Quality Assurance Manual 8

M M F X S T E E L C O R P O R AT I O N O F A M E R I C A
2415 CAMPUS DRIVE, SUITE 100 • IRVINE, CA 92612
TELEPHONE (949) 476-7600 • FACSIMILE (949) 474-1130
www.mmfx.com
QUALITY
ASSURANCE
MANUAL
8th Edition
January 2014
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.
MMFX STEEL QUALITY ASSURANCE MANUAL
Edition: 8.0
Date: January 2014
Table of Contents
1. Statements .............................................................................................................................................................................. 3
1.1. General Policy Statements ................................................................................................................................................ 3
1.2. Review of Quality Assurance Manual. ............................................................................................................................. 3
1.3. Signatures ......................................................................................................................................................................... 3
2. References and Definitions .................................................................................................................................................... 4
2.1. Reference Standards ......................................................................................................................................................... 4
2.2. Definitions ........................................................................................................................................................................ 4
3. Product ................................................................................................................................................................................... 5
3.1. Description of Products..................................................................................................................................................... 5
3.2. Manufacturing Tolerances ................................................................................................................................................ 5
4. Acceptance Quality Control .................................................................................................................................................. 6
4.1. Procurement of MMFX Steel Bars from Qualified Suppliers ........................................................................................... 6
4.2. Production of MMFX Steel Bars ...................................................................................................................................... 6
4.3. Delivery of MMFX Steel Bars from Steel Mills. .............................................................................................................. 6
4.4. MMFX Steel Bars Acceptance ......................................................................................................................................... 6
4.5. MMFX Steel Bars Certification ........................................................................................................................................ 7
4.6. Segregation of Inventory and Non-Conforming Finished Product. .................................................................................. 7
4.7 Material Storage and Shipping ........................................................................................................................................... 7
5. Inspection Records ................................................................................................................................................................. 8
5.1. Records ............................................................................................................................................................................. 8
5.2. Review of Records ............................................................................................................................................................ 8
6. Tables. ..................................................................................................................................................................................... 9
Table 1 - MMFX2 and ChrōmX 4100 Steel Bars – Standard Sizes, Dimensions and Deformations ....................................... 9
Table 2 – MMFX2 and ChrōmX 4100 Steel Bars - Mechanical Properties Requirements ...................................................... 9
7. Figures .................................................................................................................................................................................. 10
Figure 1A Schematic of MMFX 2 Bar Markings (English Units) .......................................................................................... 10
Figure 1B Schematic of ChrōmX 4100 Bar Markings (English Units) ................................................................................. 10
Figure 1C Schematic of MMFX 2 Bar Markings (Metric Units) ............................................................................................ 11
Figure 1D Schematic of ChrōmX 4100 Bar Markings (Metric Units)................................................................................... 11
Figure 2. Typical Mill Label/Tag ........................................................................................................................................... 12
Figure 3. Typical Qualified Supplier Mill Certificate - A1035 Grade 100 /AASHTO MP18 (Buy America/Buy American
Compliant) ............................................................................................................................................................................. 13
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MMFX STEEL QUALITY ASSURANCE MANUAL
Edition: 8.0
Date: January 2014
2. References and Definitions
2.1. Reference Standards
2.1.1. AASHTO (American Association of State Highway and Transportation Officials) Standard Specifications
2.1.1.1. AASHTO MP 18M/MP 18-09 - Standard Specification for Uncoated, Corrosion-Resistant, Deformed and
Plain Alloy, Billet-Steel Bars for Concrete Reinforcement and Dowels
2.1.2. ASTM International Standard Specifications
2.1.2.1. ASTM A615/A615M–13 Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete
Reinforcement
2.1.2.2. ASTM A1035/A1035M –13b Standard Specification for Deformed and Plain, Low-carbon, Chromium,
Steel Bars for Concrete Reinforcement
2.2. Definitions
2.2.1. ChrōmX™ 4100 bars – Concrete Reinforcing Bars that meet the mechanical properties of ASTM A1035 Gr 100
and AASHTO MP 18 Gr 100 with a modified chemistry.
2.2.2 Heat Number – Steel mill identification of steel melt information identifying – steel chemistry, date and location
of melt.
2.2.3. 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.
2.2.4. Qualified Supplier 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).
2.2.5 MMFX Steel - means MMFX Steel Corporation of America – subsidiary of MMFX Technologies Corporation.
2.2.6 MMFX2 bars- – Concrete Reinforcing Bars that are certified to Standard Specifications ASTM A1035 and
AASHTO MP 18
2.2.7 Non-Conforming Bars – Steel bars, which have been delivered from qualified suppliers that require thermal
treatment.
2.2.8. Non-Conforming Finished Product – Steel bars, which have received thermal treatment and failed testing to meet
either: ASTM A615 Gr 75/80 and/or ASTM A1035 and or AASHTO MP 18 Gr 100, cannot be issued mill
certifications.
2.2.9 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 18.
2.2.10 Quality Assurance Manual – document detailing the corporate quality policy and structure of the company,
referencing operating procedures to assure product to customers.
2.2.11 Quality Control Manager – company representative responsible for carrying out the policies and procedures of
the Quality Assurance Manual.
2.2.12. Red Tag – identification label placed on Non-Conforming Finished Product. Red tagged bars are segregated
from conforming bars that are certified.
2.2.13. Roll Number – Steel mill identification of steel bar rolling information identifying – date and location of rolling,
bar (size, type, grade and length).
2.2.14. 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.
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MMFX STEEL QUALITY ASSURANCE MANUAL
Edition: 8.0
Date: January 2014
3. Product
3.1. Description of Products
3.1.1. MMFX2 and ChrōmX 4100 bars, both deformed bars (rebars) and smooth bars complying to ASTM A615 Gr
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 MMFX2 and ChrōmX
4100 bars and their number designations are given in Section 6 Table 1 MMFX2 and ChromX 4100 Steel Bars –
Standard Sizes, Dimensions and Deformations. MMFX2 and ChrōmX 4100 bars shall have minimum yield
strength and tensile properties in accordance with Section 6 Table 2 - MMFX2 and ChrōmX 4100 Steel Bars Mechanical Properties Requirements. (“MMFX Steel Bars”)
3.1.1.1. For the case of deformed bars (rebars) for concrete reinforcement, the schematics of MMFX2 and ChrōmX
4100 bar markings are shown in Section 7 Figures 1A, 1B, IC and 1D.
3.1.1.2. Smooth bars do not have bar markings.
3.2. Manufacturing Tolerances
3.2.1. Surface Characteristics: Bars received at the MMFX Steel’s Qualified Supplier will be verified against the
tolerances of ASTM A 615 Grade 75/80, ASTM A 1035 and/or AASHTO MP 18M Grade 100.
3.2.2. Chemical Analysis Testing.
3.2.2.1. For MMFX2 steel bars conforming to ASTM A1035, the chemistry shall be as specified by the ASTM
A1035 standard, article 6.2.
3.2.2.2. For MMFX2 steel bars conforming to AASHTO MP18, the chemistry shall be as specified by the AASHTO
MP18 standard, article 6.3.
3.2.2.3 For ChrōmX 4100 conforming to ASTM A1035 Gr 100 and AASHTO MP 18 Gr 100, shall be specified
as ASTM A1035 Gr 100 and or AASHTO MP18 Gr 100 standards with a modified chemistry.
3.2.3. Mechanical Properties: The Mechanical Properties reported on the mill certification should conform to
the properties outlined in Section 6 Table 2 - MMFX2 and ChrōmX 4100 Steel Bars - Mechanical Properties
Requirements.
3.2.4. Markings: All MMFX Steel Bars steel bars should be marked by a distinguishing set of marks legibly rolled onto
the surface of one side of the bar. Typical MMFX2 bars complying with ASTM A1035 requirements are shown in
Section 7 Figure 1A. Schematic of MMFX 2 Bar Markings (English Units) and 1B Schematic of MMFX2 Bar
Markings (Metric Units). Typical ChrōmX 4100 bar markings are shown in Section 7 Figures 1C Schematic of
ChrōmX 4100 Bar Markings (English Units) and 1D Schematic of ChrōmX 4100 Bar Markings (Metric Units).
3.3. Product Traceability
3.3.1. The MMFX Steel products 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 Qualified Supplier Mill Certificate (see Section 7 Figure 3) will be issued for every
bar size and heat shipped from the MMFX Steel’s Qualified Supplier.
3.3.2. Traceability through Mill Label/Tag.
3.3.2.1. 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, pieces,
weight etc.
3.3.2.2. Heat number is a unique fingerprint, which identifies the chemical composition of the product; the date
the heat was melted and chemical composition certification.
3.3.2.3. Roll number is traced to rolling schedule of the steel and mechanical properties certification.
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MMFX STEEL QUALITY ASSURANCE MANUAL
Edition: 8.0
Date: January 2014
4. Acceptance Quality Control
The following flow list illustrates the steps of accepting a product delivered to MMFX Steel customers.
4.1. Procurement of MMFX Steel Bars from Qualified Suppliers
4.1.1. MMFX Steel Bars are 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:
4.1.1.1. Compatibility of supplier's steel making practices with the specifications of MMFX Steel.
4.1.1.2. Review of supplier's quality control practices and other relevant documents.
4.1.1.3. Effective document exchange and review.
4.1.1.4. Production inspection and testing.
4.1.1.5. Audits of supplier's facilities.
4.1.2. The certification and approval of MMFX Steel Bar suppliers is the responsibility of MMFX Steel. The quality
assurance manuals and certifications of the current suppliers of MMFX Steel Bars are to be supplied to MMFX
Steel.
4.1.3. MMFX Steel Purchase orders to suppliers need to include:
4.1.3.1. Technical requirements in the form of product specification and industry standards.
4.1.3.2. Additional quality requirements, if any.
4.2. Production of MMFX Steel Bars
4.2.1. MMFX Steel’s Vice President Steel Operations is responsible for the production of MMFX Steel Bars. MMFX
Steel’s Quality Control personnel are given full access to the facility during production of MMFX Steel Bars
and are provided with all production and quality records relating to the production of these bars.
4.2.2 MMFX Steel Bars 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.
4.2.3 MMFX Steel Bars billets are converted into bars at the rolling mill, which are indentified by Heat and Rolling
Numbers (see also Section 3.3). Lot sizes of MMFX Steel Bars are based on quantity of material rolled from a
specific heat.
4.3. Delivery of MMFX Steel Bars from Steel Mills.
4.3.1. The instructions for operating MMFX Steel’s Qualified Supplier facilities are given to those facility mangers and
operators to assure proper inventory and traceability of MMFX Steel Bars. rebar. Inventory records are shared
with MMFX Steel Logistics and are verified by MMFX Steel Quality Control personnel.
4.4. MMFX Steel Bars Acceptance
4.4.1. MMFX Steel Bars are delivered from Qualified Suppliers with mill Bill of Lading (BOL) including Heat and
Rolling Numbers. MMFX Steel’s Qualified Supplier performs inspection of MMFX Steel Bars. The received
bars are checked for conformity with the following requirements of ASTM A615 Gr 75/80, ASTM A1035, and/or
AASHTO MP 18, and/or additional MMFX Steel internal technical product specifications, if any (i.e. chemical
composition requirements, mill markings and mechanical properties).
4.4.2. If the MMFX2 bars conform to all requirements of ASTM A615 Gr 75/80, ASTM A1035, and or AASHTO MP
18, the product is certified and moved into the MMFX Steel’s inventory as per Section 4.5.
4.4.2.1 If the ChromX 4100 bars conform to the mechanical properties of ASTM A615 Gr 75/80, ASTM A1035 Gr 100
and or AASHTO MP 18 Gr 100 and with a modified chemistry, the product is certified and moved into the
MMFX Steel’s inventory as per Section 4.5.
4.4.3. If the MMFX Steel Bars and the Mill Certificate are conforming to all requirements of MMFX Steel, except for
mechanical properties, Product is separated and moved for Thermal-Treatment.
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MMFX STEEL QUALITY ASSURANCE MANUAL
Edition: 8.0
Date: January 2014
4.4.4. Thermal-Treatment of MMFX Steel Bars: When thermal-treatment operation is required, heat treatment is done
according with MMFX Steel’s Thermal Treatment protocol by MMFX Steel’s Qualified Supplier. The thermal
treatment process logs are prepared by the heat treatment operators and electronically stored by the Qualified
Supplier.
4.5. MMFX Steel Bars Certification
4.5.1. Product conforming to MMFX Steel Bars acceptance criteria is labeled with Qualified Supplier Mill Label/Tag
(Section 7 - Figure 2) and the Product is entered into the inventory maintained by shipping. A Qualified Supplier
Mill Certificate is issued as shown in Section 7 - Figure 3. The Qualified Supplier certified heats of MMFX2 bars
must meet the specification for dimension, chemistry and mechanical properties according to ASTM A615 Gr
75/80, ASTM A1035 and or AASHTO MP18 Gr 100. ChromX 4100 bars must meet the specification for
dimension, with a modified chemistry and mechanical properties according to ASTM A615 Gr 75/80, ASTM
A1035 Gr 100 and or AASHTO MP18 Gr 100.
4.5.2. The certification process of heat-treated bar, consists of sampling and mechanical testing according to ASTM Gr
75/80, 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
Gr 75/80, ASTM A1035 and or AASHTO MP18 requirements, are then available to be issued a Qualified
Supplier Mill Certificate (Section 7 - Figure 3).
4.5.3. In accordance with AASHTO MP18 Section 11, comparative corrosion performance data shall be furnished based
on mutual agreement between the manufacturer and the purchaser of MMFX2 bars. ChrōmX 4100 bars are not
required to provide comparative corrosion performance data in accordance with AASHTO MP18 Section 11.
4.6. Segregation of Inventory and Non-Conforming Finished Product.
4.6.1. MMFX2 bars determined to be in compliance with ASTM A615 Gr 75/ 80, A1035 and or AASHTO MP 18 criteria,
is entered into inventory. A Qualified Supplier Mill Certificate will be issued for products in inventory at the
time of shipping.
4.6.1.1 ChrōmX 4100 bars complying with ASTM A615 Gr 75/ 80, ASTM A1035 Gr 100 and or AASHTO MP 18 Gr
100 mechanical criteria and with a modified chemistry are entered into inventory. A Qualified Supplier Mill
Certificate will be issued for products in inventory at the time of shipping. A Qualified Supplier Mill Certificate
will be issued for products in inventory at the time of shipping.
4.6.2 Red tagged bars (Non-Conforming Finished Product) are placed in a segregated area of the Qualified Supplier
facility.
4.6.3. MMFX Steel has the option of: returning the Non-Conforming Finished Product to the Qualified Supplier, selling
it as a no-grade material or scraping the product.
4.7 Material Storage and Shipping
4.7.1 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 Steel Bars are not exposed to
accidental spillage of fluids etc. When storage conditions necessitate exposure to the element, either inside or outside
of MMFX Steel Qualified Supplier facilities, provide appropriate cover (i.e. tarpaulins, plastic etc.) from the elements.
4.7.2 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.)
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MMFX STEEL QUALITY ASSURANCE MANUAL
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Date: January 2014
5. Inspection Records
5.1. Records
5.1.1. The following records are kept by the Qualified Supplier in order to track the incoming materials and the
acceptance procedures.
5.1.1.1. Thermal Treatment Firing Logs
5.1.1.2. Qualified Supplier Mill Certificates
5.2. Review of Records
5.2.1. In order to maintain the highest quality and expectations for the MMFX Steel Bars, the records 5.1.1 are available
and periodically reviewed.
5.3. Maintenance of Records
5.3.1. Copies of the Qualified Supplier records 5.1.1will be kept at the offices of MMFX Steel, 2415 Campus Drive,
Suite 100, Irvine, CA 92612. It is be the responsibility of the Quality Control Manager, to keep such records
current and accurate.
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MMFX STEEL QUALITY ASSURANCE MANUAL
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Date: January 2014
6. Tables.
Table 1 - MMFX2 and ChrōmX 4100 Steel Bars – Standard Sizes, Dimensions and Deformations
(Same as ASTM A615 Table 1, ASTM A1035 Table 1 and AASHTO MP 18 Tables 2 and 3)
Nominal Dimensions A
CrossDiameter,
Perimeter
Sectional
In. [mm]
In. [mm]
Area,
In.2 [mm2]
0.375 [9.5]
0.11 [71]
1.178 [29.9]
Maximum
Average
Spacing
0.262 [6.7]
Minimum
Average
Height
0.015 [0.38]
Maximum Gap
(Chord of 12.5% of
Nominal Perimeter)
0.143 [3.6]
Deformation Requirements, in. [mm]
3 [10]
Nominal Weight,
LB/ft
[Nominal Mass,
kg/m]
0.376 [0.560]
4 [13]
0.668 [0.994]
0.500 [12.7]
0.20 [129]
1.571 [39.9]
0.350 [8.9]
0.020 [0.51]
0.191 [4.9]
5 [16]
1.043 [1.552]
0.625 [15.9]
0.31 [199]
1.963 [49.9]
0.437 [11.1]
0.028 [0.71]
0.239 [6.1]
6 [19]
1.502 [2.235]
0.750 [19.1]
0.44 [284]
2.356 [59.8]
0.525 [13.3]
0.038 [0.97]
0.286 [7.3]
7 [22]
2.044 [3.042]
0.875 [22.2]
0.60 [387]
2.749 [69.8]
0.612 [15.5]
0.044 [1.12]
0.334 [8.5]
8 [25]
2.670 [3.973]
1.000 [25.4]
0.79 [510]
3.142 [79.8]
0.700 [17.8]
0.050 [1.27]
0.383 [9.7]
9 [29]
3.400 [5.060]
1.128 [28.7]
1.00 [645]
3.544 [90.0]
0.790 [20.1]
0.056 [1.42]
0.431 [10.9]
10 [32]
4.303 [6.404]
1.270 [32.3]
1.27 [819]
3.990 [101.3]
0.889 [22.6]
0.064 [1.63]
0.487 [12.4]
11 [36]
5.313 [7.907]
1.410 [35.8]
1.56 [1006]
4.430 [112.5]
0.987 [25.1]
0.071 [1.80]
0.540 [13.7]
14 [43]
7.65 [11.38]
1.693 [43.0]
2.25 [1452]
5.320 [135.1]
1.185 [30.1]
0.085 [2.16]
0.648 [16.5]
18 [57]
13.60 [20.24]
2.257 [57.3]
4.00 [2581]
7.090 [180.1]
1.580 [40.1]
0.102 [2.59]
0.864 [21.9]
Bar
Designation
No.
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 – MMFX2 and ChrōmX 4100 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
150,000
150,000
Yield Strength, min, psi
75,000
100,000
120,000
Bar No. 3, 4, 5
7
7
7
6
7
7
7
7, 8
7
7
7
9, 10, 11
6
7
7
14, 18
6
6
-
Elongation in 8 in., min, %
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MMFX STEEL QUALITY ASSURANCE MANUAL
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Date: January 2014
7. Figures
Figure 1A Schematic of MMFX 2 Bar Markings (English Units)
Figure 1B Schematic of ChrōmX 4100 Bar Markings (English Units)
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Date: January 2014
Figure 1C Schematic of MMFX 2 Bar Markings (Metric Units)
Figure 1D Schematic of ChrōmX 4100 Bar Markings (Metric Units)
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Date: January 2014
Figure 2. Typical Mill Label/Tag
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Date: January 2014
Figure 3. Typical Qualified Supplier Mill Certificate - A1035 Grade 100 /AASHTO MP18 (Buy America/Buy American
Compliant)
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