This manual provides highway
construction personnel with relevant, practical information in order to
administer construction, perform accurate inspections, and provide relevant
construction procedural information for the various roadway and structures
items of work. It is the responsibility
and duty of all Department personnel involved in highway construction to become
familiar with the content and intent of this manual.
This manual includes
background information for select items of work. This information is intended to assist
construction personnel with understanding and solving various field problems
and issues. The examples and graphics
contained in this document are intended to provide guidance for a practical
approach to inspection and construction processes and procedures. This manual is not intended to be a complete,
all inclusive text detailing every aspect of highway construction, but rather
an operational guidebook for highway construction and inspection techniques.
In order to take complete
advantage of the information in the manual, project personnel should have a
comprehensive understanding of the Construction and Material Specifications,
Supplemental Specifications, Standard Drawings, and other pertinent contract
documents. Unless specifically
incorporated by reference into the contract documents, this manual is not
contractually binding on either contracting party. The information contained in the manual does
not replace, supersede, or otherwise modify any specification, plan, or
proposal provision, or other contract document or condition except as noted.
As the on-site
representatives of the Department, ODOT Inspectors and Engineers are authorized
to observe all work being performed to ensure compliance with the
contract. As the required inspection
activity occurs, the Department has an obligation to inform the Contractor on a
regular basis regarding the quality and compliance of the work performed. Conversely, the Contractor also shares in the
responsibility to provide information regarding construction problems or issues
to the Department for timely resolution consistent with joint issue mitigation
responsibilities (C&MS 108.02.F).
The primary goal of this
manual is to present functional highway construction information in order to
provide practical guidance to personnel involved in this effort. The Department is responsible for monitoring
and documenting construction activity in the project diary to ensure the intent
of the contract is reflected in the final product delivered to the Department. Secondly, timely and proper inspections are
critical to ensure an acceptable level of project quality. For these reasons, this manual has been
developed to assist in ensuring that correct, accurate, and thorough
administration and inspections of the work are performed consistently
statewide.
This manual provides
construction personnel with information to effectively administer the project
and to perform accurate inspections and documentation of the construction work
items. It is the duty of ODOT Project
Engineers and Inspectors to become familiar with the contents of this manual.
Included in this manual is
background information for the specific items of work. This background information will help
construction personnel understand various field problems and associated
solutions. Examples, problems and
figures are provided as guidance throughout this manual.
This manual should not be
considered a complete textbook detailing all aspects of construction. In order to completely take advantage of the
information in this manual, project personnel should be familiar with the
Construction and Material Specifications, Standard Drawings, and other contract
documents.
Unless specifically
referenced in the contract, this manual is not a part of the contract with the
Contractor. The information contained in
the manual does not replace, supersede, or modify any specification, plan, or
proposal provisions of the contract.
As the representatives of the
Department, ODOT Inspectors and Engineers observe the Contractors’ work to
ensure compliance with the specifications.
Correct and accurate inspections are critical tools to ensure the
quality of the work. As ODOT inspects
the work, Inspectors and Engineers document progress and communicate with the
Contractor daily about the quality and compliance of the work.
When work is deficient or
defective, many times the Department suffers significant financial losses due
to one of the following reasons:
·
The instructions
to the Contractor were in error or did not occur.
·
The Department
testing was performed incorrectly.
·
Inspection forms
or details are incomplete or conflicting.
·
No inspection
occurred during the construction of the item.
All of the above are
arguments that the Contractor could raise when asserting a claim. Valid or not, these are reasons that will be
debated when responsibility is discussed.
Our goal is to minimize the
Department’s responsibility in claim situations and maximize the quality of the
work performed. The Department needs to
correctly monitor the construction activities and document those activities in
the project diary to ensure the contract intent is carried through during the
construction.
The Project Engineer or
Inspector must set up a records system to adequately record the daily
activities on the project. These records
should include the following, as applicable:
·
A folder for each
reference number
·
Proposals /
addendum folder
·
A folder for each
change order
·
Supplemental specifications
·
TE-30 Material
Inspection Reports
·
TE-45 Daily
Concrete Reports
·
TE-31 Material
Inspection Reports
·
TE-24 Material
Certification Reports
·
Partnering file
·
Pre-construction
and other Meeting notes
·
C-95 issues
folder
·
Change order
items pending
·
Issue folders
(claims, etc.) / Waste Borrow Agreements
·
Correspondence
from Contractor
·
Correspondence
from others
·
ODOT
correspondence to Contractor
·
ODOT
correspondence to others
·
Delivered
materials
·
CA-EW-5
compaction tests
·
Grade checks
·
Contractor storm
sediment and erosion control checklist
·
Survey notes
·
Utility folders
·
Railroad folders
·
Estimate folder
·
CA-D-3 and CA-D-4
folders
·
C-92 / Payroll /
Labor compliance forms
·
Schedule folder
·
MOT review folder
·
Value Engineering
Proposals (VECP) File
General Guidelines for
Documentation
Documentation consists of the
written project records necessary to verify performance of the work item.
Documentation is continuous and must be coordinated with the construction
progress.
To meet the requirements for
payment on Federal-Aid and state projects, the following two conditions must be
met:
Procedures for meeting these
conditions are contained in the referenced construction procedures handbooks
and manuals.
As a rule, the Inspector's
reports or related forms should contain information in sufficient detail to
verify that construction is in substantial conformity with the plans and
specifications.
Documentation shall be
validated in every case with the following seven identifiers:
·
Date
·
Project Number
·
Item Number
·
Reference Number
·
Subject
·
Location
·
Signature or
Initials
As items of work are
completed by the Contractor, project inspectors are required to document the
work as previously discussed. Accepted
quantities will be turned in for payment on the Daily Diary under the area
entitled, "Pay Items," listing the reference number, extra work
number if applicable, participation code, description of work, location, and
quantity or lump sum amount. It must be
emphasized that all items turned in for payment must be supported by
documentation kept in the project files under the appropriate contract reference
number.
This manual describes in
detail the requirements of documenting substantial conformity with contract
requirements. Substantiation includes
the usage of specific forms and documentation of measurements and testing
methods. Progressive project inspection and control records must be related to
items being documented so that they readily substantiate and verify that
documented quantities are placed in accordance with contract requirements. These records are to be placed in the project
file each day.
For the purpose of
documentation, project records must be identified with the seven identifiers
listed above. These records must also
show location data, include computations, and be filed in the project records. Records will be on designated forms
identified within this manual.
Individual measurements will
be made with sufficient accuracy and frequency to avoid unrealistic
accumulations. The summary of final pay quantity is rounded off to the units
shown in the proposal. Include the seven
identifiers listed above with a documentation record of each pay item on a
designated form and file in the project records.
Photos, video, sketches, and
drawings may be used wherever they can aid in clarifying locations or
dimensions.
The seven identifiers listed
above must be included on tickets and tapes if no other documentation forms are
used for the item. If separate forms are used (e.g., asphalt tickets used along
with the Bituminous Concrete Inspection Form), initials should be on the
tickets, and the seven identifiers are required on the form.
The printed weight ticket
from automatic or semiautomatic scale operations is acceptable
documentation. Should material be
delivered to the project without a verifiable weight ticket from the source,
due to infrequent use or oversight, the material may be re-weighed or weight
may be checked by comparison to measured volume in place. Action taken will be recorded on the ticket.
Items paid for on a unit,
lump sum, length, area, volume, or miscellaneous basis, either in place or from
verified plan dimensions, will be validated by the initials of the person
making or verifying measurements, calculations, and observations.
Where partial loads are
involved, quantities will be determined from measurements in the vehicle or
calibrated tanks.
All printed project records
must be maintained in the field office in a file by project number. Tickets and other bulky items may be filed
separate provided they are referenced to the associated contract reference
number. Upon completion of the project,
the entire file will be moved to the District Office and maintained for future
reference. All final quantity
documentation will be delivered to the District Office in a timely manner at
the discretion of the District Documentation Coordinator after completion of
the physical work. District project
files will be maintained in a single, well-organized location for the time
period outlined in the ODOT record retention schedule.
The following forms are
called out in this manual. The District
may modify the forms ONLY if the modified forms contain all of the information
listed on the standard forms. Forms may
be found online at the following website:
http://www.dot.state.oh.us/Divisions/ConstructionMgt/Admin/Pages/InspectionForms.aspx
Forms are also available in the Construction Inspection Forms Booklet.
|
CA-C-1 |
Concrete
Control Test Form |
|
CA-C-2 |
QC/QA
Concrete QCP Checklist |
|
TE-45 |
Concrete
Inspectors Daily Report |
|
CA-D-1A |
Field
Calculation and Measurement |
|
CA-D-1B |
Field
Calculation and Measurement |
|
CA-D-2 |
Field
Calculation and Measurement |
|
CA-D-3SM |
ODOT Inspectors Daily Report |
|
CA-D-4SM |
ODOT P.E. / P.S. Daily Report |
|
CA-D-5 |
Daily
Account of Force Account Work |
|
CA-D-6 |
Pavement
Repair and Sawing Measurement |
|
CA-D-7 |
Short Term
Work Zone Review |
|
CA-D-8 |
Worksite
Traffic Supervisor (WTS) Daily Inspection Report-
1/2, 2/2 |
|
CA-D-10 |
Contractor
Signature Authorization |
|
CA-D-11 |
Contractor
Payment Certification |
|
CA-D-12 |
Contractor
Final Certification |
|
CA-EC-1 |
Weekly and
Rain Event Checklist |
|
CA-EC-2 |
Seeding Calculations |
|
CA-EW-1 |
Earthwork
Quantity Calculations |
|
CA-EW-2 |
Proof
Rolling Documentation |
|
CA-EW-3 |
Log of Test
Pit Investigation |
|
CA-EW-4 |
Moisture
Density Curve Calculation |
|
CA-EW-5 |
Nuclear
Gauge Compaction Form |
|
CA-EW-6 |
Nuclear Gauge
Compaction with Aggregate Correction |
|
CA-EW-7 |
Non-Stabilized
Drainage Base Compaction |
|
CA-EW-8 |
Authorization
of Undercuts |
|
|
Typical
Moisture Density Curves - Set C - May, 1949 |
|
|
Zero Air
Voids Graph |
|
CA-EW-9 |
Rock Blasting
Inspection Form |
|
CA-EW-10 |
Rock
Blasting Drilling Log |
|
CA-EW-11 |
Blast Site
Security Plan |
|
CA-EW-12 |
Daily
Earthwork Inspection Form |
|
CA-FP-1 |
Warranty
Asphalt Checklist |
|
CA-FP-2 |
Random Selection
of Asphalt Field Samples (448, 403) |
|
CA-FP-3 |
Summary of
Asphalt Concrete Quantities |
|
CA-FP-4 |
Asphalt
Concrete Inspection |
|
CA-FP-5 |
Roller
Capacity and Placement Rate Inspection Form |
|
CA-FP-6 |
Calculation
of Liquid Asphalt Materials |
|
CA-L-1 |
Report of
Electrical Tests |
|
CA-L-2 |
Report of
Electrical Tests |
|
CA-L-3 |
Report of
Electrical Tests |
|
CA-L-4 |
Report on
Sign Lighting |
|
CA-L-5 |
Report on
High Voltage Direct Current Tests |
|
CA-P-1 |
Pipe Construction
Inspection Form - 1/2, 2/2 |
|
CA-P-2 |
Underdrain Construction Inspection Form 1/2, 2/2 |
|
CA-P-3 |
Drainage
Structure Inspection Form 1/2, 2/2 |
|
CA-S-1 |
Inspection
Record for Drilled Shafts |
|
CA-S-2 |
Paint
Thickness, QCP #5, #8, #10 |
|
CA-S-3 |
(BR-2-75)
Pile Driving Log |
|
CA-S-4 |
High
Performance Concrete Pre-Pour Meeting
- 1/3, 2/3, 3/3 |
|
CA-S-5 |
Micro-Silica
Overlay Pre-Pour Meeting - 1/3, 2/3, 3/3 |
|
CA-S-6 |
Class S or
QC-2 Concrete Pre-Pour Meeting - 1/2,
2/2 |
|
CA-S-7 |
QCS Inspection
Documentation |
|
CA-S-8 |
(BR-5)
Piling Measurement Record |
|
CA-S-11 |
QCS &
Visual Standards Information |
|
CA-S-12 |
Bridge
Painting Quality Control Points (QCP #1 & #2) |
|
CA-S-13 |
Abrasive
Blasting (QCP#3) |
|
CA-S-14 |
Disposal of
Hazardous / Non-Hazardous Waste for Bridge Painting (QCP#4) |
|
CA-S-15 |
Prime Coat
Application (QCP#5) |
|
CA-S-16 |
Bridge
Painting Grinding Fins, Tears, Slivers and Caulking, (QCP
#6 & #9) |
|
CA-S-17 |
Intermediate
& Finish Coat Application (QCP #8 & #10) |
|
CA-S-18 |
Bridge
Painting Destructive Test Log (QCP #11) |
|
CA-S-19 |
Bridge
Painting Final Review (QCP #11) |
|
CA-S-20 |
Erection
(Demolition) Procedure Checklist |
|
CA-S-21 |
Sealing of
Concrete Surfaces Checklist |
|
CA-S-22 |
Bridge Deck
Concrete Placement Dry Run Form (Outline) |
|
CA-S-30 |
(D10-S-30)
Reinforcing Steel Verification |
|
CA-S-31 |
(D10-S-31)
Air Tests for Superstructures |
|
CA-S-32 |
(D10-S-32)
Structure Temperature Record |
|
CA-T-1 |
DLS Report Format - Weight-Based System |
|
CA-T-2 |
DLS Short Report Format - Weight-Based System |
|
CA-T-3 |
DLS Report Format - Stroke Counter System |
|
CA-T-4 |
DLS Short Report Format - Stroke Counter System |
|
CA-T-5 |
DLS Report Format - Flow Meter-Based System |
|
CA-T-6 |
DLS Short Report Format - Flow Meter-Based System |
|
CA-T-7 |
DLS Report Format - Thermoplastic System |
|
CA-T-8 |
DLS Short Report Format - Thermoplastic System |
|
C-85 Letter |
Sample
Final Estimate Letter |
|
C-85 Final |
Report of
Final Inspection |
|
C-85 LPA |
Report of
LPA Final Inspection |
|
C-85
Partial |
Report of
Partial Inspection |
|
C-85 Punchlist |
Report of
Punch List Completion |
|
TE-31 |
Sample Data |
|
TE-217 |
Bituminous
Concrete Density Determination – 446 Cores |
|
|
Daily Concrete
Pavement Documentation Form |