LABORATORY

QUALITY
MANUAL

For
 QUALITY MANUAL FOR

( )

TABLE OF CONTENTS

Title Section Page

Organization and Organizational Policies ______ ______

Laboratory Technical Staff ______ ______

Laboratory Equipment ______ ______

Test Records and Reports ______ ______

 ORGANIZATION AND ORGANIZATIONAL POLICIES

This section of the QM contains the following information:

1. The legal name and address of the laboratory.

2. The legal name and address (if different from item [1]) of the main office or
owner company.
3. Any additional information to identify the organization with responsibility for the
laboratory.
4. The ownership and management structure of the laboratory.
5. The organization chart of the laboratory, clearly showing relevant internal
organizational components.
This form revised: by:

Legal Name and Address:

Main Office Address:

Ownership:

Owner Office Address:

(if different from above)

Ownership/Management Structure: (show Organizational Chart on following page)

Title/Position Name Other Affiliation

Chief Executive Officer

(or equivalent)

President

Vice-President

Vice-President
 LABORATORY / TECHNICAL STAFF

This section of the QM contains the following information:

1. Position description(s) for each technical operational position shown on the

organizational chart.
2. A brief biographical sketch of the person currently employed for each technical
operational position shown on the organizational chart.
3. A description of the method(s) used to ensure all personnel are trained to perform
tests conducted by this laboratory in accordance with standard procedures.
4. A description of the method(s) used to evaluate the competency of each staff
member to perform tests conducted by this laboratory, to ensure all testing is
performed in accordance with standard procedures.
5. A form summarizing and recording training and evaluation activities undertaken to
comply with the procedures described in items (3) and (4).
This form revised: by:

POSITION: ________________________________________

JOB DESCRIPTION:

SUPERVISION EXERCISED / RECEIVED:

DUTIES:

QUALIFICATIONS:

Education:

Certifications:

Experience:
This form revised: by:

TECHNICIAN TRAINING

Center for Training Transportation Professionals

CTTP - TECHNICIAN TRAINING RECORD

Name Training Basic Soils ACHM PCC

Cert. No. Aggregate

Insert copies of training certificates for above training following this page.
 TECHNICIAN QUALIFICATION PROGRAM

The Arkansas State Highway and Transportation Department (Department) has contracted with the
University of Arkansas to conduct training for qualification of technicians at the Center for Training
Transportation Professionals (CTTP).

Qualification of technicians is in four areas of materials testing: 1) Basic Aggregates; 2) Soils/Aggregate;

3) Hot Mix Asphalt; and 4) Portland Cement Concrete Testing. Before a technician may become qualified
in Soils/Aggregate, Hot Mix Asphalt, and Portland Cement Concrete, the technician must first become
qualified in Basic Aggregates. The Center address is:
Center for Training Transportation Professionals
University of Arkansas at Fayetteville
4190 Bell Engineering Center
Fayetteville, Arkansas 72701
(479) 575-3997
Fax (479) 575-7639

Qualification includes a demonstration of proficiency by the technician and a written test covering the
area of qualification. Upon acceptable completion of this program, the technician will be issued a
statement of qualification showing the technician’s area of qualification. Technicians must recertify every
four years for Soils and Hot mix asphalt. Concrete recertification is required every five years.

The areas of qualification and the items included in each area are as follows:

1) Basic Aggregates
Sampling by Random Number AHTD 465
Sampling of Aggregates AASHTO T 2, AHTD 35
Reducing Field Samples Size AASHTO T 248, AHTD 349
Moisture Content AASHTO T 255, AHTD 348
Deleterious Materials AHTD 302
Crushed Particles AHTD 304
Particle Size Determination (Gradation) AASHTO T 27, AHTD 305
Materials Finer Than #200 by Washing AASHTO T 11
Fine Aggregate Specific Gravity AASHTO T 84
Coarse Aggregate Specific Gravity AASHTO T 85

2) Soils/Aggregate
Sampling Soils AHTD 30
Dry Soil Preparation AASHTO T 87, AHTD 35
Wet Soil Preparation AASHTO T 146
Moisture Content of Soils AASHTO T 265, AHTD 348
Moisture Using Calcium Carbide Tester AASHTO T 217, AHTD 347
Particle Size Determination (Gradation) AASHTO T 88, AHTD 352
Atterburg Limits AASHTO T 89 & T 90
AHTD 353 & 354
Proctors & Coarse Particle Correction AASHTO T 99, T 224,T 180, & T 272
AHTD 350, 356, 344, & 355
In-place Density & Moisture Determination AASHTO T 310, AHTD 330
Nuclear Methods
3) Asphalt Plant and Field Testing
Sampling by Random Number AHTD 465
Sampling Bituminous Paving Mixtures AASHTO T 168, ASTM D979
AC Content Determination by Nuclear Gauge AASHTO T 287
Rice Theoretical Specific Gravity AASHTO T 209
Bulk Specific Gravity AASHTO T 166
Nuclear Density Determination ASTM D 2950, AHTD 461
Volumetric Method AASHTO MP 2
Percent Air Voids in Paving Mixtures AASHTO T 269
Density Using Gyratory Compactor AASHTO T 312
Asphalt Content by Nuclear Method AHTD 449 & 449A
Resistance To Moisture Damage AASHTO T 283
Mixture Conditioning of HMA AASHTO PP 2
Volumetric Design for HMA AASHTO PP 28

4) Portland Cement Concrete Testing

Sampling Freshly Mixed Concrete AASHTO T 141
Making and Curing of Cylinder AASHTO T 23
Slump of Hydraulic Cement Concrete AASHTO T 119
Air Content AASHTO T 152
Unit Weight of Freshly Mixed Concrete AASHTO T 121
 PERIODIC TECHNICIAN COMPETENCY REVIEW

All materials technicians shall be trained prior to performing test procedures. The
following training procedure shall be followed for each test:

1. The trainee shall have access to the latest copy of the applicable test specification.
2. A qualified technician shall demonstrate the test procedure.
3. The laboratory supervisor shall observe the trainee and document his/her ability to
perform the test procedure.
4. Technician performance shall be reviewed at 6-month intervals.
5. The supervisor shall record the test demonstrated, the date of review, and
performance results.
6. If an unsatisfactory result is recorded for a test method, the supervisor shall review
the test method and repeat the evaluation.
(See table on following page)
This form revised: ____________________________ by: _________________

TECHNICIAN TRAINING AND EVALUATION RECORD

TECHNICIAN_________________________________________

TEST METHOD DATE EVALUATOR RESULTS (P/F)

 LABORATORY EQUIPMENT

This section of the Quality Manual contains the following information:

1. An inventory of major sampling, testing, calibration, and verification equipment

associated with the test methods employed by the testing laboratory.
2. A copy of the manufacturer’s instructions pertaining to the test equipment listed
in item (1), if available, or a reference to the location of such documents.
3. A description of procedures used regarding all calibration and verification of
equipment.
4. In-house procedures used for calibration and verification of equipment.
5. A description of equipment used in performing tests that requires calibration or
verification. Included with the description is all pertinent information regarding
the calibration/verification items, calibration/verification procedures and intervals,
and equipment used in such procedures. Calibration worksheets/records
pertaining to each item of equipment follow the equipment description page.

(See table on following page).

 General Laboratory Equipment

Inventory/Serial Calibration/Verification Calibration

Item Description Manufacturer Number Interval Procedure
 Asphalt Laboratory Equipment

Inventory/Serial Calibration/Verification Calibration

Item Description Manufacturer Number Interval Procedure
 Soils Laboratory Equipment

Inventory/Serial Calibration/Verification Calibration

Item Description Manufacturer Number Interval Procedure
 Concrete Laboratory Equipment

Inventory/Serial Calibration/Verification Calibration

Item Description Manufacturer Number Interval Procedure
 Equipment Calibration/Verification Record
(Required for each item on laboratory equipment listing)

Item Description:

Manufacturer:

Inventory/Serial Number:

Calibration/Verification Interval:

Calibration Procedure:

Date Calibration/Verification Item Checked by: Comments

 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING SIEVES

Item: Sieves

Purpose:
This method provides instructions for checking the physical condition of laboratory test sieves
ranging in size from 75 mm (3 in.) to 0.075 mm (No. 200).

Inspection Equipment Required:

1. A caliper readable to 0.01 mm (Use for No. 4 sieve and coarser.)

Tolerance:
Sieves shall meet the physical requirements specified in AASHTO M 92.

Procedure:

(Step 1 applies only to sieves having openings greater than or equal to 4.75 mm)

1. Select approximately 30 openings (or all square openings if less than 30), in segments
of 3 or 4 openings along a 45-degree line. Measure and record both dimensions of each
sieve opening.

2. Inspect the general condition of the sieve. Check the frame and solder joints for cracks
or holes (check for pin holes in the finer sieves).
3. Make sure the sieve has an appropriate label.
4. Check for tightness of the wires on each individual sieve.
 Sieve Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify physical condition of sieve and critical dimensions for
sieves larger than #4 (4.75 mm)

Calibration Procedure: In-House Procedure #

Calibration Equipment: Digital Calipers

Comment On:
Frame:
Joints:
Cloth:
Tightness:
Other:

1 16
2 17
3 18
4 19
5 20
6 21
7 22
8 23
9 24
10 25
11 26
12 27
13 28
14 29
15 30

Requirement (according to AASHTO M 92) =

Comments:

Initial By:
 WIRE CLOTH SIEVE INSPECTION REPORT

Date: _______________ Verified by: _________________________

Sieve Sizes mm (Millimeters) Condition Quantity

Minimum Maximum
75 mm (3”) 72.8 77.2 Good ___ Replace ___
62.5 mm (2 1/2 ") 61.1 64.9 Good ___ Replace ___
50 mm (2”) 48.5 51.5 Good ___ Replace ___
37.5mm (1 1/2 ") 36.4 38.6 Good ___ Replace ___
31.3mm(1 1/4 ") 30.5 32.6 Good ___ Replace ___
28 mm (1 1/8 “) Good ___ Replace ___
25mm (1”) 24.2 25.8 Good ___ Replace ___
19 mm (3/4 ") 18.4 19.6 Good ___ Replace ___
5/8 " 15.S 16.5 Good ___ Replace ___
12.5 mm (1 2 “) 12.11 12.89 Good ___ Replace ___
9.5 mm(3/8 ") 9.2 9.8 Good ___ Replace ___
4.75 mm (# 4) 4.6 4.9 Good ___ Replace ___
#8 Good ___ Replace ___
#10 Good ___ Replace ___
# 16 Good ___ Replace ___
# 20 Good ___ Replace ___
# 30 Good ___ Replace ___
# 40 Good ___ Replace ___
# 50 Good ___ Replace ___
# 80 Good ___ Replace ___
# 100 Good ___ Replace ___
# 200 Good ___ Replace ___
Dust Receiver Good ___ Replace ___

The table is for sieve openings in mm (millimeters). On the identification plate of some sieves
the sieve opening will be in microns. To convert microns to mm (millimeters): multiply the number of
microns by 0.001.

Example: On the identification plate of a #16 sieve - the openings indicated are 1190 microns.
(1190 x 0.001) = 1.19 mm

A #16 sieve Minimum allowable opening = 1.135 mm

Maximum allowable opening = 1.225 mm
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR CALIBRATION OF

SCALES OR BALANCES
(AASHTO M 231)

Purpose:
This procedure provides instructions for checking the accuracy of scales and balances.

Inspection Equipment

1. Standard Weight Set of sufficient mass to reach 90% of scales capacity.

2. A level is required to check the scale's level position, if one is not built into the unit.

Procedure:

1. Turn electronic scales on allowing for a warm up of approximately 30 minutes.

2. Ensure that the scale base is seated on all comers and is level. (NOTE: Some leveling devices
are located under the scale pan.
3. Be aware of excessive air movement during the calibration process. Document if air
movement appears to be excessive.
4. Check for Off-Center Error. Measure this effect by placing the load (90 % of capacity) at
various positions on the pan and observe any differences in indication. The difference between
the lowest and the highest indication is the maximum Off-Center Error, which should be within
the accuracy range listed for the class of scale being checked.
5. Set the zero point and the full-scale indication. Place weights on the pan in increasing
increments as indicated on calibration form. Observe and record the indications. The difference
at any point is the inaccuracy.
 SCALE OR BALANCE VERIFICATION

MANUFACTURER: ___________________________ MODEL#: ____________________

INVENTORY#: ________________________ CLASS OF SCALE: ___________________

MAXIMUM CAPACITY: ___________________ SMALLEST DIVISION: ______________

Off-Center Error: Center-Front: ___________Right: ___________Center: ___________

Center-Back: ___________ Left: ___________

GRAMS SCALE READING VERIFIES

0.5(.0011 1b.) Yes ____ No _____
1(.0022 1b.) Yes ____ No _____
2(.0044 1b.) Yes ____ No _____
3(.0066 1b.) Yes ____ No _____
5(.011 1b.) Yes ____ No _____
10(.022 1b.) Yes ____ No _____
20(.044 1b.) Yes ____ No _____
30(.066 1b.) Yes ____ No _____
50(.110 1b.) Yes ____ No _____
100(.220 1b.) Yes ____ No _____
200(.440 1b.) Yes ____ No _____
300(.660 1b.) Yes ____ No _____
500(1.102 1b.) Yes ____ No _____
1000(2.205 1b.) Yes ____ No _____
2000(4.409 1b.) Yes ____ No _____
5000(11.02 1b.) Yes ____ No _____
10000(22..05 1b.) Yes ____ No _____
15000(33.07 1b.) Yes ____ No _____
20000(44.09 1b.) Yes ____ No _____

VERIFIED BY: ______________________________ DATE: _________________

NOTE CHECK OFF-CENTER ERRORS OF ELECTRONIC SCALES BY PLACING WEIGHT THAT IS

APPROMMATELY 90% OF SCALE CAPACITY NEAR THE CENTER AND AT EACH CORNER.
 SCALE OR BALANCE CALIBRATION

GENERAL PURPOSE BALANCES AND SCALES

CLASS PRINCIPAL SAMPLE WEIGHT READABILITY ACCURACY
G2 2 kg or less 0.1g 0.1 g or 0.1 %
G5 Over 2 kg thru 5 kg 1g 1g or 0.1%
G20 Over 5 kg thru 20 kg 5g 5g or 0.1%
G100 Over 20 kg 20g 20g or 0.1 %

ACCEPTANCE TOLERANCES FOR DIFFERENT CLASSES OF SCALES

CLASS G2 CLASS G5
TEST WEIGHT TOLERANCE RANGE TEST WEIGHT TOLERANCE RANGE
0.5 0.6-04 2 3. 0-1 .0
1 1.1-0.9 3 4.0-2.0
2 2.1-1.9 5 6.0-4.0
3 3.1-2.9 10 11.0-9.0
5 5.1-4.9 20 21.0-19.0
10 10 .1- 9.9 30 31.0-29.0
20 20.1-19.9 50 51.0-49.0
30 30.1-29.9 100 101.0-99.0
50 50.1-49.9 200 201.0-199.0
'100 100.1-99.9 300 301.0-299.0
200 200.2-199.8 500 501.0-499.0
300 300.3-299. 7 1000 1001.0-999.0
500 500.5-499.6 2000 2002.0-1998.0
1000 1001.0-999.0 5000 5005.0-4995.0
2000 2002.0-1998.0

CLASS G20 CLASS G100

TEST WEIGHT TOLERANCE RANGE TEST WEIGHT TOLERANCE,RANGE
10 15.0-5.0 30 50.0-10.0
20 25.0-15.0 50 70.0-30.0
30 35.0-25.0 100 120.0-80.0
50 55.0-45.0 200 220.0-180.0
100 105.0-95.0 300 320.0-280'0
200 205.0-195.0 500 520.0-480.0
300 305.0-295.0 1000 1020.0-980.0
500 505.0-495.0 2000 2020.0-1980.0
1000 1005. 0-995.0 5000 5020. 0.-4980.0
2000 2005.0-1995.0 10000 10020.0-9980.0
5000 5005.0-4995. 0 15000 15020.0-14980 0
10000 10010.0-9990 20000 20020.0-19980.0
15000 15015.0-14985.0
20000 20020.0-19980.0
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING OVENS

Item: Oven

Purpose:
This method provides instructions for verifying the settings on general-purpose ovens.

Inspection Equipment Required:

1. A calibrated thermometer graduated in 1.0 °C increments having a range that includes
the temperature range to be checked.
2. A brass thermometer well to retain heat while the door is open. This is not required for
ovens that provide accommodations for a thermometer that can be read without
opening the oven door.

Tolerance:
Ovens shall be capable of maintaining a constant temperature range listed in the appropriate
test methods.

Procedure:
1. Place the thermometer inside the brass well or in the thermometer well provided by the
oven allowing temperature readings external to the oven. At least two inches of the
thermometer tip shall protrude into the oven.
2. Take the first reading at least one hour after closing the oven (the oven should remain
undisturbed during this time).
3. Take at least three consecutive readings that are approximately 30 minutes apart.
4. If a reading is outside the specified range, adjust the temperature of the oven and begin
step three again.
5. The oven is deemed acceptable if all three consecutive readings are within the specified
tolerance.

Ovens shall be calibrated at a minimum of three temperatures: typical target temperature (°F),
typical target plus 20 °F, and typical target minus 20 °F. This requirement may be waived for
ovens that are to remain at a constant temperature.
 OVEN VERIFICATION

INVENTORY #: ________________MANUFACTURER: ______________

MODEL#: _________________

MINIMUM TEMPERATURE: _________ MAXIMUM TEMPERATURE: ________

SET TEMPERATURE
THERMOMETER READINGS
30 MIN. 60 MIN. 90 MIN.

NOTE: Allow oven to stabilize 1/2 hour with each temperature change.

Comments:

Date: ____________________ Verified By: _____________________________

 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING THERMOMETERS

Item: Thermometer

Purpose:
This method provides instructions for checking the accuracy of laboratory thermometers.

Inspection Equipment Required:

1. NIST traceable calibration thermometer(s) containing the range of the thermometer to
be tested.
2. Water Bath
3. Brass thermometer wells

Tolerance:
Thermometers shall meet the tolerances specified in the applicable test method. If no tolerance
is specified, then the thermometer shall be accurate to +/- 1 °C.

Procedure:
TEMPERATURES BELOW 200 °F:
1. Select five temperatures in the range of the thermometer to be tested.
2. Prepare a water bath at the selected temperatures.
3. Place the calibration thermometer and the thermometer to be tested in the
water bath and let set for 15 minutes.
4. Record the temperature of both thermometers.
5. Repeat for additional temperatures.
TEMPERATURES ABOVE 200 °F:
1. Prepare an oven or ovens at the selected temperatures.
2. Place the calibration thermometer and the thermometer to be tested in the
brass thermometer well inside the oven and let set for 20 minutes.
3. Record the temperature of both thermometers.
4. Repeat for additional temperatures.

Note: It may be necessary to prepare both a water bath and an oven in order to test the range
of the thermometer.
 THERMOMETER VERIFICATION

SET THERMOMETER READINGS

THERMOMETER READING THERMOMETER ASTM # THERMOMETER
READING I.D. # RANGE

NOTE: Allow oven to stabilize 1/2 hour with each temperature change.

Comments:

Date: ____________________ Verified By: _____________________________

 IN-HOUSE PROCEDURE #______

PROCEDURE FOR VERIFYING CONICAL MOLD AND TAMPER

Item: Mold and Tamper used in AASHTO T-84

Purpose:
This method provides instructions for checking the critical dimensions of sand cone and tamper
used in the above test method.

Inspection Equipment Required:

1. Calipers readable to 0.01 mm.
2. Balance, 500 g capacity, readable to 0.1 g.
3. Ruler readable to 1mm.

Tolerance:
Equipment shall meet the dimensional tolerances specified in the applicable test method.

Procedure:
CONE
1. Measure the inside diameter at the top of the cone to the nearest 1 mm by taking two
readings 90-degrees apart using the ruler. Record the results.
2. Invert the cone and repeat Step 1.
3. Place the cone on a flat glass surface. Measure and record the depth of the cone using
the ruler.
4. Using the calipers, measure the thickness of the cone to the nearest 0.1 mm by taking 2
reading 90-degrees apart at the top of the cone and 2 readings 90-degrees apart at the
bottom of the cone. Record all results.
TAMPER
1. Measure and record the diameter of the tamping face to the nearest 1 mm by taking
two readings 90-degrees apart using the ruler.
2. Determine and record the mass of the tamper to the nearest 0.1 g.
 Cone and Tamper Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify critical dimensions of the cone and tamper

Calibration
Procedure: In-House Procedure #

Calibration
Equipment: Digital Calipers, Scale CL1, and ruler read. to 1 mm.

Top Inside Diameter of Cone: Tolerance = 40 +/- 3 mm

Bottom Inside Diameter of

Cone: Tolerance = 90 +/- 3 mm

Height of Cone: Tolerance = 75 +/- 3 mm

Thickness of Cone: Tolerance = at least 0.8 mm

Diameter of tamper face: Tolerance = 25 +/- 3 mm

Mass of tamper: Tolerance = 340 +/- 15 g

Pass/Fail:

Comments:

Initial By:
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING SIEVE SHAKERS

Item: Sieve Shaker

Purpose:
This method provides instructions for checking the sieving thoroughness of sieve shakers.

Inspection Equipment Required:

1. Sieves (3/4”, 1/2", #4, #8, #16, #50, #100)
2. Balance, readable to 0.1 g.
3. Pan

Tolerance:
Sieve shakers shall sieve thoroughly such that after one minute of continuous hand sieving, not
more than 0.5% by mass of total original sample passes any sieve.

Procedure:

1. Prepare a well-graded aggregate sample of adequate size based on nominal maximum

aggregate size as described in AASHTO T-27.
2. Record the mass of the total sample.
3. Sieve the sample for 7 minutes.
4. Hand-sieve each sieve for one minute, tapping the sieve against the opposite hand 150
times during the minute.

5. Record the mass of the material that passes the sieve during one minute of hand
sieving.

6. Calculate the percent passing during hand sieving.

 Sieve Shaker Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify thoroughness of sieve shakers

Calibration Procedure: In-House Procedure #

Calibration Equipment: Sieves, Scale CL1, pan

Original Mass of
Sample:

After Hand Sieving:

Mass Passing Percent Passing
3/4"
1/2"
#4
#8
#16
#50
#100

Tolerance: No sieve shall have greater than 0.5% passing by total mass of sample.

Pass/Fail:

Comments:

Initial
By:
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING MECHANICAL SPLITTER

Item: Mechanical Splitter

Purpose:
This method provides instructions for checking the critical dimensions of a mechanical sample
splitter.

Inspection Equipment Required:

1. Calipers or a ruler readable to 1 mm.

Tolerance:
Equipment shall meet the dimensional tolerances specified in the applicable test method.

Procedure:
FINE AGGREGATE SPLITTER
1. Count the number of openings. There should be an even number of chutes, numbering
at least 12.
2. Measure and record the width of each chute. Chutes should be at least 50% larger than
the maximum aggregate size used in the splitter.

COARSE AGGREGATE SPLITTER

1. Count the number of openings. There should be an even number of chutes, numbering
at least 8.
2. Measure and record the width of each chute. Chutes should be approximately 50%
larger than the maximum aggregate size used in the splitter
 Mechanical Splitter Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify critical dimensions of the mechanical splitter

Calibration Procedure: In-House Procedure #

Calibration Equipment: Ruler, readable to 1 mm.

Number of Chutes: Tolerance = even number

at least 8 for coarse, 12 for fine

Chute Opening: Tolerance = approx. 50% larger than

largest aggregate size

Pass/Fail:

Comments:

Initial
By:
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING GYRATORY MOLDS and PLATES

Item: Gyratory Molds and Plates

Purpose:
This method provides instructions for verifying the dimensions on gyratory molds and plates.

Inspection Equipment Required:

1. Accepted calibrated digital calipers reading to 0.01 mm having a range which includes
the dimensions to be checked.
2. Cleaning supplies.

Tolerance:
Molds and plates shall be of the required range as listed in the appropriate test methods.

Procedure:
1. Clean all surfaces.
2. Measure the inside diameter of the mold at four approximately equally spaced locations.
Record and average the four observations.
3. Measure the wall thickness of the mold at four approximately equally spaced locations.
Record and average the four observations.
4. Measure the height of the mold at four approximately equally spaced locations. Record
and average the four observations.
5. Measure the diameter of each plate at four approximately equally spaced locations.
Record and average the four observations.
6. The molds and plates are deemed acceptable if all of the average measurements the
specified tolerance.

If any of the results are outside the specified tolerance, contact the equipment manufacturer.
 Gyratory Mold Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Items: Wall Thickness, Height, Inside Diameter

Calibration Procedure: In-House Procedure #

Calibration Equipment: Digital Calipers

Wall Thickness (mm) Height (mm)

Meas. 1 Meas. 1
Meas. 2 Meas. 2
Meas. 3 Meas. 3
Meas. 4 Meas. 4

Avg: Avg:

Acc. Range: >7.5 Acc. Range: >250

Pass/Fail: Pass/Fail:

Inside Diameter (mm)

Meas. 1 Comments:
Meas. 2
Meas. 3
Meas. 4

Avg:

Acc. Range: 149.90-150.00

Pass/Fail: Initial:
 Pine Top and Bottom Plates Verification Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Next
Calibration
Serial #: Due:
Last
Location: Calibration:

Calibration Items: Plate Diameter

Calibration Procedure: In-House Procedure #

Calibration Equipment: Digital Calipers

Top Plate Diameter (mm) Bottom Plate Diameter (mm)

Meas. 1 Meas. 1
Meas. 2 Meas. 2
Meas. 3 Meas. 3
Meas. 4 Meas. 4

Avg: Avg:

Acc. Range: 149.50-149.75 Acc. Range: 149.50-149.75

Pass/Fail: Pass/Fail:

Comments:

Initial:
 Troxler Bottom Plates Verification Worksheet

Equipment
ID: Date:
Manufacturer: Performed by:
Model #:
Next Calibration
Serial #: Due:
Location: Last Calibration:

Calibration Items: Plate Diameter

Calibration Procedure: In-House Procedure #

Calibration Equipment: Digital Calipers

Bottom Plate Diameter (mm)

Meas. 1
Meas. 2
Meas. 3
Meas. 4

Avg:

Acc. Range: 149.50-149.75

Pass/Fail:

Comments:

Initial:
 Pine Gyratory Compactor Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Items: Angle, Speed, Pressure, Height

Calibration Procedure: Follow manufacturer's instructions

Calibration Equipment: Calibration kit with appropriate compactor

Ram Pressure (kPa) Tilt Angle (deg.)

Proving Ring Reading Angle Jig Reading

Target: Left:
Actual: Right:
% Difference: Difference:

Target: Acc. Range: 0.1083-0.1118

Actual:
% Difference: Angle:

Tolerance: +/-3% Acc. Range: 1.23 - 1.27

Pass/Fail: Pass/Fail:

Height (mm) Speed (Gyrations/min.)

6" Block 10 Gyrations

Target: Target Time:

Actual: Actual Time:
Acc. Range: +/- 0.05 Acc. Range: +/- 0.3 sec
Pass/Fail: Pass/Fail:

Roller Clearance: Left _______________ Comments:

Back _______________
Right _______________
Zero Position OK? _______________
Initial:
 Troxler Gyratory Compactor Calibration Worksheet
Equipment
ID: Date:
Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Items: Angle, Speed, Pressure, Height

Calibration Procedure: Follow manufacturer's instructions

Calibration Equipment: Calibration kit with appropriate compactor

Ram Pressure (kPa) Tilt Angle (deg.)

Load Cell Reading Angle Reading

Target:
Actual: Angle:
% Difference:
Acc. Range: 1.23 - 1.27
Tolerance: +/-3%
Pass/Fail:
Pass/Fail:

Height (mm) Speed (Gyrations/min.)

6" Block

Target: Target Gyr:

Actual: Actual Time:
Acc. Range: +/- 0.05 Acc. Range: +/- 0.5 sec
Pass/Fail: Pass/Fail:

Comments:

Initial:
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR PERFORMING LEAK TEST ON NUCLEAR GAUGES

Item: Nuclear Gauges

Purpose:
This method provides instructions for performing a leak test on nuclear gauges.

Inspection Equipment Required:

1. Leak test kit from Troxler.

Tolerance:
The leak test results should report less than 0.005 uCi (185 Bq).

Procedure:
1. Get out the yellow kit, which is stored in Office of Laboratory Supervisor
2. Obtain one envelope for each nuclear device. The envelope should contain filter paper,
plastic bag, and adhesive label.
3. Go to the nuclear device.
4. On the filter paper, record the following WITH A PENCIL!!!!!:
- Model number of device, serial number of device, date of leak test
5. Moisten the filter paper with Radiac Wash.
6. Use tongs and wood dowel to wipe the designated areas of the device.
(This is usually a black box area beneath the control panel of the device.)
Make sure to wipe with the side of the filter paper where numbers are written!
7. Allow the filter paper to dry.
8. Place the filter paper in the plastic bag.
9. Fill out all information on triplicate form.
10. Retain the customer copy for records.
11. Staple the left edge of the triplicate form to the plastic bag containing the filter paper.
(The form should be on top.)
12. Send the leak test form and sample to Troxler at the address on the addressed
envelope.
13. Record testing dates in equipment files and in AASHTO records (QM).
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING FINE AGGREGATE ANGULARITY APPARATUS

Item: Fine Aggregate Angularity Apparatus

Purpose:
This method provides instructions for checking the critical dimensions of a fine aggregate
angularity apparatus.

Inspection Equipment Required:

1. Digital calipers readable to 0.01 mm.
2. Straightedge.

Tolerance:
Equipment shall meet the dimensional tolerances specified in AASHTO T-304.

Procedure:
CYLINDRICAL MEASURE
1. Measure and record the inside diameter of the cylinder.
2. Measure and record the inside height of the cylinder.
3. Measure and record the thickness of the bottom of the cylinder.

FUNNEL
1. Measure and record the inside diameter of the opening of the funnel.
2. Measure and record the inside height of the funnel, using the straightedge to identify a
plane from which to measure.

FUNNEL STAND
Measure and record the vertical distance between the funnel opening and the top of the
cylinder.

GLASS PLATE
1. Measure and record the width of the glass plate.
2. Measure and record the length of the glass plate.
3. Measure and record the thickness of the glass plate.
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING PROPORTIONAL CALIPERS

Item: Proportional Calipers

Purpose:
This method provides instructions for checking the critical dimensions of proportional calipers
used in the determination of flat and elongated particles.

Inspection Equipment Required:

1. Digital calipers readable to 0.01 mm.

Tolerance:
Equipment shall meet the dimensional tolerances specified in the applicable test method.

Procedure:
1. Set the device to the appropriate max:min ratio, usually 5:1.
2. Measure and record the width of the minimum opening and the maximum opening.
3. Repeat for at least four additional opening widths
 IN-HOUSE PROCEDURE #____

PROCEDURE FOR VERIFYING DIGITAL CALIPERS

Item: Digital Calipers

Purpose:
This method provides instructions for verifying the accuracy of digital calipers used in the
calibration of laboratory equipment.

Inspection Equipment Required:

1. Gage blocks accurate to 0.01 mm.

Tolerance:
Equipment shall meet the dimensional tolerances specified in the applicable test methods.

Procedure:
1. Measure gage blocks at a variety of dimensions.
2. Measure and record the caliper measurement.
3. Record the known dimension of the gage block.
4. Repeat for a minimum of three measurements.
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING PROCTOR HAMMERS

Item: Proctor Hammer

Purpose:
This method provides instructions for checking the critical dimensions of the proctor hammers.

Inspection Equipment Required:

1. Calipers readable to 0.02 mm.
2. Tape measure readable to 1mm.
3. Balance, capacity 5 kg, readable to 1 g.

Tolerance:
Equipment shall meet the dimensional tolerances specified in the applicable test method.

Procedure:
1. Measure and record the diameter of the rammer face determined by taking two reading
90-degrees apart using the calipers.
2. Pull up the handle, measure and record the drop height of the hammer. Determine this
height inside the guide-sleeve using the tape measure.
3. Remove the hammer from the guide-sleeve. Determine and record its mass to the
nearest 1 g.
Measure and record the diameters of the vent holes near the end of the hammer.
 Standard Proctor Hammer Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify critical dimensions of the proctor hammer

Calibration Procedure: In-House Procedure #

Calibration Equipment: Calipers, tape measure, and Scale CL1.

Diameter of Rammer Face: Tolerance = 50.80 +/- 0.25 mm

Drop Height of Hammer: Tolerance = 305 +/- 2 mm

Mass of Hammer: Tolerance = 2.495 +/- 0.009 kg

Vent Hole Diameters: Tolerance = approx. 3/8 inch

Pass/Fail:

Comments:

Initial By:
 Modified Proctor Hammer Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify critical dimensions of the proctor hammer

Calibration Procedure: In-House Procedure #

Calibration Equipment: Calipers, tape measure, and Scale CL1.

Diameter of Rammer Face: Tolerance = 50.80 +/- 0.25 mm

Drop Height of Hammer: Tolerance = 457 +/- 2 mm

Mass of Hammer: Tolerance = 4.536 +/- 0.009 kg

Vent Hole Diameters: Tolerance = approx. 3/8 inch

Pass/Fail:

Comments:

Initial By:
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING PROCTOR MOLDS

Item: Soil Molds used in AASHTO T-99 and AASHTO T-180

Purpose:
This method provides instructions for checking the critical dimensions of 100 mm (4-in.) and
150 mm (6-in.) molds used in soil testing.

Inspection Equipment Required:

1. Calipers, capable of measuring the height and inside diameter of the molds and readable
0.01 mm.

Tolerance:
The height and diameter of the molds checked shall meet the dimensional tolerances specified
in the applicable test method listed above.

Procedure:

1. Measure and record the inside diameter of the mold to the nearest 0.01 mm. Rotate the
mold 90-degrees (1/4 turn) and measure and record the inside diameter again.
2. Turn the mold over and repeat Step 1.
3. Measure and record the height of the mold to the nearest 0.01 mm. Rotate the mold
90-degrees (1/4 turn) and measure and record the height again.
4. Measure and record the height of the collar to the nearest 1 mm. Rotate the collar 90-
degrees (1/4 turn) and measure and record the height again.
5. Measure and record the inside diameter of the collar to the nearest 0.01 mm. Rotate
the collar 90-degrees (1/4 turn) and measure and record the inside diameter again.
 4" Proctor Mold Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify critical dimensions of the proctor mold

Calibration Procedure: In-House Procedure #

Calibration Equipment: Calipers

Top Inside Diameter of Mold: Tolerance = 101.60 +/- 0.41 mm

Bottom Inside Diameter of Mold: Tolerance = 101.60 +/- 0.41 mm

Height of Mold: Tolerance = 116.43 +/- 0.13 mm

Height of Collar: Tolerance = approx. 60 mm

Inside Diameter of Collar: Tolerance = 101.60 +/- 0.41 mm

Pass/Fail:

Comments:

Initial By:
 6" Proctor Mold Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify critical dimensions of the proctor mold

Calibration Procedure: In-House Procedure #

Calibration Equipment: Calipers

Top Inside Diameter of Mold: Tolerance = 152.40 +/- 0.66 mm

Bottom Inside Diameter of Mold: Tolerance = 152.40 +/- 0.66 mm

Height of Mold: Tolerance = 116.43 +/- 0.13 mm

Height of Collar: Tolerance = approx. 60 mm

Inside Diameter of Collar:

Pass/Fail:

Comments:

Initial By:
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING THE LIQUID LIMIT DEVICE

AND GROOVING TOOL

Item: Liquid Limit Device, Grooving Tool, and Gage

Purpose:
This method provides instructions for checking the critical dimensions of a liquid limit device,
grooving tool, and gage.

Inspection Equipment Required:

1. Digital calipers readable to 0.01 mm.
2. Straightedge.

Tolerance:
Equipment shall meet the dimensional tolerances specified in AASHTO T-89.

Procedure:
LIQUID LIMIT DEVICE
1. Measure the diameter of the cup and calculate the radius. Record the radius of the cup.
2. Measure and record the thickness of the cup.
3. Measure and record the depth of the cup using a straightedge to identify a plane from
which to measure.
4. Measure and record the distance from the cup at the cam follower to the base.
5. Measure and record the thickness of the base.
6. Measure and record the length of the base.
7. Measure and record the width of the base.

GROOVING TOOL
1. Measure and record the thickness of the curved end.
2. Measure and record the thickness of the cutting edge.
3. Measure and record the width of the curved end.

GAGE
1. Measure and record the depth of the gage.
2. Measure and record the width of the gage.
3. Measure and record the length of the gage.
 Liquid Limit Device and Grooving Tool Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify critical dimensions of the Liquid Limit Device Grooving Tool, and Gage

Calibration Procedure: In-House Procedure #

Calibration Equipment: Calipers, balance reading to 0.1 g, and ruler reading to 1 mm.

Diameter of Cup: Tolerance = 54 +/- 2 mm

Radius of Cup =
(dia./2):

Thickness of Cup: Tolerance = 2 +/- 0.1 mm

Depth of Cup: Tolerance = 27 +/- 1 mm

Cup to Base (at

cam follower): Tolerance = 47 +/- 1.5 mm

Thickness of Base: Tolerance = 50 +/- 5 mm

Length of Base: Tolerance = 150 +/- 5 mm

Width of Base: Tolerance = 125 +/- 5 mm

Grooving Tool
Thickness: Tolerance = 10 +/- 0.1 mm

Width of Cutting
Edge of Tool: Tolerance = 2 +/- 0.1 mm

Width of Grooving
Tool: Tolerance = 13.5 +/- 0.1 mm

Depth of Gage: Tolerance = 10 +/- 0.2 mm

Width of Gage: Tolerance = 10 +/- 0.2 mm

Length of Gage: Tolerance = At least 15.9 mm

Comments: Initial By:

 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING VACUUM SYSTEMS

Item: Vacuum system used in AASHTO T-209

Purpose:
This method provides instructions for checking the vacuum pressure.

Inspection Equipment Required:

1. NIST Traceable residual manometer or secondary vacuum gauge.
2. Water vapor trap.
3. Hoses, connectors, tools, misc.

Tolerance:
Equipment shall be capable of applying the vacuum specified in the applicable test method.

Procedure:
1. Connect the gauges and/or manometer to the system with the trap in-line between the
system and the gauges.
2. Make sure all connections are air-tight.
3. Open the number of lines normally used in testing and read and record the pressure
indicated on the gauges and/or on the manometer.
 Vacuum Gauge Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Next Calibration
Serial #: Due:
Location: Last Calibration:

Verify pressure
Calibration Item: readings
Calibration Procedure: In-House Procedure #
Calibration Equipment: NIST Traceable Residual Manometer
or secondary vacuum gauge.

Pressure:
Primary Gauge/Manometer Sec. Gauge/Man.
Rdg. Rdg.
(A) (B)

Acceptable Range: 3.7 +/- 0.3 kPa

Pass/Fail:

Comments:

Initial By:
 IN-HOUSE PROCEDURE #_____

PROCEDURE FOR VERIFYING TIMERS

Item: Timer

Purpose:
This method provides instructions for checking the accuracy of timing devices.

Inspection Equipment Required:

1. Timer, readable to 0.1 sec., having a verified accuracy within the tolerance listed in
appropriate test methods.

Tolerance:
Equipment shall meet accuracy requirements specified in the applicable test method.

Procedure:
1. Hold the calibrated timer in one hand and the timer to be checked in the opposite hand.
2. Start the timers simultaneously by pressing the “start” buttons at the same time.
3. Allow the timers to run for at least 15 minutes then stop the timers simultaneously.
Record the time indicated by both timers.
4. Record the difference between the two timers. Calculate and record the percent
accuracy.

% accuracy = (A – B) x 100
B

where A = reading on lab timer (sec)

B = reading on standard timer (sec)
 Timer Calibration Worksheet

Equipment ID: Date:

Manufacturer: Performed by:
Model #:
Serial #: Next Calibration Due:
Location: Last Calibration:

Calibration Item: Verify time readings

Calibration Procedure: In-House Procedure #
Calibration Equipment:

Time:
Control Timer Rdg. Test Timer Rdg.
(A) (B)

Calculate % Accuracy:

% Accuracy = (A - B) x 100 =
B

Comments:

Initial By:
 TEST RECORDS AND REPORTS

This section of the QM contains the following information:

1. A description of the methods used to produce test records and reports, including
methods to check and amend reports.

2. Typical data sheets (test report forms) used for all tests covered by the Quality
Manual and performed by the laboratory.

3. Samples of completed forms for all tests covered by the Quality Manual.

4. Proficiency Sample test results for methods covered by the accreditation of the
laboratory.

5. Sample log containing date, sample ID, project number, description, and remarks
concerning the condition of the sample.
 PROFICIENCY SAMPLE TEST RECORDS

Test records for each test method covered in the AMRL Proficiency Sample Program are
included in this section of the Quality Manual, maintained by the Laboratory Supervisor.

Test results for the AMRL Proficiency Sample Program shall be reported to the
administrator of the program by the date indicated for the sample. Copies of the report
shall be placed in the Quality Manual after review by the Laboratory Manager.

Proficiency sample test records will be maintained in the Quality Manual for a period of
not less than three years. When a proficiency sample test record is more than three
years old, it may then be transferred to the historical file.
 DATA SHEETS

Sample data sheets for each test method covered in this manual are included in this
section. Blank sheets are maintained and available from the Laboratory Manager.
 SAMPLE REPORTS

Sample report sheets for test methods covered in this manual are included in this
section. Complete project reports are maintained in designated locations, as
determined by the Laboratory Manager or the appropriate Area Specialist.
 SAMPLE LOG

A sample log of samples received by the laboratory is included in this section.

Comments concerning the date of receipt, sample ID, project number, sample
description, and remarks regarding the condition of the sample when received are
noted on the following pages. Additional information may be available from the
Laboratory Manager.
 SUBCONTRACTING

A complete listing of outside sources utilized by the laboratory is included in this

section. This listing contains services provided for equipment calibration and
verification, equipment rental, training, and testing services (as applicable). Each entry
contains the name of the company and/or individual providing the service, address,
phone number, and comprehensive description of the services provided by that
company or individual. When applicable, proof of pertinent CTTP certifications held by
such companies or individuals are included.

Equipment Calibration
Name Address / Phone # Services Provided

Equipment Rental
Name Address / Phone # Equipment Provided*

*For multiple items, an equipment inventory listing may be more appropriate.

Testing Services
Lab/Technician Name
Laboratory Address Services Provided CTTP Certification #

Training / Other
Name Address / Phone # Services Provided