develop specific written procedures and maintain specific records. Written procedures are required for technician training, performance evaluation, tracking test specimens and test results, resolving technical problems, evaluating other laboratories providing services, and equipment calibration and maintenance. Laboratory records are required for technician training, performance evaluations, and equipment calibration and maintenance.
Aggregate
The aggregate inspection is based on ASTM C1077 and the Standard Specification for Concrete Aggregates (ASTM C33). These standards give essential characteristics for test methods, general use and special apparatus, facilities, quality systems, personnel qualifications, and laboratory organization evaluated during the inspection. The laboratory work space is checked along with the following general use items: balances, scales, sample splitters, sieves, sieving devices, and ovens. The special apparatus prescribed for the specific gravity and organic impurities tests are also checked.
Tests to be demonstrated by a technician of the inspected laboratory are selected by the laboratory from the following list of required methods: Organic Impurities in Fine Aggregates for Concrete (ASTM C40); Materials Finer than 75-µm (No. 200) Sieve in Mineral Aggregates by Washing (ASTM C117); Specific Gravity and Absorption of Coarse Aggregate (ASTM C127); Specific Gravity and Absorption of Fine Aggregate (ASTM C128); Sieve Analysis of Fine and Coarse Aggregates (ASTM C136); Total Moisture Content of Aggregate by Drying (ASTM C566); and Reducing Field Samples of Aggregate to Testing Size (ASTM C702). Additional test methods for aggregates may be selected by the laboratory to be included in the onsite inspection.
The quality system requirements are essentially identical to those for the concrete inspection listed in ASTM C1077. When a laboratory is inspected for both concrete and concrete aggregates, the only additional requirements pertain to procedures and records for aggregate testing equipment.
Steel Reinforcing Bars
The inspection for testing of steel reinforcing bars is based on tests specified in Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement (ASTM A615),Standard Specification for Low Alloy Steel Deformed and Plain Bars for Concrete Reinforcement (ASTM C706), Standard Specification for Rail-Steel and Axle-Steel Deformed and Plain Bars for Concrete Reinforcement (ASTM A996). The requirements in these specifications are supplemented by Standard Test Methods of Tension Testing of Metallic Materials (ASTM E8) and Standard Test Methods and Definitions for Mechanical Testing of Steel Products (ASTM A370). The apparatus and procedures used in making these tests are examined during the inspection.
The standard specifications and test methods give requirements for measuring deformations, the tensile testing machines, grips, liners, bend test jig and bending pins. In addition, marking and measuring tools such as punches, micrometers, dividers, and scales are required. Each of these items is checked to determine if it meets specification requirements and is operating satisfactorily.
Measuring bar deformations, a tensile test and a bend test for steel reinforcing bars may be demonstrated for the laboratory inspector to assure that the prescribed procedures are being followed. The procedures used in the demonstrations are compared with that detailed in the standards.
Pozzolan
The pozzolan inspection is based on the standard test methods for determining the physical properties of pozzolan admixtures and the test for loss on ignition. The requirements are set forth in Standard Specification for Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Portland Cement Concrete (ASTM C618), and the test procedures are prescribed in Standard Test Methods for Sampling and Testing Fly Ash or Natural Pozzolan for Use as a Mineral Admixture in Portland-Cement Concrete (ASTM C311). The apparatus and procedures specified in these standards are examined during an inspection.
The standard test methods have requirements for facilities, special test apparatus, and general use apparatus. The laboratory work area, the moist room or cabinet, the dry storage room or cabinet, and water storage tanks are the facilities checked during the inspection. The special items examined include the mechanical mixers, flow tables, compression testing machines, 2-inch (50-mm) cube molds, bar molds, No. 325 sieving equipment, autoclaves, density equipment, muffle furnaces and crucibles, Vicat apparatus, and air content apparatus . Mix balances and glass graduates are the general use items tested. Each item is checked to determine if it meets specification requirements and is operating properly.
The tests are demonstrated by a technician from the laboratory for the CCRL inspector to determine whether the prescribed procedures are being followed. The tests to be demonstrated are selected by the laboratory from the following list: Normal Consistency (ASTM C187); Soundness Test by Autoclave (ASTM C151); Strength Activity Index with Portland Cement(ASTM C109); Increase of Drying Shrinkage of Mortar Bars (ASTM C157); Reactivity with Cement Alkalies (ASTM C441); Moisture Content (ASTM C311); Mineral Admixtures for Sulfate Resistance (ASTM C1012); Air-Entrainment of Mortar (ASTM C185); Amount Retained when Wet-Sieved on a No. 325 (45- µm) Sieve (ASTM C430); Loss on Ignition (ASTM C114); and Density (ASTM C188). The procedures used are compared with the procedures detailed in ASTM C311.
Slag Cement
The slag cement inspection is based on the standard test methods for determining the physical properties of slag cement. The requirements are set forth in the Standard Specification for Slag Cement for Use in Concrete and Mortars (ASTM C989). The apparatus and procedures specified in this standard are examined during an inspection.
The standard test methods have requirements for facilities, special test apparatus, and general use apparatus. The laboratory work area, the moist room or cabinet, and water storage tanks are the facilities checked during the inspection. The special items examined include the mechanical mixers, flow tables, compression testing machines, 2-inch (50-mm) cube molds, No. 325 sieving equipment, Blaine air permeability fineness apparatus, density equipment, and air content apparatus. Mix balances, balance weights, and glass graduates are the general use items tested. Each item is checked to determine if it meets specification requirements and is operating properly.
The tests are demonstrated by a technician from the laboratory for the CCRL inspector to determine whether the prescribed procedures are being followed. The tests to be demonstrated are selected by the laboratory from the following list: Slag-Activity Tests with Portland Cement, Slag Cement Density, Amount of Slag Cement Retained when Wet-Sieved on a No. 325 Sieve, Slag Cement Fineness by Air Permeability, and Air-Entrainment of Slag Cement Mortar. The procedures used are compared with the procedures detailed in ASTM C989.
If requested by the laboratory, Normal Consistency (C187), Autoclave Expansion (C151), and Loss on Ignition (C114) can be added to the inspection. Vicat apparatus, autoclaves, bar molds, muffle furnaces, and crucibles would be inspected.
The laboratory's quality system is inspected using the criteria listed in Standard Practice C1222. The standard requires no minimum group of test methods that the laboratory must perform; rather, it requires proficiency in those tests that it performs.
(1) Organization
The laboratory provides the following: the complete legal name and address of the laboratory; a list of other facilities under the technical direction of the laboratory; a list of principal officers of the organization; and a description of the management structure of the laboratory.
(2) Human Resources
A check is made to ensure that the Director of Testing is a full time employee of the laboratory with at least three years supervisory experience in the testing of slag cement, and is also one of the following: a chemist, a materials analyst, an engineer, a person with experience having satisfactorily directed testing of slag cement, or an individual with an equivalent science-oriented education. A review of the laboratory's written descriptions of training and ongoing performance evaluation is conducted; and records for each technician which document their work experience, education, training, and evaluations are examined.
(3) Operations
The laboratory's written procedures for sampling, handling, and testing cement are examined; the final test report or laboratory records is reviewed to determine that these documents include the information required by the specification; a check is made to verify that these records and reports are retained for at least three years; and amended reports are reviewed to ensure that the original report was referenced.
(4) Quality
A review of the laboratory's written procedures for handling technical complaints and assuring the quality of external technical services utilized is conducted; a check is made for participation in the appropriate CCRL Cement Proficiency Sample Program; and the applicable ASTM standard test methods used by the laboratory are reviewed to ensure that the most recent revision is being used.
(5) Equipment
The laboratory's equipment inventory is examined; and calibration or verification procedures and records for this equipment are reviewed.
(6) Qualification of Methods for Chemical Testing (C114)
The manager of the testing laboratory is questioned regarding the scope of their chemical testing related to C989. Based on this information, there is an examination of the qualification data for each component to confirm that the accuracy and precision is within the limits set forth in C114. A check is also made to ensure that the qualification has been completed within two years of the review date.
Masonry
The following standards are used as the basis for the masonry inspection program: C67, C140, C270 and C1093. C1093 provides criteria for evaluating the capability of a laboratory to properly perform tests on masonry materials. C67 (brick), C140 (concrete masonry units) and C270 (mortar) detail the test procedures and the equipment used. An inspection program is offered for masonry mortar or for concrete masonry unit and brick or a combination of the two. All masonry inspections include a review of the quality system. The laboratory need not perform all the tests, but rather have the required equipment and demonstrate the ability to perform the procedures within its reported range of testing.
Masonry Mortar
The standard test methods specify requirements for facilities, special apparatus, and general use apparatus. The facilities inspected include the general laboratory work area, the moist room or cabinet, and the water storage tanks. The special apparatus checked includes mechanical mixers, flow tables, compression testing machines, 2-inch (50-mm) cube molds, air content measures, and the water retention apparatus. The following general use items are also checked: mix balances, balance weights, and glass graduates. Each item is evaluated to determine if it meets specification requirements and is in satisfactory operating condition.
The selected standard tests are demonstrated by a technician from the laboratory for the CCRL inspector to determine whether the prescribed procedures are being followed. Tests are selected by the laboratory from the following list: Compressive Strength of Hydraulic Cement Mortars (ASTM C109); Air Content of Hydraulic Cement Mortar (ASTM C185); and, Water Retention of Hydraulic Cement-Based Mortars and Plasters (ASTM C1506). The procedures demonstrated are compared with those in the standards.
Unit Masonry
The standard test method, C140, specify requirements for facilities, special apparatus, and general use apparatus. The facilities inspected include the general laboratory work area and the drying storage facilities. The special apparatus checked includes compression testing machines, ovens, capping equipment and measurement equipment. The general use items, balances and balance weights, are also checked. Each item is evaluated to determine if it meets specification requirements and is in satisfactory operating condition. The selected standard tests are demonstrated by a technician from the laboratory for the CCRL inspector to determine whether the prescribed procedures are being followed. Tests are selected by the laboratory from the following list: sampling & identifying concrete masonry units (CMU), measurement of dimensions, sulfur or gypsum capping, compressive strength testing, and absorption & moisture . The procedures demonstrated are compared with those in the standards.
Brick
The ASTM standard test method, C67, specify requirements for facilities, special apparatus, and general use apparatus. The facilities inspected include the general laboratory work area and the drying storage facilities. The special apparatus checked includes compression testing machines, ovens, capping equipment and measurement equipment. The general use items, balances and balance weights, are also checked. Each item is evaluated to determine if it meets specification requirements and is in satisfactory operating condition. The selected standard tests are demonstrated by a technician from the laboratory for the CCRL inspector to determine whether the prescribed procedures are being followed. Tests are selected by the laboratory from the following list: measurement of dimensions, sulfur or gypsum capping, compressive strength testing, Specimen preparation, absorption, and initial rate of absorption. The procedures demonstrated are compared with those in the standards.Quality System
The Standard Practice C1093 is used for the basis of review of the quality system. The system can be broken down into three parts: personnel Qualifications, Quality System Criteria, and Quality System Manual.
Personnel Qualifications - A check of the qualification of management and supervisory positions will be conducted. This check will include the years of experience in the testing field and qualification based on education or years of experience in the position.
Quality System Criteria - The laboratory's test records, and calibration or verifications equipment records are reviewed for frequency and criteria. Participation in the applicable proficiency sample program (PSP) will be confirmed. A review of the corrective actions taken when poor PSP results are obtained. The laboratory's test reports are reviewed for specified criteria. The applicable ASTM standard test methods used by the laboratory are reviewed to ensure that the most recent revision is being followed.
Quality System Manual(QSM) - The laboratory's Quality System Manual(QSM) is reviewed for organization criteria including organizational charts, technical services offered, a description of training methods and performance evaluations, biographical sketches and qualifications. Also, the manual will be reviewed for information about the laboratory's testing equipment. Included in this review is a check for an inventory, calibration procedures, frequencies, and traceability. A review of the laboratory's written procedures for sample identification, storage, retention and disposal of samples will also be conducted.