STATE OF OHIO

DEPARTMENT OF

TRANSPORTATION

COLUMBUS, OHIO

CONSTRUCTION AND MATERIAL

SPECIFICATIONS

JULY 19, 2013

An Equal Opportunity Employer

     Copies of the Construction and Material Specifications may be purchased by contacting:

        Ohio Department of Transportation

        Office of Contracts

        P.O. Box 899

        Columbus, Ohio 43216-0899

        Telephone (614) 466-3778, 466-3200

Table of Contents

100  General Provisions  1

101  Definitions And Terms. 1

102  Bidding Requirements And Conditions. 11

103  Award And Execution Of Contract 16

104  Scope Of Work. 17

105  Control Of Work. 22

106  Control Of Material 30

107  Legal Relations And Responsibility To Public. 33

108  Prosecution And Progress. 46

109  Acceptance, Measurement, And Payment 61

200  Earthwork  86

Item 201  Clearing And Grubbing. 86

Item 202  Removal Of Structures And Obstructions. 89

Item 203  Roadway Excavation And Embankment 95

Item 204  Subgrade Compaction And Proof Rolling. 107

Item 205  Chemically Stabilized Embankment 112

Item 206  Chemically Stabilized Subgrade. 114

Item 208  Rock Blasting. 119

Item 209  Linear Grading. 133

250 Pavement Repairs  136

Item 251  Partial Depth Pavement Repair 136

Item 252  Full Depth Rigid Pavement Removal And Flexible Replacement 137

Item 253  Pavement Repair 138

Item 254  Pavement Planing. 140

Item 255  Full Depth Pavement Removal And Rigid Replacement 141

Item 256  Bonded Patching Of Portland Cement Concrete Pavement 146

Item 257  Diamond Grinding Portland Cement Concrete Pavement 149

Item 258  Dowel Bar Retrofit 151

300 Bases  155

Item 301  Asphalt Concrete Base. 155

Item 302  Asphalt Concrete Base. 156

Item 304  Aggregate Base. 158

Item 305  Portland Cement Concrete Base. 161

Item 320  Rubblize And Roll 162

Item 321  Cracking And Seating Existing Non- Reinforced Concrete Pavement 164

400  Flexible Pavement 167

Item 401  Asphalt Concrete Pavements—General 167

Item 402  Asphalt Concrete Mixing Plants. 183

Item 403  Asphalt Concrete Quality Control And Acceptance. 185

Item 407  Tack Coat 197

Item 408  Prime Coat 199

Item 409  Sawing And Sealing Asphalt Concrete Pavement Joints. 200

Item 410  Traffic Compacted Surface. 202

Item 411  Stabilized Crushed Aggregate. 204

Item 421  Microsurfacing. 205

Item 422  Chip Seal 212

Item 423  Crack Sealing, Hot Applied. 220

Item 424  Fine Graded Polymer Asphalt Concrete. 223

Item 441  Contractor Mix Design And Quality Control—General 225

Item 442  Superpave Asphalt Concrete. 238

Item 443  Stone Matrix Asphalt Concrete. 241

Item 446  Asphalt Concrete. 246

Item 448  Asphalt Concrete. 250

450  Rigid Pavement 252

Item 451  Reinforced Portland Cement Concrete Pavement 252

Item 452  Non-Reinforced Portland Cement Concrete Pavement 271

Item 455   Quality Control Plan, Testing And Assurance For Qc/Qa Concrete  272

Item 499  Concrete—General 283

500  Structures  292

Item 501  Structures—General 292

Item 502  Structures For Maintaining Traffic. 299

Item 503  Excavation For Structures. 300

Item 504  Sheet Piling Left In Place. 305

Item 505  Pile Driving Equipment Mobilization. 306

Item 506  Static Load Test 306

Item 507  Bearing Piles. 309

Item 508  Falsework And Forms. 314

Item 509  Reinforcing Steel 317

Item 510  Dowel Holes. 321

Item 511  Concrete For Structures. 323

Item 512  Treating Concrete. 344

Item 513  Structural Steel Members. 359

Item 514 Painting Of Structural Steel 378

Item 515  Prestressed Concrete Bridge Members. 402

Item 516  Expansion And Contraction Joints Joint Sealers And Bearing Devices  413

Item 517  Railings. 417

Item 518  Drainage Of Structures. 419

Item 519  Patching Concrete Structures. 421

Item 520  Pneumatically Placed Mortar 423

Item 522  Structural Plate Corrugated Metal Structures On Footings. 428

Item 523  Dynamic Load Test 429

Item 524  Drilled Shafts. 430

Item 526 Approach Slabs. 439

600 Incidentals  441

Item 601 Slope And Channel Protection. 441

Item 602  Masonry. 446

Item 605  Underdrains. 451

Item 606  Guardrail 455

Item 607  Fence. 458

Item 608  Walks, Curb Ramps, And Steps. 460

Item 609  Curbing, Concrete Medians, And Traffic Islands. 463

Item 610  Cellular Retaining Walls. 467

Item 611  Pipe Culverts, Sewers, Drains, And Drainage Structures. 471

Item 613  Low Strength Mortar Backfill 494

Item 614  Maintaining Traffic. 497

Item 615  Roads And Pavements For Maintaining Traffic. 515

Item 616  Dust Control 517

Item 617  Reconditioning Shoulders. 518

Item 618  Rumble Strips On Shoulders. 520

Item 619  Field Office. 521

Item 620  Delineators. 524

Item 621  Raised Pavement Markers (Rpm) 525

Item 622  Concrete Barrier 529

Item 623  Construction Layout Stakes  And Survey Monuments. 531

Item 624  Mobilization. 535

Item 625 Highway Lighting. 537

Item 626  Barrier Reflectors. 551

Item 630  Traffic Signs And Sign Supports. 553

Item 631  Sign Lighting And Electrical Signs. 565

Item 632  Traffic Signal Equipment 570

Item 633  Traffic Signal Controllers. 584

Item 638  Water Mains And Service Branches. 594

640  Pavement Marking  604

Item 641  Pavement Marking—General 604

Item 642  Traffic Paint 610

Item 643  Polyester Pavement Marking. 613

Item 644  Thermoplastic Pavement Marking. 615

Item 645  Preformed Pavement Marking. 619

Item 646  Epoxy Pavement Marking. 621

Item 647  Heat-Fused Preformed Thermoplastic Pavement Marking. 626

650  Roadsides  632

Item 651  Topsoil Stockpiled. 632

Item 652  Placing Stockpiled Topsoil 632

Item 653  Topsoil Furnished And Placed. 633

Item 654  Renovating Existing Soil 633

Item 656  Roadside Cleanup. 634

Item 657  Riprap For Tree Protection. 635

Item 658  Tree Root Aeration. 637

Item 659  Seeding And Mulching. 638

Item 660  Sodding. 651

Item 661 Planting Trees, Shrubs, Perennials And Vines. 654

Item 662  Landscape Watering. 658

Item 666  Pruning Existing Trees. 659

Item 670  Erosion Protection. 660

Item 671  Erosion Control Mats. 661

700 Material Details  665

701  Cementitious Materials. 695

702  Asphalt Material 696

703  Aggregate. 706

704  Masonry Units. 727

705  Concrete Incidentals. 727

706  Concrete And Clay Pipe. 738

707  Steel, Aluminum, And Plastic Pipe. 768

708  Paint 784

709  Reinforcing Steel 788

710  Fence And Guardrail 791

711  Structural Steel And Structure Incidentals. 799

712  Miscellaneous. 807

720  Delineator Materials. 815

721  Raised Pavement Marker Materials. 816

725 Highway Lighting Materials. 817

726 Barrier Reflector Materials. 835

730  Traffic Sign And Support Material 836

731  Sign Lighting And Electrical Signs Material 840

732  Traffic Signal Material 842

733  Traffic Signal Controller Material 858

740  Pavement Marking Material 892

748  Water Main And Service Branch Material 902

Subject Index  906

100  GENERAL PROVISIONS

101  DEFINITIONS AND TERMS

101.01  General.  These Construction and Material Specifications are written to the Bidder before award of the Contract and to the Contractor after award of the Contract.  The sentences that direct the Contractor to perform Work are written as commands.  For example, a requirement to provide cold-weather protection would be expressed as, “Provide cold-weather protection for concrete,” rather than “The Contractor shall provide cold-weather protection for concrete.”  In the imperative mood, the subject “the Bidder” or “the Contractor” is understood.

All requirements to be performed by others have been written in the active voice.  Sentences written in the active voice identify the party responsible for performing the action.  For example, “The Engineer will determine the density of the compacted material.”  Certain requirements of the Contractor may also be written in the active voice, rather than the active voice and imperative mood, if the sentence includes requirements for others in addition to the Contractor.  For example, “After the Contractor provides initial written notice, the Engineer will revise the Contract as specified in 104.02.”

Sentences that define terms, describe a product or desired result, or describe a condition that may exist are written in indicative mood.  These types of sentences use verbs requiring no action.  For example, “The characteristics of the soils actually encountered in the subgrade may affect the quality of the cement and depth of treatment necessary.”

101.02  Abbreviations.  The following abbreviations, when used in the Contract Documents, represent the full text shown.

AAN               American Association of Nurserymen

AASHTO       American Association of State Highway and Transportation Officials

AC                  Asphalt Cement (pavement), Alternating Current (traffic)

ACBF             Air Cooled Blast Furnace slag (aggregate)

ACI                American Concrete Institute

ACIA             Asynchronous Communications Interface Adapter (traffic controller)

ADT               Average Daily Traffic

ADTT             Average Daily Truck Traffic

AIC                Amps Interrupting Capacity

AISC              American Institute of Steel Construction

AISI               American Iron and Steel Institute

ANFO             Ammonium Nitrate Fuel Oil

ANSI              American National Standards Institute

AOS                Apparent Opening Size (fabric)

AREA            American Railway Engineering Association

ASCE             American Society of Civil Engineers

ASME            American Society of Mechanical Engineers

ASTM            American Society of Testing and Materials

ATFDB          Asphalt treated Free Draining Base

AWG              American Wire Gauge

AWPA            American Wood Preservers' Association

AWS               American Welding Society

AWWA          American Water Works Association

BBR               Bending Beam Rheometer (asphalt test)

BMP               Best Management Practice (erosion)

BOF                Basic Oxygen Furnace (aggregate)

BSG                Bulk Specific Gravity

BTEX             Benzene, toluene, ethyl benzene, and xylene (a soil test)

BUSTR          Bureau of Underground Storage Tank Regulations (Division of Fire Marshal)

C&MS           Construction and Material Specifications

CAPWAP      Case Pile Wave Analysis Program

CBAE            Cut Back Asphalt Emulsion

CCRL            Cement and Concrete Reference Laboratory

CCS                Crushed Carbonate Stone

CECI              Contactors Erosion Control Inspector

CFR                Code of Federal Regulations

CIE                 Commission Internationale d'Eclairage (illumination)

CPESC           Certified Professional in Erosion and Sediment Control

CRS                Cationic Rapid Set (asphalt emulsion)

CRSI              Concrete Reinforcing Steel Institute

CSS                Cationic Slow Set (asphalt emulsion)

CVN               Charpy V-notch (steel test)

CWT              Hundred Weight (100 lbs)

DC                  Direct Current

DCA               / District Construction Administrator

DDD               District Deputy Director

DET                District Engineer of Tests

DGE               District Geotechnical Engineer

DLS                Data Logging System (traffic markings)

DNR               Department of Natural Resources

DRC               Dry Rodded Condition (asphalt test)

DSR                Dynamic Shear Rheometer (asphalt test)

DZA               Deficient Zone Average (concrete test)

EAF                Electric Arc Furnace

EDA               Earth Disturbing Activity

EEI                 Edison Electric Institute

EIA                 Electronic Industries Alliance

EPA                Environmental Protection Agency

EQS                Exceptional Quality Solids (compost)

FAA                Fine Aggregate Angularity (asphalt aggregate)

FCM               Fracture Critical Member (steel test)

FEMA            Federal Emergency Management Agency

FHWA           Federal Highway Administration, Department of Transportation

FRP                Fiber Reinforced Polymer

FSS                 Federal Specifications and Standards, General Services Administration

GGBFS          Ground Granulated Blast Furnace Slag

GS                   Granulated Slag

HDPE             High Density Polyethylene

HFRS             High Float Rapid Setting (emulsion)

HMWM         High Molecular Weight Methacrylate

ICEA              Insulated Cable Engineers Association

IEEE              Institute of Electrical and Electronic Engineers

IES                 Illuminating Engineering Society

IMSA             International Municipal Signal Association

IPCEA           Insulated Power Cable Engineers Association

IPS                  International Pipe Standard

ISSA               International Slurry Seal Association

ITE                 Institute of Transportation Engineers

IZEU              Inorganic Zinc Epoxy Urethane

JMF                Job Mix Formula

LED                Light Emitting Diode

LWT               Loaded Wheel Test (asphalt test)

MBF               Thousand Board Feet (wood)

MC                 Medium Cure (asphalt emulsion)

MCB              Microchannel Bus (traffic controller)

MMK             Blaw-Knox Materials Management Kit

MOV              Metal Oxide Varistor (traffic controller)

MPI                Magnetic Particle Inspection (steel test)

MSDS            Material Safety Data Sheets

MSG               Maximum Specific Gravity (asphalt)

MTD              Maximum Theoretical Density (asphalt)

NACE            National Association of Corrosion Engineers

NCHRP         National Cooperative Highway Research Program

NEMA           National Electrical Manufacturers Association

NHI                National Highway Institute

NIST              National Institute of Standards and Technology

NOI                Notice of Intent

NPDES           National Pollutant Discharge Elimination System

OAC               Ohio Administrative Code

ODOT            Ohio Department of Transportation

OEPA             Ohio Environmental Protection Agency

OH                  Open Hearth (aggregate)

OHWM          Ordinary High Water Mark

OMM             Office of Materials Management (the Lab)

OMUTCD     Ohio Manual of Uniform Traffic Control Devices

ORC               Ohio Revised Code

ORDC            Ohio Rail Development Commission

OSHA            Occupational Safety and Health Administration

OTE                Office of Traffic Engineering

OWPCA         Ohio Water Pollution Control Act

OZEU             Organic Zinc Epoxy Urethane

PAT                Project Average Thickness (concrete test)

PAV                Pressure Aging Vessel (asphalt test)

PB                   Polybutylene (conduit)

PCC                Portland Cement Concrete

PCS                Petroleum Contaminated Soil

PDA                Pile Dynamic Analysis (steel piling)

PE                   Polyethylene (conduit)

PG                   Performance Grade (asphalt test)

pH                  Potential of Hydrogen

PLS                 Pure Live Seed

PVC                Polyvinyl chloride

QA                  Quality Assurance

QC                  Quality Control

QCFS             Quality Control Fabricator Specialist (structures)

QCP                Quality Control Program, or Quality Control Points (steel test)

QCQC            Quality Control Qualification Committee

QPL                Qualified Products List

RACP             Reclaimed Asphalt Concrete Pavement

RAP                Recycled Asphalt Pavement

RC                  Rapid Cure (asphalt emulsion)

REA               Rural Electrification Administration

RFI                 Radio Frequency Interference (traffic controller)

RH                  Relative Humidity

RMS               Root Mean Square (traffic controller)

RPCC             Recycled Portland Cement Concrete

RPM               Raised Pavement Marker (traffic)

RS                   Rapid Set (asphalt emulsion)

RTFO             Rolling Thin-Film Oven (asphalt test)

RUS                Rural Utilities Service

SAE                Society of Automotive Engineers

SBA                Styrene Butadiene Amene

SBR                Styrene Butadiene Rubber

SBS                Styrene Butadiene Styrene

SCD                Standard Construction Drawing

SF                   Standard Fabricated members (structures)

SI                    International System of Units (Metric)

SMA               Stone Matrix Asphalt

SPD                Surge Protection Device (traffic controller)

SPST              Single Pole / Single Throw (traffic controller)

SS                   Slow Set (asphalt emulsion)

SSD                Saturated Surface Dry (aggregate)

SSPC              Society for Protective Coatings

SWPPP           Storm Water Pollution Prevention Plan

TCE                Trichloroethylene

TMPTA         Tri-methyolpropane Tri-acrylate (paint)

TNP                Total Neutralizing Power

TODS             Tourist-Oriented Directional Signs

TSEC             Temporary Sediment and Erosion Control

TSR                Tensile Strength Ratio (asphalt test)

UF                   Unique Fabricated members (structures)

UL                  Underwriters' Laboratories, Inc

USACE          United States Army Corps of Engineers

USC                United States Code

VA                  Verification Acceptance

VAC               Volts Alternating Current

VCA               Volume of Coarse Aggregate (asphalt test)

VECP             Value Engineering Change Proposal

VMA              Voids in the Mineral Aggregate 

VME              VersaModule Eurocard (traffic controller)

WDT              Watchdog Timer

WEAP            Wave Equation Analysis (steel piling)

WPS               Welding Procedure Specification (steel test)

WZRPM        Work Zone Raised Pavement Marker (traffic)

XCU               Explosion, Collapse and Underground

101.03  Definitions.  The following terms or pronouns, when used in the Contract Documents, are defined as follows:

Advertisement.  The public announcement, as required by law, inviting Bids for Work to be performed or materials to be furnished.

Award.  The written acceptance by the Director of a Bid.

Bid.  The offer of a Bidder, on the prescribed form properly signed and guaranteed, to perform the Work and to furnish the labor and materials at the prices quoted.

Bid Documents.  The Bid Documents include the Invitation for Bids, Addenda, Proposal, Expedite file, contract form and required bonds, Specifications, Supplemental Specifications, Special Provisions, general and detailed plans, Plan notes, standard construction drawings identified in the Plans, notice to contractor, and any other document designated by the Department as a Bid Document, all of which constitute one instrument.

Bidder.  An individual, firm, or corporation submitting a Bid for the advertised Work, acting directly or through the duly authorized representative, and qualified as provided in ORC 5525.02 to 5525.09.

Bridge.  A structure, including supports, erected over a depression or an obstruction, such as water, a highway, or a railway, and having a track or passageway for carrying traffic or other moving loads and having a length measured along the center of roadway of 10 feet (3.048 m) or more between undercopings of abutments or extreme limits of openings for multiple boxes.

A.      Length.  The length of a bridge structure is the over-all length measured along the centerline of the roadway surface.

B.      Roadway Width.  The clear width measured at right angles to the longitudinal centerline of the bridge between the bottom of curbs or guard timbers or, in the case of multiple heights of curbs, between the bottoms of the lower risers.  For curb widths of 1 foot (0.3 m) or less, the roadway width is measured between parapets or railings.

Calendar Day or Day.  Every day shown on the calendar.

Certified Test Data.  A test report from a manufacturer’s or an independent laboratory approved by the Director listing actual test results of samples tested for compliance with specified Department requirements.  The Department will accept certified test data from manufacturers’ laboratories if their products have been used satisfactorily on prior Department contracts and their test data has been confirmed.  Include a statement that the test data furnished is representative of the material furnished to a Department project or to a supplier.  The report is identified by number or date and identifies the Department project or supplier to which the material is shipped.  Submit reports signed by a person having legal authority to act for the manufacturer or independent laboratory.

Change Order.  A written order issued by the Director to the Contractor, covering changes to the terms and conditions, plans and/or quantities, within or beyond the scope of the Contract and establishing the basis of payment and time adjustments for the work affected by the changes.

Claims.  Disputes that are not settled through Steps 1 and 2 of the Dispute Resolution and Administrative Claim Process. The Dispute becomes a Claim when the Contractor submits a Notice of Intent to File a Claim.

Completion Date.  The date, as shown in the Contract Documents, on which the Work contemplated shall be completed.

Construction Limits. These limits must encompass all Work. This includes removals, room for construction equipment to complete work, site access, etc.

Contract.  The written agreement between the Department and the Contractor setting forth the obligations of the parties, including, but not limited to, the performance of the Work and the basis of payment.

Contract Bond.  The approved forms of security, executed by the Contractor and its Sureties, guaranteeing complete execution of the Work as required by the Contract Documents and the payment of all legal debts pertaining to the construction of the Project which security shall comply with and be subject to ORC 5525.16 and 5525.13, and related provisions.

Contract Documents.  The Contract Documents include the Invitation for Bids, Addenda, Proposal, contract form and required bonds, Specifications, Supplemental Specifications, Special Provisions, general and detailed plans, Plan notes, standard construction drawings identified in the Plans, notice to contractor, Change Orders, Supplemental Agreements, Extra Work Contracts, and any other document designated by the Department as a Contract Document, all of which constitute one instrument.

Contract Item (Pay Item).  A specifically described unit of Work for which a price is provided in the Contract.

Contract Price.  The amount of compensation bid by the Contractor for a Contract Item in the Proposal or the amount of compensation established for a Contract Item added or modified pursuant to the Contract Documents.

Contract Time.  The number of workdays or calendar days, including authorized adjustments, allowed for completion of the Project.  When a specified Completion Date is shown in the Contract Documents instead of the number of workdays or calendar days, completion of the Project shall occur on or before that date.  Specified Completion Date and Calendar Day Contracts shall be completed on or before the day indicated even when that date is a Saturday, Sunday, or holiday.

Contractor.  The individual, firm, or corporation contracting with the Department for performance of prescribed Work, acting directly or through a duly authorized representative and qualified under the provisions of ORC 5525.02 to 5525.09 inclusive, and any amendments thereto.

County.  The designated county in which the Work specified is to be done.

Culvert.  Any structure not classified as a Bridge that provides an opening under the roadway.

Department.  The Department of Transportation, State of Ohio.

Director.  Administrative head of the Department appointed by the Governor.

Disputes. Disagreements, matters in question and differences of opinion between the Department’s personnel and the Contractor.

Engineer.  Duly authorized agent of the Department acting within the scope of its authority for purposes of engineering and administration of the Contract.

Equipment.  All machinery and equipment, together with the necessary supplies for upkeep and maintenance, and also tools and apparatus necessary for the proper construction and acceptable completion of the Work.

Extra Work.  An item of Work not provided for in the Contract as awarded but found essential to the satisfactory completion of the Contract within its intended scope.

Extra Work Contract.  A Contract concerning the performance of Work or furnishing of materials involving Extra Work.  Such Extra Work may be performed at agreed prices or on a force account basis as provided in ORC 5525.14.

Fabricator.  The individual, firm, or corporation that fabricates structural metals or prestressed concrete members as an agent of the Contractor.

Final Inspector.  An Engineer appointed by the DDD who inspects the completed Work and accepts it if it complies with the Contract Documents.

Inspector.  The Engineer’s authorized representative assigned to make detailed inspections of Contract performance.

Invitation for Bids.  The invitation for Proposals for all Work on which Bids are required.  Such Proposal will indicate with reasonable accuracy the quantity and location of the Work to be done or the character and quality of the material to be furnished and the time and place of the opening of Proposals.

Laboratory.  The testing laboratories of the Department, including the Office of Materials Management located at 1600 West Broad Street, Columbus, Ohio, and various District testing facilities.

Materials.  Any materials or products specified for use in the construction of the Project and its appurtenances.

Partnering. A collaborative process for project cooperation and communication meant to achieve effective and efficient contract performance and completion of the Project within budget, on schedule, safely and with requisite quality in accordance with the contract.

Plans.  The drawings, standard construction drawings and supplemental drawings provided by the Department that show the location, character, dimensions, and details of the Work.

Prebid Question. A written inquiry submitted by a prospective bidder.

Profile Grade.  The trace of a vertical plane intersecting the top surface of the proposed wearing surface, usually along the longitudinal centerline of the roadbed.  Profile grade means either elevation or gradient of such trace according to the context.

Project Limits. Project limits are points on the mainline centerline of construction where the proposed improvement, as described in the project description on the Title Sheet (excluding incidental construction), begins and ends

Project Right-of-Way.  That portion of the Right-of-Way between the beginning and end of the Project.

Project.  The specific section of the highway together with all appurtenances and Work to be performed thereon under the Contract.

Proposal.  The approved form on which the Department requires Bids to be prepared and submitted for the Work.

Proposal Guaranty.  The security furnished with a Bid to guarantee that the Bidder will enter into the Contract if its Bid is accepted.

Questionnaire.  The specified forms on which the Contractor shall furnish required information as to its ability to perform and finance the Work required under ORC 5525.01.

Reasonably Close Conformity.  Reasonably close conformity means compliance with reasonable and customary manufacturing and construction tolerances where working tolerances are not specified.  Where working tolerances are specified, reasonably close conformity means compliance with such working tolerances.  Without detracting from the complete and absolute discretion of the Engineer to insist upon such tolerances as establishing reasonably close conformity, the Engineer may accept variations beyond such tolerances as reasonably close conformity where they will not materially affect the value or utility of the Work and the interests of the Department.

Registered Engineer.  An engineer registered with the Ohio State Board of Registration for Professional Engineers and  Surveyors to practice professional engineering in the State of Ohio

Registered Surveyor.  A surveyor registered with the Ohio State Board of Registration for Professional Engineers and Surveyors to practice professional surveying in the State of Ohio.

Right-of-Way.  A general term denoting land, property, or interest therein, usually in a strip, acquired for or devoted to a highway.

Road.  A general term denoting a public way for purposes of vehicular travel, including the entire area within the Right-of-Way, as defined in ORC 5501.01.

Roadbed.  The graded portion of a highway within top and side slopes, prepared as a foundation for the pavement structure and shoulder.

Roadside.  The areas between the outside edges of the shoulders and the Right-of-Way boundaries.  Unpaved median areas between inside shoulders of divided highways and infield areas of interchanges are included.

Roadside Development.  Those items necessary to the highway that provide for the preservation of landscape materials and features; the rehabilitation and protection against erosion of all areas disturbed by construction through seeding, sodding, mulching, and the placing of other ground covers; such suitable planting; and other improvements as may increase the effectiveness and enhance the appearance of the highway.

Roadway.  The portion of a highway within limits of construction.

Shop Drawings. The drawings provided by the Contractor or Supplier that describe any portion of the Work that will remain in place permanently.

Shoulder.  The portion of the roadway contiguous to the traveled way for accommodation of stopped vehicles, for emergency use, and for lateral support of base and surface courses.

Sidewalk.  That portion of the roadway primarily constructed for the use of pedestrians.

Signatures on Contract Documents.  All signatures on Contract Documents must meet the requirements of 102.06.

Special Provisions.  Additions and revisions to the standard and Supplemental Specifications covering conditions peculiar to an individual Project.

Specifications.  The directions, provisions, and requirements contained herein as supplemented by the Supplemental Specifications and Special Provisions.

State.  The State of Ohio acting through its authorized representative.

Street.  A general term denoting a public way for purpose of vehicular travel, including the entire area within the Right-of-Way.

Structures.  Bridges, culverts, catch basins, drop inlets, retaining walls, cribbing, manholes, endwalls, buildings, sewers, service pipes, underdrains, foundation drains, and other features that may be encountered in the Work and not otherwise classed herein.

Subcontractor.  An individual, firm, or corporation to whom the Contractor sublets part of the Contract to be performed on the job site, who prior to such undertaking receives the written consent of the Director, and who is qualified under ORC 5525.02 through 5525.09 inclusive.

Subgrade.  The portion of a Roadbed upon which the pavement structure and shoulders are constructed.

Substructure.  All of that part of the structure below the bearings of simple and continuous spans, skewbacks of arches, and tops of footings of rigid frames, together with backwalls and wings.

Superintendent.  The Contractor’s authorized representative in responsible charge of the Work.

Superstructure.  The entire structure except the Substructure.

Supplement.  A list of requirements for fabrication plants, methods of test, or other miscellaneous requirements that are maintained on file in the Office of the Director.

Supplemental Agreement.  A written agreement executed by the Contractor and by the Director covering necessary alterations.

Supplemental Specifications.  Detailed specifications supplemental to or superseding these Specifications.

Surety.  The corporation, partnership, or individual, other than the Contractor, executing a bond furnished by the Contractor.

Titles (or Headings).  The titles or headings of the sections and subsections herein are intended for convenience of reference and shall not be considered as having any bearing on their interpretation.

Waters of the United States.  Waters that are under the jurisdiction of the Corps of Engineers under the Clean Water Act as defined by 33 CFR Ch. II Part 328, which as applied to Ohio means: the Ohio River and Lake Erie and any other river, stream, creek, lake, pond, or wetland that drains directly or indirectly into the Ohio River or Lake Erie.

Work.  All labor, materials, equipment, tools, transportation, supplies, and other incidentals and all tasks that comprise the project or any portion thereof, as described by the Contract Documents.

Work Limits. Work Limits are the extreme limits of the contractor’s responsibility on a project, including all temporary and incidental construction, with the exception of work zone traffic control devices required for maintenance of traffic.

Workday.  A calendar day that the Contractor normally works.

Working Drawings.  Stress sheets, shop drawings, erection plans, falsework plans, installation plans, certified drawings, frame work plans, cofferdam plans, bending diagrams for reinforcing steel, or any other supplementary plans or similar data that the Contractor is required to submit.

101.04  Interpretations.  In order to avoid cumbersome and confusing repetition of expressions in these Specifications, it is provided that whenever anything is, or is to be, done, if, as, or, when, or where “contemplated, required, determined, directed, specified, authorized, ordered, given, designated, indicated, considered necessary, deemed necessary, permitted, reserved, suspended, established, approval, approved, disapproved, acceptable, unacceptable, suitable, accepted, satisfactory, unsatisfactory, sufficient, insufficient, rejected, or condemned,” it shall be understood as if the expression were followed by the words “by the Engineer” or “to the Engineer.”

102  BIDDING REQUIREMENTS AND CONDITIONS

102.01  Prequalification of Bidders.  A Bidder must be prequalified by the Department according to ORC Chapter 5525 and the rules and regulations governing prequalification in order to submit a Bid.  Upon request, the Department will provide a prequalification application, applicable rules and regulations, and other relevant information.  For prospective Bidders that are not yet prequalified, furnish the Department with a properly completed prequalification application at least 30 days before the date specified for the receipt of Bids.  The prequalification certificate is the Bidder’s license to Bid and perform construction for the Department.

For foreign Contractors, refer to ORC 5525.18 and Ohio Administrative Rule 5501:2-3-07.

102.02  Contents of Bid Documents.  Use the Proposal to prepare and submit Bids for the Work.  Upon request, the Department will provide Bid Documents that include or reference the following:

A.      Location and description of the Project.

B.      Estimate of quantities and description of the Work.

C.      Time to complete the Work.

D.      Amount of the Proposal Guaranty.

E.      Department’s deadline for receiving a completed Bid.

F.      Schedule of contract items.

G.      Standard Specifications, Special Provisions, Supplemental Specifications, and the Plans.

H.     Proposal.

102.03  Issuance of Proposals.

A.      General.  Upon request, the Department will provide applicable rates and other relevant information for obtaining bidding information and submitting a Bid.

B.      Department Will Not Issue.  The Department may refuse to sell or issue Bid Documents to a prospective Bidder for any of the following reasons:

1.      The prospective Bidder owes the Department for previously issued plans.

2.      The prospective Bidder has defaulted on previous contracts.

3.      The prospective Bidder is debarred from bidding on and receiving Department contracts.

4.      The prospective Bidder is currently in the debarment process.

102.04  Interpretation of Quantities in Proposal.  The quantities in the Bid Documents are approximate and the Department uses them for the comparison of Bids only.

The Department will only pay the Contractor for the actual quantities of Work performed and accepted according to the Contract Documents.  The Department may increase, decrease, or omit the scheduled quantities of Work as provided in 109.04 without invalidating the Bid prices.

102.05  Examination of Bid Documents and Project Site  and Submission of Prebid Questions.  Carefully examine the Bid Documents and perform a reasonable site investigation before submitting a Bid.  Submitting a Bid is an affirmative statement that the Bidder has investigated the Project site and is satisfied as to the character, quality, quantities, and the conditions to be encountered in performing the Work.  A reasonable site investigation includes investigating the Project site, borrow sites, hauling routes, and all other locations related to the performance of the Work.

When available, the Department will include in the Contract Documents or provide for the Bidder’s review at the Department’s offices or website, one or more of the following:

A.      Record drawings.

B.      Available information relative to subsurface exploration, borings, soundings, water levels, elevations, or profiles.

C.      The results of other preliminary investigations.

A reasonable site investigation includes a review of these documents. 

Should a question arise at any time during the examination of Bid Documents or investigation of the site the Bidder may seek clarification by submitting a Prebid Question.  Submit all Prebid Questions in writing via the Department’s website.  The Department will post a response on its website to all questions submitted before a deadline of 10:00 am four working days prior to the public opening of Bids.  Responses to Prebid Questions posted on the Department’s website are not  revisions to the Bidding Documents and are not binding. The Department is not obligated to respond to, or otherwise act upon, a Prebid Question submitted after this deadline, but reserves the right to act upon any information received.      

102.06  Preparation of Bids.  Prepare a Bid according to this subsection and the requirements found in the Bid Documents.  Properly complete the Expedite file and submit it using the software specified in the Bid Documents rather than completing it by handwriting, typing, or using unauthorized computer-generated forms.

Provide a unit price for each item listed in the Proposal.  Calculate and place the products for the respective unit prices and quantities in the “Bid Amount” column.  For a lump sum item, place the same price in the “Unit Price” column and in the “Bid Amount” column pertaining to that item.  Indicate the total Bid amount by adding the values entered in the “Bid Amount” column for the listed items.  Submit the Expedite file using the software specified in the Bid Documents.

Properly execute the Proposal by completing the miscellaneous section and attaching  the required signatures  in the space provided in the Expedite file.

ENTITY SUBMITTING PROPOSAL
REQUIRED SIGNATURE

Individual

The individual or a duly authorized agent.

Partnership

A partner or a duly authorized agent.

Joint Venture

A member or a duly authorized agent of at least one of the joint venture firms.

Corporation

An authorized officer or duly authorized agent of the corporation.  Also, show the name of the state chartering the corporation and affix the corporate seal.

Limited Liability Company

A manager, a member, or a duly authorized agent.

102.07  Duty to Notify of Errors in Bid Documents.  Notify the Department of errors and omissions in the Bid Documents.  Make notification by submitting a question in the manner described in 102.05.  The Contractor’s duty to disclose errors and omissions is not only a bidding requirement but is also a legal requirement that cannot be ignored. 

Failure to provide the required notification prior to the opening of bids shall constitute a waiver by the Contractor and does not obligate the Department for any costs based upon any apparent or patent ambiguity arising from insufficient data or obvious errors in the Bid documents.  Knowingly withholding information regarding an error or omission in the Bid Documents, or intentionally misrepresenting an item of Work for financial or competitive gain may result in civil or criminal penalties in excess of the value of the item bid.

102.08  Unbalanced Bidding.  Bid all items correctly and price each quantity as indicated in the Bid Documents.  The Department will reject a Mathematically Unbalanced Bid if the Bid is also Materially Unbalanced.  A Mathematically Unbalanced Bid is a Bid containing lump sum or unit price items that do not include reasonable labor, equipment, and material costs plus a reasonable proportionate share of the Bidder’s overhead costs, other indirect costs, and anticipated profit.  A Materially Unbalanced Bid is when the Department determines that an award to the Bidder submitting a Mathematically Unbalanced Bid will not result in the lowest ultimate cost to the Department.

102.09  Proposal Guaranty.  The Department will reject a Bid submitted without a Proposal Guaranty in the amount designated and payable to the Director.  Submit the required Proposal Guaranty in one of the following forms:

A.      Properly executed project Bid bond submitted on the Department’s form.

B.      Properly executed electronic bid transfer to the Department's account.

C.      Certified check drawn on the account of the Bidder submitting the Bid.

D.      Cashier’s check.

E.      Properly executed electronic project Bid bond submitted using the software specified in the Bid Documents.

When submitting a Bid bond, ensure that the Surety is licensed to do business in the State.

If the Department invites alternate Bids and the Bidder elects to Bid more than one alternate, the Bidder may submit one Proposal Guaranty in the amount required for a single alternate.  The Proposal Guaranty covers each individual Bid.

If the Department invites combined Bids and the Bidder elects to Bid only on one package, then the Bidder must submit only one Proposal Guaranty.  If the Bidder bids on the combined Bid package, the Bidder must submit a Proposal Guaranty in the amount required for the combined Bid.  The combined Proposal Guaranty covers each individual Bid.

102.10  Delivery of Bid.   Unless otherwise indicated in the Proposal, all Bids must be submitted using the electronic Bid submission software specified in the Proposal.  The Department will accept Bids until the time and date designated in the Notice to Bidders.  The Department will return Bids received after the designated time to the Bidders unopened. The Department will return all Bids not prepared and submitted in accordance with the Proposal.

102.11  Withdrawal of Bids.  After Bids are opened, ORC 5525.01 requires that a Bidder identify a mistake in its Bid within 48 hours of the Bid opening.  After Bids are opened the Bidder must provide a written request to withdraw a Bid already filed with the Department.  Any Bidder for whom a request to withdraw its Bid is approved by the Department will not be permitted to participate in any manner in a contract awarded for that project for which the Bid was withdrawn. 

102.12  Combination Proposals.  The Department may elect to issue Bid Documents for projects in combination or separately, so that Bids may be submitted either on the combination or on separate units of the combination.  The Department reserves the right to make awards on combination Bids or separate Bids to the best advantage of the Department.  The Department will not consider combination Bids, other than those it specifically identifies in the Bid Documents.  The Department will write separate Contracts for each individual Project included in the combination.

102.13  Public Opening of Bids.  The Department will publicly open Bids at the time and place indicated in the notice to Contractors.  The Department will announce the total Bid amount for each Bid.

Bidders or their authorized agent and other interested persons are invited to the opening.

The Department may postpone the receipt of Bid time or the opening of Bids time.  If the Department changes the hour or the date of the receipt of Bids or the opening of Bids, it will issue an addendum or public notice to notify prospective Bidders.

102.14  Disqualification of Bidders.  The Department will declare a Bid non-responsive and ineligible for award when any of the following occur:

A.      The Bidder lacks sufficient prequalification work types or dollars to be eligible for award.

B.      The Bidder fails to furnish the required Proposal Guaranty in the proper form and amount.

C.      The Bid contains unauthorized alterations or omissions.

D.      The Bid contains conditions or qualifications not provided for in the Bid Documents.

E.      The Proposal is not prepared as specified.

F.      A single entity, under the same name or different names, or affiliated entities submits more than one Bid for the same Project.

G.      The Bidder fails to submit a unit price for each contract item listed, except for lump sum items where the Bidder may show a price in the “Bid Amount” column for that item.

H.     The Bidder fails to submit a lump sum price where required.

I.       The Bidder fails to submit a complete Expedite file using the software specified in the Proposal.

J.       The Bidder is debarred from submitting Bids.

K.      The Bidder has defaulted, has had a Contract terminated for cause by the Department, has either agreed not to Bid or has had debarment proceedings initiated against the Bidder’s company and/or its key personnel.

L.      The Bidder submits its Bid or Proposal Guaranty on forms other than those provided by the Department.

M.     The Bidder fails to properly complete the supplemental questionnaire section of the Expedite file.

N.      The Bidder submits a Materially Unbalanced Bid as defined by 102.08.

O.      The Bidder fails to acknowledge addenda.

P.      The Department finds evidence of collusion.

Q.      Any other omission, error, or act that, in the judgment of the Department, renders the Bidder’s bid non-responsive.

102.15   Material Guaranty.  Before any Contract is awarded, the Department may require the Bidder to furnish a complete statement of the origin, composition, and manufacture of any or all Materials to be used in the construction of the Work together with samples.  The Department may test the samples as specified in these Specifications to determine their quality and fitness for the Work.

102.16  Certificate of Compliance with Affirmative Action Programs.  Before any Contract is awarded, the Department will require the Bidder to furnish a valid Certificate of Compliance with Affirmative Action Programs, issued by the State EEO Coordinator dated prior to the date fixed for the opening of bids.

102.17  Drug-Free Safety Program.  During the life of this project, the Contractor and all its Subcontractors, that provide labor on the Project site, must be enrolled in and remain in good standing in the Ohio Bureau of Worker’s Compensation (“OBWC”) Drug-Free Safety Program (“DFSP”) or a comparable program approved by the OBWC.

In addition to being enrolled in and in good standing in an OBWC-approved DFSP or a comparable program approved by the OBWC, the Department requires each Contractor and Subcontractor that provides labor, to subject its employees who perform labor on the project site to random drug testing of 5 percent of its employees. The random drug testing percentage must also include the on-site supervisors of the Contractors and Subcontractors. Upon request, the Contractor and Subcontractor shall provide evidence of required testing to the Department.

Each Subcontractor shall require all lower-tier Subcontractors that provides labor on the project site with whom the Subcontractor is in contract for the Work to be enrolled in and be in good standing in the OBWC-approved DFSP prior to a lower-tier Subcontractor providing labor at the Site.

The Department will declare a bid non-responsive and ineligible for award if the Contractor is not enrolled and in good standing in the Ohio Bureau of Workers’ Compensation’s Drug-Free Safety Program (DFSP) Discount Program or a similar program approved by the Bureau of Workers’ Compensation within 8 days of the bid opening. Furthermore, the Department will deny all requests to sublet when the subcontractor does not comply with the provisions of this section. 

Failure of the Contractor to require a Subcontractor to be enrolled in and be in good standing in the an OBWC-approved DFSP prior to the time that the Subcontractor provides labor at the Site, shall result in the Contractor being found in breach of the Contract and that breach shall be used in the responsibility analysis of that Contractor or the Subcontractor who was not enrolled in a program for future contracts with the State for five years after the date of the breach.

103  AWARD AND EXECUTION OF CONTRACT

103.01  Consideration of Proposals.  After opening and announcing the Bids, the Department will compare the Bidders’ proposed prices.  The proposed price is the summation of the products of the estimated quantities shown in the Proposal and the unit Bid prices.  If the amount shown for the proposed product differs from the actual product of the unit Bid price and the estimated quantity, then the actual product will govern.

The Department may reject any or all Bids, waive technicalities, or advertise for new Bids without liability to the Department.

103.02  Award of Contract.  The Department will award a Contract or reject Bids within 10 days after Bid opening.  The Department will mail a letter to the address on the Bid notifying the successful Bidder of Bid acceptance and Contract award.  The Department will award to the lowest competent and responsible bidder.  The Department will not award a Contract until it completes an investigation of the apparent low Bidder.

If the Department’s estimate for the cost of the improvement is not confidential, the Department will not award a Contract for an amount greater than 5 percent more than the Department’s estimate.  If the Department’s estimate is confidential, the Department may award the Contract according to ORC 5525.15.

103.03  Cancellation of Award.  The Department may cancel a Contract award at any time before all parties sign the Contract without liability to the Department.

103.04  Return of Proposal Guaranty.  Immediately after the opening and checking of Bids, the Department will return all Proposal Guaranties provided in the form of a certified check or cashier’s check, except to the three lowest Bidders.  Within 10 days after opening bids, the Department will return the Proposal Guaranties of the two remaining unsuccessful Bidders.  After the successful Bidder submits the signed Contract, Contract Bonds, and other Contract Documents, and after the Department signs the Contract, the Department will return the Proposal Guaranty to the successful Bidder.  The Department will not return Bid bonds.

103.05  Requirement of Contract Bond.  Furnish Contract Bonds within 10 days after receiving notice of award.  Furnish Contract Bonds to the Director on the prescribed form, in the amount of the contract, and according to ORC 5525.16.

103.06  Execution of Contract.  Sign and return the Contract, along with the certificate of compliance, Contract Bonds, and other required Contract Documents, within 10 days after notice of award.  The State does not consider a proposal binding until the Director signs the Contract.  If the Director does not sign the Contract within 20 days after receiving the successful Bidder’s signed Contract, certificates, Contract Bonds, and other Contract Documents, the successful Bidder may withdraw the Bid without prejudice.

103.07  Failure to Execute Contract.  If the successful Bidder fails to sign the Contract and furnish the Contract Bonds, the Department will have just cause to cancel the award.  The successful Bidder shall forfeit the Proposal Guaranty to the Department, not as a penalty, but as liquidated damages.  The Department may award the Contract to the next lowest responsive Bidder, re-advertise the Work, or take any other action decided by the Director.

104  SCOPE OF WORK

104.01  Intent of the Contract Documents.  The intent of the Contract Documents is to provide for the construction and completion of the Work.  Perform the Work according to the Contract Documents.

104.02  Revisions to the Contract Documents.

A.      General.  The Department reserves the right to revise the Contract Documents at any time.  Such revisions do not invalidate the Contract or release the Surety, and the Contractor agrees to perform the Work as revised.

The provisions of this section are subject to the limitation of ORC 5525.14.

B.      Differing Site Conditions.  During the progress of the Work, if subsurface or latent physical conditions are encountered at the site differing materially from those indicated in the Contract Documents or if unknown physical conditions of an unusual nature, differing materially from those ordinarily encountered and generally recognized as inherent in the Work provided for in the Contract Documents, are encountered at the site, notify the Engineer as specified in 108.02.F of the specific differing conditions before they are disturbed or the affected Work is performed.

Upon notification, the Engineer will investigate the conditions and if it is determined that the conditions materially differ and cause an increase or decrease in the cost or time required for the performance of any Work under the Contract, the Department will make an adjustment and modify the Contract as specified in 108.06 and 109.05.  The Engineer will notify the Contractor of the determination whether or not an adjustment of the Contract is warranted.

C.      Suspension of Work.  If the performance of all or any portion of the Work is suspended or delayed by the Engineer in writing for an unreasonable period of time (not originally anticipated, customary, or inherent to the construction industry) and the Contractor believes that additional compensation or time is due as a result of such suspension or delay, notify the Engineer as specified in 104.05.

Upon receipt of notice, the Engineer will evaluate the Contractor’s request.  If the Engineer agrees that the cost or time required for the performance of the Work has increased as a result of such suspension and the suspension was caused by conditions beyond the control of and not the fault of the Contractor, its suppliers, or subcontractors at any approved tier, and not caused by weather, the Engineer will make an equitable adjustment (excluding profit) and modify the contract as specified in 108.06 and 109.05.  The Engineer will notify the Contractor of its determination whether or not an adjustment to the Contract Documents is warranted.  Failure of the Engineer to suspend or delay the Work in writing does not bar the Contractor from receiving a time extension or added compensation according to 108.06 or 109.05.

The Department will not make an adjustment under this subsection in the event that performance is suspended or delayed by any other cause, or for which an adjustment is provided or excluded under any other term or condition of this Contract.

D.      Significant Changes in Character of the Work.  The Engineer may alter the Work as necessary to complete the Project.  The Engineer will make appropriate adjustments according to 108.06 and 109.05, if such alterations significantly change the character of the Work.

If the Contractor disagrees as to whether an alteration constitutes a significant change, use the notification procedures specified in 108.02.G.

The term “significant change” is defined as follows:

1.      when the character of the Work as altered differs materially in kind or nature from that involved or included in the original proposed construction; or

2.      when the product of the quantity in excess of the estimated quantity of a contract item and the unit price exceeds the limits set forth in Table 104.02-1.

Table 104.02-1

Contract Price

Contract Limits

Up to $500,000

$25,000

$500,001 to $2,000,000

5% of Total Contract Price

Over $2,000,000

$100,000

If the decrease in quantity of any unit price Contract Item exceeds 25 percent of the estimated quantity, and the total of all such adjustments for all Contract Items is more than $400, then after the determination of final quantities according to 109.12.C, the Engineer will adjust the unit prices for the affected Contract item by multiplying the bid unit price by the factor obtained from Table 104.02-2.

Table 104.02-2

% Decrease

Factor

% Decrease

Factor

25

1.08

67

1.51

26 to 27

1.09

68

1.53

28 to 29

1.10

69

1.56

30 to 31

1.11

70

1.58

32 to 33

1.12

71

1.61

34 to 35

1.13

72

1.64

36

1.14

73

1.68

37 to 38

1.15

74

1.71

39

1.16

75

1.75

40 to 41

1.17

76

1.79

42

1.18

77

1.84

43

1.19

78

1.89

44 to 45

1.20

79

1.94

46

1.21

80

2.00

47

1.22

81

2.07

48

1.23

82

2.14

49

1.24

83

2.22

50

1.25

84

2.31

51

1.26

85

2.42

52

1.27

86

2.54

53

1.28

87

2.67

54

1.29

88

2.83

55

1.31

89

3.02

56

1.32

90

3.25

57

1.33

91

3.53

58

1.35

92

3.88

59

1.36

93

4.32

60

1.38

94

4.92

61

1.39

95

5.75

62

1.41

96

7.00

63

1.43

97

9.08

64

1.44

98

13.25

65

1.46

99

25.00

66

1.49

          If the increase in quantity of any unit price Contract Item exceeds 25 percent of the estimated quantity, and the total of all adjustments for all Contract Items is more than $400, then after a final determination of final quantities according to 109.12.C, the Engineer will adjust the unit prices for the Contract Items exceeding 25 percent of the estimated quantity by multiplying the bid unit price by the factor obtained from Table 104.02-3

Table 104.02-3

% Increase

Factor

25 to 28

0.95

29 to 35

0.94

36 to 42

0.93

43 to 51

0.92

52 to 61

0.91

62 to 72

0.90

73 to 85

0.89

86 to 100

0.88

101 to 117

0.87

118 to 138

0.86

139 to 163

0.85

164 to 194

0.84

195 to 233

0.83

234 to 284

0.82

285 to 354

0.81

354 to 400

0.80

When the increase in quantity or decrease in quantity of any unit price contract item does not exceed the limits set forth in Tables 104.02-1 and 104.02-2, there is no significant change in the character of the work and the change is considered a minor change.  Department will pay for minor changes in the Work at the unit bid price.

E.      Eliminated Items.  The Department may partially or completely eliminate contract items.

The Department will only make an adjustment to compensate the Contractor for the reasonable cost incurred in preparation to perform  significantly changed work as set forth in 104.02.D or work completely eliminated prior to the date of the Engineer’s written order to significantly change or completely eliminate the Work.  The adjustment will be determined according to 109.04 and 109.05.  Such payment will not exceed the price of the Contract Item.

The Department will not seek a savings for maintaining traffic, mobilization, and construction layout stakes items for Eliminated Items of Work, unless there is a significant change.

F.      Extra Work.  Perform Extra Work as directed by the Engineer.  The Department will pay for Extra Work as specified in 109.05.  Time extensions, if warranted, will be determined according to 108.06.

G.     Unilateral Authority to Pay.  The Department has unilateral authority to pay the contractor sums it determines to be due to the contractor for work performed on the project.  This unilateral authority to pay by the Department does not preclude or limit the rights of the Department and the contractor to negotiate and agree to the amounts to be paid to the contractor.

104.03  Rights in and Use of Materials Found on the Work.  Upon obtaining the Engineer’s approval, the Contractor may use material, such as stone, gravel, or sand, found in the plan excavation for another Contract Item.  The Department will pay for both the excavation of the material under the corresponding Contract Item and for the placement of the excavated material under the Contract Item(s) for which the excavated material is used.  Excavate or remove material only from within the grading limits, as indicated by the slope and grade lines.

Obtain written permission from the Engineer according to 107.11.A.

104.04  Cleaning Up.  Maintain the Project in a presentable condition.  Remove all rubbish, layout stakes, sediment control devices as directed by the Engineer, excess material, temporary structures, and equipment, including stream channels and banks within the Right-of-Way at drainage structures, and all borrow and waste areas, storage sites, temporary plant sites, haul roads, and other ground occupied by the Contractor in connection with the Work.  Establish suitable vegetative cover in these areas by seeding and mulching according to Item 659, except for cultivated fields.  Leave the Project site in an acceptable condition as determined by the Engineer.  The cost of cleanup is incidental to all contract items.  The Department may withhold 10 percent of the Bid amount for the mobilization contract item, if included, until performance under this section is complete.  See 624.04.

105  CONTROL OF WORK

105.01  Authority of the Engineer.  The Engineer will decide questions concerning all of the following:

A.      The quality and acceptability of Materials furnished.

B.      The quantity of Work performed.

C.      The Contractor’s rate of progress.

D.      The interpretation of the Contract Documents.

E.      Acceptable fulfillment of the Contract.

F.      Contractor compensation.

The Engineer may suspend all or part of the Work when the Contractor fails to correct conditions that are unsafe for the workers or the general public, fails to comply with the Contract Documents, or fails to comply with the Engineer’s orders.  The Engineer may suspend the Work due to adverse weather conditions, conditions considered adverse to the prosecution of the Work, or other conditions or reasons in the public interest.

The Engineer’s acceptance does not constitute a waiver of the Department’s right to pursue any and all legal remedies for defective work or work performed by the Contractor in an un-workmanlike manner.

105.02  Plans and Working Drawings.  The Plans show details of structures, the lines and grades, typical cross-sections of the Roadway, and the location and design of structures.  Keep at least one set of Plans at the Project at all times.

Prepare working drawings when required by the Contract Documents and after verifying applicable field and plan elevations, dimensions, and geometries.  Where Work consists of repairs, extension, or alteration of existing structures, take measurements of existing structures to accurately join old and new Work.

Unless otherwise indicated, the Department will review working drawing submittals to ensure conformance with the Contract and to provide the Contractor a written response to document the results of its review as follows:

A.      “ACCEPTED.” The Department accepts the submittal for construction, fabrication, or manufacture.

B.      “ACCEPTED AS NOTED.” The Department accepts the submittal for construction, fabrication, or manufacture, subject to the Contractor’s compliance with all Department comments or corrections to the submittal.  If also marked “RESUBMIT,” the Department still accepts the submittal, but requires the Contractor to provide a corrected submittal to the Department.

C.      “NOT ACCEPTED.” The Department does not accept the submittal.  The submittal does not conform to Contract requirements.  Do not begin construction, fabrication, or manufacture of Work included in the submittal.  Revise the submittal to comply with Department comments or corrections and Contract requirements and provide the revised submittal to the Department for another review.

The Department’s acceptance will not relieve the Contractor of responsibility to complete the Work according to the Contract.  Include the cost of furnishing working drawings in the cost of the Work they cover.

105.03  Conformity with Contract Documents.  Perform all Work and furnish all Materials in reasonably close conformity with the lines, grades, cross-sections, dimensions, and material requirements as shown on the Plans and as specified.

If the DCA determines the Work is not in reasonably close conformity with the Contract Documents and determines the Contractor produced reasonably acceptable Work, the DCA may accept the Work based on engineering judgment.  The DCA will document the basis of acceptance in a Change Order that provides for an appropriate adjustment to the Contract Price of the accepted Work or Materials. If the DCA determines the Work is not in reasonably close conformity with the Contract Documents and determines the Work is inferior or unsatisfactory, remove, replace, or otherwise correct the Work at no expense to the Department.

105.04  Coordination of the Contract Documents.  The Contract Documents are those defined in 101.03.  A requirement appearing in one of these documents is as binding as though it occurs in all.  The Engineer will resolve discrepancies using the following descending order of precedence:

A.      Addenda.

B.      Proposal and Special Provisions.

C.      Plans.

D.      Supplemental Specifications.

E.      Standard Construction Drawings.

F.      Standard Specifications.

Immediately notify the Engineer upon discovering any latent error or omission in the Contract Documents.

105.05  Cooperation by Contractor.  The Department will supply the Contractor with two sets of the Contract Documents, except for the standard construction drawings, which will only be supplied if requested.  The Department will provide only one copy of these Specifications.

Provide the constant attention necessary to progress the Work according to the Contract Documents.  Cooperate with the Engineer, inspectors, and all other contractors on or adjacent to the Project.

105.06  Superintendent.  Provide a Superintendent for the Project that is available and responsive at all times and is responsible for all aspects of the Work, irrespective of the amount of subcontract Work.  The Superintendent must be capable of reading and understanding the Contract Documents and experienced in the type of Work being performed.  The Superintendent shall receive instructions from the Engineer or the Engineer’s authorized representatives.  The Superintendent shall promptly execute the Engineer’s orders or directions and promptly supply the required materials, equipment, tools, labor, and incidentals.

105.07  Cooperation with Utilities.  Unless otherwise provided for by the Contract Documents, the Department will direct the utility owners to relocate or adjust water lines, gas lines, wire lines, service connections, water and gas meter boxes, water and gas valve boxes, light standards, cableways, signals, and all other utility appurtenances within the limits of the proposed construction at no cost to the Contractor.

If the contractor is directed by a utility company to perform any work not specifically contained in this note, the Department will not compensate the contractor for this work unless the Department approves the request in writing before the work begins.  If the work is not preapproved by the Department, the contractor will be responsible for obtaining reimbursement for its work from the utility company which directed the contractor to perform the work.

In the event that the contractor requests that additional work, not specifically contained in this note, be performed by a utility company, the contractor will be responsible for reimbursing the utility company for the additional work unless the Department has agreed in writing to pay for the additional work before the work begins.

The Contract Documents will indicate various utility items and indicate a time frame or date when the Department expects the owners to complete utility relocation or adjustment.  Provide utility owners adjusting facilities during construction with adequate notification of the scheduled Work to prevent conflict with the Contractor’s schedule of operations.

When bidding, consider all permanent and temporary utility appurtenances in present and relocated positions as shown in the Contract Documents.

According to ORC 153.64 and at least 2 Workdays prior to commencing construction operations in an area that may affect underground utilities shown on the Plans, notify the Engineer, the registered utility protection service, and the owners that are not members of the registered utility protection service.

The owner of the underground utility shall, within 48 hours, excluding Saturdays, Sundays, and legal holidays, after notice is received, start staking, marking, or otherwise designating the location, course, ±2 feet (±0.6 m), together with the approximate depth of the underground utilities in the construction area.

If the utility owners fail to relocate or adjust utilities as provided for in the Contract Documents and the Contractor sustains losses that could not have been avoided by the judicious handling of forces, equipment, and plant, or by reasonable revisions to the schedule of operations, then the Engineer will adjust the Contract according to 108.06 and 109.05.

105.08  Cooperation Between Contractors.  At any time, the Department may contract for other work on or near the Project.

Separate contractors working within the limits of the Project shall conduct their work without interfering with or hindering the progress or completion of Work being performed by other contractors and shall cooperate with each other as directed by the Engineer.

105.09  Authority and Duties of the Inspector.  Inspectors are authorized to inspect the Work and the preparation, fabrication, or manufacture of materials.  Inspectors are not authorized to alter or waive requirements of the Contract Documents.  Inspectors are authorized to notify the Contractor of Work that does not conform to the Contract; reject materials that do not conform to Specification requirements; and until the issue is decided by the Engineer, suspend portions of the Work if there is a question regarding the Contract Documents, use of unapproved material, or safety.  Inspectors are not obligated or authorized to provide direction, superintendence, or guidance to the Contractor, its crew, its subcontractors, or suppliers to accomplish the Work.

Any action or inaction of the Inspector does not constitute a waiver of the Department’s right to pursue any and all legal remedies for defective work or work performed by the Contractor in an un-workmanlike manner.

105.10  Inspection of Work.  The Engineer may inspect materials and the Work.  Provide the Engineer or the Engineer’s representative access to the Work, information, and assistance necessary to conduct a complete inspection.  Notify the Engineer at least 24 hours prior to all required inspections.

When directed by the Engineer, remove or uncover completed Work to allow inspection.  After the Engineer’s inspection, restore the Work according to the requirements of the Contract Documents.  If the inspected Work conformed to the requirements of the Contract Documents, the Department will pay for uncovering or removing and restoring the Work as Extra Work according to 109.05.  If the inspected Work did not conform to the Contract Documents, the Department will not pay for uncovering or removing and restoring the Work.

The Department shall have the discretion to dictate the level of inspection for any item of work. The Contractor bears sole responsibility for the quality of work and compliance with the contract regardless of the Department’s level of inspection.

The Department’s failure to identify defective Work or material shall not, in any way, prevent later rejection when defective Work or material is discovered, or obligate the Department to grant acceptance under 109.11 or 109.12.

Inspection of Work may include inspection by representatives of other government agencies or railroad corporations that pay a portion of the cost of the Work.  This inspection will not make other government agencies or railroad corporations a party to the Contract and will not interfere with the rights of the Contractor or Department.

105.11  Removal of Defective and Unauthorized Work.  Work that does not conform to the requirements of the Contract is defective.

Unless the Department formally accepts defective Work according to 105.03, immediately remove and replace defective Work.

Unauthorized Work is Work done contrary to the instructions of the Engineer, beyond the plan lines, or any extra work done without the Department’s permission.  The Department will not pay for unauthorized Work.  The Engineer may order the Contractor to remove or replace unauthorized Work at no expense to the Department.

If the Contractor fails to comply with the Engineer’s orders under the provisions of this subsection, the DCA may correct or remove and replace defective or unauthorized Work and deduct the costs from the Contract Price.

105.12  Load Restrictions.  Comply with all legal load restrictions when hauling materials on public roads.

Operate equipment of a weight or so loaded as to not cause damage to structures, to the roadway, or to other types of construction.  Comply with subsection 501.05.B.6 for allowed loads on bridges.

Do not use off road vehicles on bases or pavements unless permitted by the DCA in writing.

Do not haul on concrete pavement, base, or structures before the expiration of the curing period.

Do not exceed the legal load limits in this section unless permitted by the Director in writing.

105.13  Haul Roads.  Prior to hauling equipment or materials, provide written notification to the Engineer of the specific roads or streets on the haul route.  If the haul route includes roads and streets that are not under the jurisdiction and control of the State and the DCA determines that State controlled roads are not available or practical for a haul route, the Contractor may use local roads and streets that are not restricted by local authorities.  If the DCA determines that state controlled roads are available and practical for a haul route, revise the proposed haul route provided in the original written notification and resubmit to the DCA.

If the Engineer determines that haul route roads were properly used during construction to haul equipment and materials and that the haul route roads were damaged, then the Engineer may order the Contractor to perform immediate and practical repairs to ensure reasonably normal traveling conditions.  The Engineer will pay for repairs according to applicable provisions of 109.04 and 109.05.

The Contractor shall not file a claim for delays or other impacts to the Work caused by disputes with the local authorities regarding the use of local roads or streets as haul routes.  The Contractor shall save the State harmless for any closures or hauling restrictions outside the Project limits beyond the control of the Department.

105.14  Maintenance During Construction.  Maintain the Work during construction and until Final Inspector accepts the work under 109.12, except for portions of the Work accepted under 109.11.  The Contractor is responsible for damage done by its equipment.

Maintain the previous courses or subgrade during all construction operations, when placing a course upon other courses of embankment, base, subgrade, concrete or asphalt pavement, or other similar items previously constructed.  This maintenance includes, but is not limited to draining, re-compacting, re-grading, or if destroyed, the removal of Work previously accepted by the Department.

Maintain the Post Construction Storm Water Best Management Practice (BMP) features. Prevent sediment laden surface water from coming in contact with the BMP features during construction.

Maintain the Work during construction and before acceptance of the Work under 109.12, except for portions of the Work accepted under 109.11.  The Department will not provide additional compensation for maintenance work.

105.15  Failure to Maintain Roadway or Structure.  If the Contractor, at any time, fails to comply with the provisions of 105.14, the Engineer will immediately notify the Contractor of such noncompliance.  If the Contractor fails to remedy unsatisfactory maintenance within 24 hours after receipt of such notice, the Engineer may immediately proceed to maintain the Project, and deduct the entire cost of this maintenance from monies due or to become due the Contractor on the Contract.

105.16  Borrow and Waste Areas.  Prior to beginning borrow or wasting operations, obtain the Engineer’s written approval of a detailed operation plan that addresses the following concerns:

A.      Control of drainage water.

B.      Cleanup, shaping, and restoration of disturbed areas.

C.      Disposal of regulated materials.

D.      Avoidance of regulated areas.

E.      Excavation and filling of waste and borrow areas.

F.      Saving of topsoil.

G.      Temporary Sediment and Erosion Control BMPs required for compliance under the Clean Water Act, Ohio Water Pollution Control Act, (OWPCA) (ORC Chapter 6111) and the NPDES permit.

Perform all engineering necessary to ensure long term stability of all side slopes and foundations of all borrow and waste areas. Furnish a certification by a Registered Engineer attesting to the stability of all borrow and waste areas. All damage resulting from the instability of borrow and waste areas, the removal of borrow materials, the placement of waste materials, or the hauling of material to and from these areas is the sole responsibility of the Contractor. Repairs to approved haul roads will be made in accordance with 105.13.

Perform all engineering, including any field investigation, necessary to ensure long term stability of all side slopes and foundations of all borrow and waste areas.

Ensure that all side slopes of all waste areas do not reduce horizontal sight distance as defined by the current version of the Department’s Location and Design Manual.

Have the proposed borrow and waste areas reviewed by an environmental consultant that is pre-qualified by the Department for ecological work.  Have the environmental consultant certify that the proposed borrow and waste operations will not impact the “Waters of the United States” or an isolated wetland.  If consultant certification is not provided, obtain the 404/401 permits necessary to perform the operations as proposed.  Have the environmental consultant certify that the work conforms to the requirements of the permit(s).  Provide all documentation submitted to obtain the appropriate permit(s) and a copy of the permit(s) to the Department’s Office of Environmental Services.

If burning is permitted under the OAC-3745-19 and ORC 1503.18, submit a copy of the Ohio EPA permit and the Ohio DNR permit to the Engineer and copies of all information used to obtain the permit.

Prior to the disposal of waste materials, submit to the Department an executed copy of the Contract or permission statement from the property owner.  The Contract or permission statement must indicate that the waste materials are not the property of the Department.  Further, it must expressly state that the Department is not a party to the Contract or permission statement and that the Contractor and property owner will hold the Department harmless from claims that may arise from their contract or permission statement.

Restoration of all borrow or waste areas includes cleanup, shaping, replacement of topsoil, and establishment of vegetative cover by seeding and mulching according to 104.04 and Item 659.  Ensure the restored area is well drained unless approval is given by the Engineer to convert a pit area into a pond or lake, in which case confine restoration measures to the disturbed areas above the anticipated normal water level.  The cost of work described herein is incidental to the Contract.

For waste sites shown on the plan, the plan will indicate if the clearances have or have not been obtained for the project right-of-way locations.  No extension of time or additional compensation will be paid for any delays due to not having the written permit(s) to waste in a floodplain.

The allowed use of Project Right-of-Way and other Department property for borrow and waste is detailed in 104.03 and 107.11.

Borrow and Waste Area shall adhere to 107.10.

105.17  Construction and Demolition Debris.  OAC-3745-37, OAC-3745-400, and ORC Chapter 3714 regulates the use and disposal of construction and demolition debris.  Notify the local Board of Health or the local Ohio EPA office 7 days before placing clean hard fill off the Right-of-Way.  Submit copies of this notification to the Engineer.

Legally dispose of debris containing wood, road metal, or plaster at a licensed construction and demolition debris site.

Under the regulations cited above the disposal of brush, trees, stumps, tree trimmings, branches, weeds, leaves, grass, shrubbery, yard trimmings, crop residue, and other plant matter is restricted.  If allowed by the Contract Documents, the Contractor may waste brush, trees, stumps, tree trimming, branches, weeds, leaves, grass, shrubbery, yard trimmings, crop residue, and other plant matter within the Right-of-Way.  Otherwise, submit a plan and any required permits to legally dispose of these materials off the Right-of-Way to the Engineer.  Provide all documents submitted to obtain this permit to the Engineer.

If the Project contains garbage or solid and hazardous waste, the Contract Documents will detail the removal of these items.

When wasting PCC, mix the PCC with at least 30 percent natural soil to construct an inner core in the waste area.  Cover this inner core with 3 feet (1.0 m) of natural soil on the top and 8 feet (2.4 m) on the side slopes.  Place and compact the material according to 203.06.D to prevent future settlement and sliding.

Clean hard fill consisting of reinforced or non-reinforced concrete, asphalt concrete, brick, block, tile or stone that is free of all steel as per 703.16 shall be managed in one or more of the following ways:

1.     Recycled into a usable construction material.

2.     Disposed in licensed construction and demolition debris facility.

3.     Used in legitimate fill operations on the site of generation according to 105.16.

4.     Used in legitimate fill operations on a site other than the site of generation to bring a site up to grade on an existing roadbed or parking lot project.

A Beneficial Reuse Certification form needs to be properly executed by the Recipient prior to any material leaving the project.

105.18  Acceptance.  The Department will accept Work according to 109.12 or completed sections of the Project according to 109.11.

105.19  Value Engineering Change Proposals.  The Department will Partner with the Contractor by considering the Contractor’s submission of a Value Engineering Change Proposal (VECP) which will reduce construction costs and possibly time on projects that do not contain Design Build provisions or incentive provisions based on time. The purpose of this provision is to encourage the use of the ingenuity and expertise of the Contractor in arriving at alternate plans, specifications or other requirements of the contract. Savings in construction costs and possibly time will be shared equally between the Contractor and the Department. The Contractor’s costs for development, design and implementation of the VECP are not eligible for reimbursement. The VECP must not impair any of the essential functions and characteristics of the project such as service life, reliability, economy of operation, ease of maintenance, safety and necessary standardized features. The submission of the value engineering change proposal shall conform with Supplement 1113. Acceptance of a VECP is at the sole discretion of the Director.

The Department will not approve VECPs with any of the following characteristics:

A.      Consist only of non-performing items of work contained in the plans.

B.      Include plan errors identified by the Contractor as part of the cost reduction.

C.      The VECP designer/consultant for the Contractor is also the designer of record for ODOT.

D.      Changes to any special architectural or aesthetic treatments. 

E.      Requires concrete beams to be installed with less than 17' vertical clearance over a state highway.

F.      Changes the type or buildup of permanent pavement.

G. Compromises controlling design criteria or would require a design exception as discussed in Volume I, Section 100, of the Location and Design Manual.

H. Proposes a time savings for any project which has an Incentive / Disincentive clause, which was awarded based on A+B Bidding or Lane Rental.

Engineering and drawing development and implementation costs for the VECP are not recoverable.

The Contractor shall have no claim against the Department for any costs or delays due to the Department’s review or rejection of the initial VECP.

If the Department already is considering revisions to the contract which are subsequently proposed as a VECP, the Department may reject the Contractor’s initial VECP or portions thereof and may proceed with such revisions without any obligations to the Contractor.

106  CONTROL OF MATERIAL

106.01  Source of Supply and Quality Requirements.  Notify the Engineer of the proposed sources of supply before the delivery of materials.  The Engineer may approve materials at the source of supply before delivery.  If the proposed sources of supply cannot produce the specified material, then furnish materials from alternate sources without adjustment to the Contract Price or Completion Date.

106.02  Samples, Tests, and Cited Specifications.  The Engineer will inspect and determine whether the materials comply with the specified requirements before they are incorporated into the Work.  The Department may sample and test materials or require certifications.  Unless specified, the Department will pay for and test materials according to AASHTO, ASTM, or the methods on file in the office of the Engineer.  A qualified representative of the Department will take test samples according to Departmental procedures.  Read any reference to other specifications or testing methods to mean the version in effect at the pertinent Project Advertisement date.  All materials being used are subject to inspection, test, or rejection at any time before their incorporation into the Work.  The Department will furnish copies of the tests to the Contractor’s representative upon request.  Furnish the required samples and specified material certifications at no expense to the Department other than provided in 109.03.

Equip all transports and distributors hauling asphalt material with an approved submerged asphalt material sampling device.

106.03  Small Quantities and Materials for Temporary Application.  The Engineer may accept small quantities and materials for temporary application that are not intended for permanent incorporation in the Work.  The Engineer may accept these small quantities and materials for temporary application in either of the following cases:

A.      Where similar materials from the same source have recently been approved.

B.      Where the materials, in the judgment of the Engineer, will serve the intended purpose.

106.04  Plant Sampling and Testing Plan.  The Engineer may undertake the inspection of materials at the source.

In the event plant sampling and testing is undertaken, the Contractor and its material provider shall meet the following conditions:

A.      Cooperate and assist the Engineer with the inspection of materials.  Provide full entry to the Engineer at all times to such parts of the plant as may concern the manufacture or production of the materials being furnished.  Agree to all documentation and inspection requirements of the TE-24 plant sampling and testing plan.

B.      If required by the Engineer, arrange for the inspector to use an approved building on site.  The building should be located near the plant and independent of any building used by the material producer.

C.      Maintain and provide adequate safety measures at the plant at all times.

The Department reserves the right to retest all materials that have been tested and accepted at the source of supply before their incorporation into the Work.  After the approved materials have been delivered to the site, the Department may reject all materials that when retested do not meet the requirements of the Contract Documents.

106.05  Storage of Materials.  Properly store all materials to ensure the preservation of their quality and fitness for the Work.  The Engineer may re-inspect stored materials before their incorporation into the Work, even though they were approved before storage.  Locate stored materials to facilitate their prompt inspection.  The Contractor may use approved portions of the Project Right-of-Way for storage; however, if any additional space is required, the Contractor must provide it at the Contractor’s expense.  Do not use private property for storage purposes without written permission from the owner or lessee.  If requested by the Engineer, furnish copies of the written permission.  Restore all storage sites to their original condition at no expense to the Department.  The Contractor and property owner will hold the Department harmless from claims that may arise from their contract or permission statement.  This subsection does not apply to the stripping and storing of topsoil, or to other materials salvaged from the Work.

Areas used to Store Materials shall conform to 107.10.

106.06  Handling Materials.  Handle all materials in such manner as to preserve their quality and fitness for the Work.  Transport aggregates from the storage site to the project site in vehicles constructed to prevent loss or segregation of materials after loading and measuring.  Ensure that there are no inconsistencies in the quantities of materials loaded for delivery and the quantities actually received at the place of operations.

106.07  Unacceptable Materials.  Unacceptable materials are all materials not conforming to the requirements of these Specifications at the time they are used.  Immediately remove all unacceptable materials from the project site unless otherwise instructed by the DCA.  The DCA will determine if unacceptance materials may remain conforming to supplement 1102. The DCA must approve the use of previously identified unacceptable materials that have been corrected or repaired.  If the Contractor fails to comply immediately with any order of the DCA made under the provisions of this subsection, the DCA will have authority to remove and replace defective materials and to deduct the cost of removal and replacement from any monies due or to become due to the Contractor.

106.08  Department-Furnished Material.  Furnish all materials required to complete the Work, except when otherwise provided in the Proposal.

The Department will deliver the Department-furnished materials to the Contractor at the points specified in the Contract Documents.

Include the cost of handling and placing of all Department-furnished materials in the contract price for the contract item for which they are used.

The Department will hold the Contractor responsible for all material upon delivery of the materials to the Project site.  The Department will make deductions from any monies due the Contractor to make good any shortages and deficiencies, for any cause whatsoever, and for any damage that may occur after such delivery, and for any demurrage charges.

106.09  Steel and Iron Products Made in the United States.  Furnish steel and iron products that are made in the United States according to the applicable provisions of Federal regulations stated in 23 CFR 635.410 and State of Ohio laws, and ORC 153.011 and 5525.21.  “United States” means the United States of America and includes all territory, continental or insular, subject to the jurisdiction of the United States.

A.      Federal Requirements.  All steel or iron products incorporated permanently into the Work must be made of steel or iron produced in the United States and all subsequent manufacturing must be performed in the United States.  Manufacturing is any process that modifies the chemical content; physical shape or size; or final finish of a product.  Manufacturing begins with the initial melting and mixing, and continues through the bending and coating stages.  If a domestic product is taken out of the United States for any process, it becomes a foreign source material.

B.      State Requirements.  All steel products used in the Work for load-bearing structural purposes must be made from steel produced in the United States.  State requirements do not apply to iron.

C.      Applications.

1.      When the Work is Federally funded both the Federal and State requirements apply.  This includes all portions of the Work, including portions that are not Federally funded.

2.      When the Work has no Federal funds, only the State requirements apply.

D.      Exceptions.  The Director may grant specific written permission to use foreign steel or iron products in bridge construction and foreign iron products in any type of construction.  The Director may grant such exceptions under either of the following conditions:

1.      The cost of products to be used does not exceed 0.1 percent of the total Contract cost, or $2,500, whichever is greater.  The cost is the value of the product as delivered to the project.

2.      The specified products are not produced in the United States in sufficient quantity or otherwise are not reasonably available to meet the requirements of the Contract Documents.  The Director may require the Contractor to obtain letters from three different suppliers documenting the unavailability of a product from a domestic source, if the shortage is not previously established.

E.      Manufactured Products.  In order for a manufactured product to be subject to Federal requirements, the product must consist of at least 90% steel or iron content when it is delivered to the job site for installation.

          Examples of products subject to Federal requirements include, but are not limited to, the following:

          1.      Steel or iron products used in pavements, bridges, tunnels or other structures, which include , but are not limited to, the following: fabricated structural steel, reinforcing steel, piling, high strength bolts, anchor bolts, dowel bars, permanently incorporated sheet piling, bridge bearings, cable wire/strand, prestressing/post-tensioning wire, motor/machinery brakes and other equipment for moveable structures;

          2.      Guardrail, guardrail posts, end sections, terminals, cable guardrail;

          3.      Steel fencing material, fence posts;

          4.      Steel or iron pipe, conduit, grates, manhole covers, risers;

          5.      Mast arms, poles, standards, trusses, or supporting structural members for signs, luminaires, or traffic control systems; and

          6.      Steel or iron components of precast concrete products, such as reinforcing steel, wire mesh and pre-stressing or post-tensioning strands or cables

The miscellaneous steel or iron components, subcomponents and hardware necessary to encase, assemble and construct the above components (or manufactured products that are not predominately steel or iron) are not subject to Federal requirements.  Examples include, but are not limited to, cabinets, covers, shelves, clamps, fittings, sleeves, washers, bolts, nuts, screws, tie wire, spacers, chairs, lifting hooks, faucets, door hinges, etc.

F.      Proof of Domestic Origin.  Furnish documentation to the Engineer showing the domestic origin of all steel and iron products covered by this section, before they are incorporated into the Work.  Products without a traceable domestic origin will be treated as a non-domestic product.

106.10  Qualified Products List. The Department may use Qualified Product Lists (QPL) for approval of manufactured materials.  The Office of Materials Management (OMM) will maintain the QPL and the standard procedure for the QPL process.  Inclusion of a material onto the QPL will be determined by OMM with support from other Department offices.   To be kept on the QPL, manufacturers must recertify their material according to the Department’s standard procedure by January 1 of each year.  When a material requires QPL acceptance, only provide materials listed on the QPL at the time of delivery of the material to the project.  Provide the Engineer documentation according to the Department’s standard procedure that, at the time of delivery, the material provided is on the QPL.

107  LEGAL RELATIONS AND RESPONSIBILITY TO PUBLIC

107.01  Laws to be Observed.  Stay fully informed of all Federal and State laws, all local laws, ordinances, and regulations, and all orders and decrees of authorities having any jurisdiction or authority that affect those engaged or employed on the Work, or that affect the conduct of the Work.  Observe and comply with all such laws, ordinances, regulations, orders, and decrees.  The Contractor shall protect and indemnify the State and its representatives against any claim or liability arising from or based on the violation of any such law, ordinance, regulation, order, or decree, whether by the Contractor or the Contractor’s employees, subcontractors, or agents.

The Contractor, under Title VI of the Civil Rights Act and related statutes, agrees that in the hiring of employees for the performance of Work under this Contract or any subcontract hereunder, neither the Contractor, the subcontractor, nor any person acting on behalf of such Contractor or subcontractor shall, by reasons of race, religion, color, sex, national origin, disability or age, discriminate against any citizen of the United States in the employment of labor or workers, who is qualified and available to perform the Work to which the employment relates.

Neither the Contractor, the subcontractor, nor any person on their behalf shall, in any manner, discriminate against or intimidate any employee hired for the performance of Work under this Contract on account of race, religion, color, sex, national origin, disability or age.

Comply with OAC-4123:1-3, entitled “Specific Safety Requirements of the Industrial Commission of Ohio Relating to Construction,” as amended, and with the Federal Occupational Safety and Health Act of 1970 and Code of Federal Regulations, Title 29, Chapter XVII, Part 1926 and as amended.

107.02  Permits, Licenses, and Taxes.  Procure all permits and licenses; pay all charges, fees, and taxes; and provide all notices necessary and incidental to the due and lawful prosecution of the Work.

107.03  Patented Devices, Materials, and Processes.  Before employing any design, device, material, or process covered by letters of patent or copyright, provide for its use by suitable legal agreement with the patentee or owner.  The Contractor and the Surety shall indemnify and save harmless the State, any affected third party, or political subdivision from any and all claims for infringement of patented design, device, material, process, or any trademark or copyright, and shall indemnify the State for any costs, expenses, and damages that it may be obliged to pay by reason of any infringement, at any time during the prosecution or after the completion of the Work.

107.04  Restoration of Surfaces Opened by Permit.  The Director may grant to the municipality in which the Work is performed a reservation of rights to construct or reconstruct any utility service in the highway or street or to grant permits for same, at any time.

Any individual, firm, or corporation wishing to make an opening in the highway must secure a permit.  Allow parties bearing such permits, and only those parties, to make openings in the highway.  When ordered by the Engineer, make in an acceptable manner all necessary repairs due to such openings.  The necessary repairs will be paid for as Extra Work, or as provided in the Contract Documents, and will be subject to the same conditions as the original Work performed.

107.05  Federal-Aid Provisions.  When the United States Government pays for all or any portion of the Project’s cost, the Work is subject to the inspection of the appropriate Federal agency.

Such inspections will not make the Federal Government a party to this Contract.  The inspections will in no way interfere with the rights of either party to the Contract.

107.06  Sanitary Provisions.  Provide and maintain sanitary accommodations in a neat condition for the use of employees and Department representatives that comply with the requirements of the State and local Boards of Health, or of other authorities having jurisdiction over the Project.

107.07  Public Convenience and Safety.  At all times, ensure that the Work interferes as little as possible with the traffic.  Provide for the safety and convenience of the general public and the residents along the highway and the protection of persons and property.  Do not close any highways or streets unless specifically allowed by the Contract.

107.08  Bridges Over Navigable Waters.  Conduct all Work on navigable waters so that it does not interfere with free navigation of the waterways and that it does not alter the existing navigable depths, except as allowed by permit issued by the U.S. Coast Guard.  Work within the flood plain of a navigable stream may require a permit from the U.S. Army Corps of Engineers.  If an U.S. Army Corps of Engineers permit is required, provide all documentation submitted to obtain the permit(s) and a copy of the permit(s) to the Department.

107.09  Use of Explosives.  When the use of explosives is necessary for the prosecution of the Work, exercise the utmost care not to endanger life or property, including new Work.  The Contractor is responsible for all damage resulting from the use of explosives.

Obtain written permission to perform in-stream blasting from the Chief of the Division of Wildlife, Ohio DNR according to ORC 1533.58.  Provide the Engineer with all documentation submitted to obtain this permit and with a copy of the permit.

The Contractor agrees, warrants, and certifies that it will observe State laws and local ordinances and regulations relative to the use and storing of explosives kept on the Project site.

Perform all blasting operations according to Item 208.

107.10  Protection and Restoration of Property.  The Contractor is responsible for the preservation of all public and private property impacted by the Contractor’s operations.

The Contractor is responsible for all damage or injury to property, during the prosecution of the Work, resulting from any act, omission, neglect, defective work or materials, or misconduct in the manner or method of executing the Work.  The Contractor will remain responsible for all damage and injury to property until the Project is accepted under 109.12, except for portions of the Work accepted under 109.11.

If the Contractor causes any direct or indirect damage or injury to public or private property by any act, omission, neglect, or misconduct in the execution or the non-execution of the Work, then it must restore, at its own expense, the property to a condition similar or equal to that existing before the damage or injury.

If mail boxes, road, or street name signs and supports interfere with the Work, then remove and erect them in a temporary location during construction in a manner satisfactory to and as directed by the Engineer.  After completion of the Work and before final acceptance of the Project, erect the mailboxes, road, or street name signs and supports in their permanent locations according to the plans unless otherwise directed by the Engineer.  Consider the cost of this Work as incidental to the affected items.

Cooperate with the Engineer in protecting and preserving survey monuments that are affected by the Work as required by ORC 5519.05. At the beginning of the Work, verify the position of all survey monuments in the area to be improved, according to 623. If survey monuments not shown in the Contract Documents are unexpectedly encountered, then protect, reference, and preserve them in the same manner as survey monuments that are shown in the Contract Documents.

Do not create staging areas, store materials and equipment, or borrow or waste materials in  areas labeled as an environmental resources areas in the Contract Documents.  All properties to be utilized by the Contractor outside the  project Right-of-Way must be cleared for all environmental resource impacts prior to the beginning of work. Environmental resources include but may not be limited to:

1.      Cultural Resources

a.      Buildings, structures, objects, and sites eligible for or listed on the National Register of Historic Places

b.      Historic or prehistoric human remains, cemeteries, and/or burial sites (pursuant with ORC 2909.05 and 2927.11

2.      Ecological Resources

a.      Wetlands

b.      Streams

c.       Wooded areas with trees to be removed in excess of 8 inches diameter at breast height

3.      Public Lands

a.      Lands meeting the criteria of 49 U.S.C. 303, 23 CFR 771.I35: 4(f).

b.      Lands meeting the criteria of 16 U.S.C. 4601-4, 36 CFR59.1: 6(f).

4.      FEMA Mapped 100 year Floodplains 

5.      Hazardous Waste Areas

Except for locations utilized specifically for:

1.parking of equipment between workdays for maintenance type projects;

2.disposal or stockpile locations that currently hold a Federal, ODNR or OEPA sanctioned permit that specifically allows the disposal or stockpiling activity.  This exception requires the contractor to provide the Engineer with the permitted facility’s name, location, site ID number and the permit holder’s certification that disposal or stockpiling the project generated material is compliant with the recipient’s permit.

All areas proposed to be utilized by the Contractor outside the project construction limits and not described above shall be reviewed by environmental contractor(s) that are prequalified by the Department for each environmental resource.  This exception applies to projects with “maintenance” in the project description.  Have the consultant(s) certify that the proposed site to be utilized for the contractor will not impact:  

1.      Cultural Resources

2.      Ecological Resources

3.      Public Lands

4.      FEMA Mapped 100 year Floodplains 

5.      Hazardous Waste Areas

Provide all documentation and the consultant certification to the Office of Environmental Services with a copy to the Engineer.

Should the areas proposed for use by the Contractor outside the project right of way limits contain environmental resources the Contractor is responsible to the Department for all environmental clearances and permits prior to the beginning of work.

107.11  Contractor’s Use of the Project Right-of-Way or Other Department-Owned Property.

A.      Disposal of Waste Material and Construction Debris and Excavation of Borrow on the Project Right-of-Way or on Other Department-Owned Property.  Dispose of waste material according to 105.16 and dispose of construction debris according to 105.17.  In addition to the rights granted in 104.03, the Contractor’s use of the Project Right-of-Way or other Department-owned property for the disposal of waste material and construction debris and excavation of borrow material is restricted as follows:

1.      If the Contract Documents identify locations for the disposal of waste material and construction debris or excavation of borrow material within the Project Right-of-Way or on other Department-owned property, then only perform these operations in these designated locations.

2.      If the Contract Documents do not identify locations for the disposal of waste material and construction debris or excavation of borrow material within the Project Right-of-Way or on other Department-owned property, then do not Bid assuming that the Department will make such locations available.

If the Contractor’s request to use locations within the Project Right-of-Way or on other Department-owned property is approved by the Engineer, then the Department may allow the Contractor to dispose of waste material and construction debris or excavate borrow material for a fee of $0.50 per cubic yard.

B.      Contractor’s Use of Portable Plants Within the Project Right-of-Way or on Other Department-Owned Property.  The Contractor’s use of portable plants within the Project Right-of-Way or on other Department-owned property is limited as follows:

1.      If the Contract Documents identify locations within the Project Right-of-Way or on other Department-owned property to place a portable plant, then only place a portable plant in these designated locations subject to the requirements of 107.11.C.

2.      If the Contract Documents do not identify locations within the Project Right-of-Way or on other Department-owned property to place a portable plant, then do not bid assuming that the Department will make such locations available.

However, the Department will consider a Value Engineering Change Proposal (VECP) for the placement of a portable plant within the Project Right-of-Way or on other Department-owned property and, if accepted, may allow the use of a particular site on its property subject to the requirements of 107.11.C.

C.      Placement of a Portable Plant within the Project Right-of-Way or on Other Department-Owned Property.  To place a portable plant within the Project Right-of-Way or on other Department-owned property, comply with the following requirements:

1.      Local noise ordinances.

2.      Obtain any necessary EPA permits for the operation of the plant.  Provide the Department with a copy of the information submitted to obtain the permit and a copy of the permit.

3.      Provide the Engineer written certification that the plant will supply material only for the Project for which it was approved.  Do not use the plant to supply any other project or to sell materials commercially.

4.      Submit a traffic control plan to the Engineer for approval that details the anticipated truck movements and provides acceptable protection, warning, and guidance to motorists, pedestrians, and the workers.

D.      Equipment Storage and Staging.  The Contractor may use, fee-free, any portion of the Project within the Project Right-of-Way for staging, equipment storage, or an office site with the approval of the Engineer, provided such usages do not interfere with the Work and are not prohibited by the Contract Documents.  Do not bid in anticipation of using any properties within the Project Right-of-Way or Department-owned property outside the Project Right-of-Way for equipment storage or staging.

E.      Equipment Removal and Site Restoration.  Remove all Contractor equipment and completely restore all utilized sites used as required by 104.04 before Final Acceptance as provided in 109.12.

107.12  Responsibility for Damage Claims and Liability Insurance.  The Contractor shall indemnify and save harmless the State and all of its representatives, municipalities, counties, public utilities, any affected railroad or railway company, and any fee owner from whom a temporary Right-of-Way was acquired for the Project from all suits, actions, claims, damages, or costs of any character brought on account of any injuries or damages sustained by any person or property on account of any negligent act or omission by the Contractor or its subcontractors or agents in the prosecution or safeguarding of the Work.

The Contractor shall procure and maintain insurance for liability for damages imposed by law and assumed under this Contract, of the kinds and in the amounts hereinafter provided from insurance companies authorized to do business in the State by the Ohio Department of Insurance.  The cost of insurance is incidental to all contract items.  Before the execution of the Contract by the Director, furnish to the Department a certificate or certificates of insurance in the form satisfactory to the Department demonstrating compliance with this subsection.  Provide an insurance certificate or certificates that show that the Contractor’s liability and auto policies coverage are not reduced, restricted, or canceled until 30 days written notice has been given to the Department by the insurer.  Mail all certificates and notices to:  Administrator, Office of Contracts, Ohio Department of Transportation, 1980 West Broad Street, Columbus, Ohio 43223.  Upon request, the Contractor shall furnish the Department with a certified copy of each policy, including the provisions establishing premiums.

The types and minimum limits of insurance are as follows:

A.      Workers’ Compensation Insurance.  Comply with all provisions of the laws and rules of the Ohio Bureau of Workers’ Compensation covering all operations under Contract with the Department whether performed by it or its subcontractors.  In addition, if a portion of the Work is performed from a barge or ship or requires unloading material from a barge or ship on a navigable waterway of the United States, it is the responsibility of the Contractor to arrange coverage for that portion of the Work under the Longshore and Harborworkers’ Compensation Act [33 USC Section 901 et seq.] and the Jones Act [5 USC Section 751 et seq.] and provide proof of coverage to the Department.

B.      Commercial General Liability Insurance.  The minimum limits for liability insurance are as follows:

General Aggregate Limit                       $2,000,000

Products - Completed Operations      

Aggregate Limit                                                $2,000,000

Personal and Advertising Injury Limit         $1,000,000

Each Occurrence Limit                          $1,000,000

Obtain the above minimum coverages through primary insurance or any combination of primary and umbrella insurance.  In addition, the Department will require the General Aggregate Limit on a per project basis.

Ensure that the Commercial General Liability Insurance policy names the State of Ohio, Department of Transportation, its officers, agents, and employees as additional insureds with all rights to due notices in the manner set out above.  Obtain Explosion, Collapse, and Underground (XCU) coverage at the same limits as the commercial general liability insurance policy.  In addition, if blasting is to be performed, obtain XCU coverage providing a minimum Aggregate Limit of $5,000,000 and Each Occurrence Limit of $1,000,000.  Submit proof of insurance, endorsements, and attachments to the Engineer prior to starting the Work.

C.      Comprehensive Automobile Liability Insurance.  The Comprehensive Automobile Liability policy shall cover owned, non-owned, and hired vehicles with minimum limits as follows:

Bodily Injury and Property Damage Liability Limit

Each Occurrence                                    $1,000,000

Insurance coverage in the minimum amounts set forth neither relieves the Contractor from liability in excess of such coverage, nor precludes the Department from taking such other actions as are available to it under any other provisions of this Contract or otherwise in law.

Clearly set forth all exclusions and deductible clauses in all proof of insurance submitted to the Department.  The Contractor is responsible for the deductible limit of the policy and all exclusions consistent with the risks it assumes under this Contract and as imposed by law.

If the Contractor provides evidence of insurance in the form of certificates of insurance, valid for a period of time less than the period during which the Contractor is required by terms of this Contract, then the Department will accept the certificates, but the Contractor is obligated to renew its insurance policies as necessary.  Provide new certificates of insurance from time to time, so that the Department is continuously in possession of evidence that the Contractor’s insurance is according to the foregoing provisions.

If the Contractor fails or refuses to renew its insurance policies or the policies are canceled or terminated, or if aggregate limits have been impaired by claims so that the amount available is under the minimum aggregate required, or modified so that the insurance does not meet the requirements of 107.12.C, the Department may refuse to make payment of any further monies due under this Contract or refuse to make payment of monies due or coming due under other contracts between the Contractor and the Department.  The Department in its sole discretion may use monies retained pursuant to this subsection to renew or increase the Contractor’s insurance as necessary for the periods and amounts referred to above.  Alternatively, should the Contractor fail to comply with these requirements, the Department may default the Contractor and call upon the Contractor’s Surety to remedy any deficiencies.  During any period when the required insurance is not in effect, the Engineer may suspend performance of the Contract.  If the Contract is so suspended, the Contractor is not entitled to additional compensation or an extension of time on account thereof.

Nothing in the Contract Documents and insurance requirements is intended to create in the public or any member thereof a third party beneficiary hereunder, nor is any term and condition or other provision of the Contract intended to establish a standard of care owed to the public or any member thereof.

107.13  Reporting, Investigating, and Resolving Motorist Damage Claims.  The Contractor and the Department are required to report, investigate, and resolve motorist damage claims according to 107.10 and 107.12 and as follows.

When a motorist reports damage to its vehicle either verbally or in writing to the Contractor, the Contractor shall within 3 days make and file a written report to the District’s construction office In the event that the Department directly receives the motorist’s claim, the Department shall within 3 days send the claim report to the Contractor. In the event the Contractor has not agreed to resolve the motorist claim, the District’s construction office shall forward the report to the Department’s Court of Claims Coordinator who, as a co-insured party, may then contact the Contractor’s insurance company and request that the insurance company investigate and resolve the claim. If the Contractor or their insurance company does not resolve the claim in a timely manner, the Department may advise the motorist of the option of pursuing the claim in the Ohio Court of Claims..

In the event of a lawsuit filed against the Department in the Ohio Court of Claims by the motorist, the Department, as co-insured party, may request the Contractor’s insurance company to defend this lawsuit and hold the Department harmless according to 107.12.

If the lawsuit claim amount is $2,500 or less and the Court of Claims Coordinator determines that the Contractor is responsible for the claimed damages then the Department's Court of Claims Coordinator may, after notifying the Contractor, determine that it would be in the best interest of the Department to settle the claim. Any settlement amount including court costs may be assessed to the Contractor and deducted from the project. The Engineer will notify the Contractor prior to executing the deduction. The Contractor or the Contractor's insurance company may within 14 days appeal the assessment decision of the Court of Claims Coordinator to the District Construction Engineer. The decision of the DCA will be made within 14 days and will be administratively final.. 

107.14  Opening Sections of Project to Traffic.  The Engineer may order the Contractor to open a section of the Work to the safe use of traffic at any time.  The Department will make an adjustment according 108.06 and 109.05 to compensate the Contractor for the added costs and delay, if any, resulting from such an opening.

107.15  Contractor’s Responsibility for Work.  Until the Final Inspector accepts the Work during the Final Inspection according to 109.12.A, the Contractor is responsible for the Project and will take every precaution against injury or damage to any part thereof by the action of the elements or from any other cause, whether arising from the execution or from the non-execution of the Work.  Rebuild, repair, restore, and make good all injuries or damages to any portion of the Work occasioned by any of the above causes before final acceptance.  Bear the expense of the repairs except when damage to the Work was due to unforeseeable causes beyond the control of and without the fault or negligence of the Contractor, including but not restricted to weather, civil disturbances, or governmental acts.

In the event that the Engineer determines that damage to completed permanent items of Work results from traffic using a substantially completed section of Roadway, the Department may compensate the Contractor for repair of the damage as authorized by Change Order.  To receive compensation for the damage the Contractor must meet the following requirements.

A.      Notify the Engineer of each occurrence of damage in writing within 10 Calendar Days.

B.      Contact the local law enforcement agency to determine if the accident was investigated and a report filed.  If an accident report was filed, obtain the report and notify the motorist, and copy their insurance company, via registered mail that the motorist is responsible for the cost of damage repairs.  If the motorist does not respond within 30 days, make a second attempt to contact the motorist and copy the insurance company via registered mail.

C.      If no response is received from the motorist or insurance company within 30 days, send a letter to the Engineer and include documentation of good faith effort to seek recovery from responsible parties.

D.      The Department will make an adjustment according to 108.06 and 109.05 to compensate the Contractor for the added costs and delays, if any, resulting from repairing damaged Work.

If there is no accident report on file and no means of identifying the guilty motorist, the Contractor will likewise be compensated to repair the damaged Work.

In case of suspension of Work by the Contractor or under the provisions of 105.01, the Contractor is responsible for the Project and shall take necessary precautions to prevent damage to the Project; provide for normal drainage; and erect any necessary temporary structures, signs, or other facilities at its expense.  During such period of suspension of Work, properly and continuously maintain in an acceptable growing condition all living material in newly established plantings, seedings, and soddings furnished under the Contract, and take adequate precautions to protect new tree growth and other important vegetative growth against injury.

The Engineer may direct the Contractor to remove graffiti any time during the Work.  The Department will make an adjustment according to 108.06 and 109.05 to compensate the Contractor for the added costs and delays, if any, resulting from all ordered graffiti removal.

107.16  Contractor’s Responsibility for Utility Property and Services.  At points where the Contractor’s operations are adjacent to properties of railway, cable, telephone, and power companies, or are adjacent to other property, and any damage to their property may result in considerable expense, loss, or inconvenience, do not commence with the operation until all arrangements necessary for the protection of the property have been made.

Cooperate with the owners of any underground or overhead utility lines in their removal and rearrangement operations to ensure these operations progress in a reasonable manner, that duplication of rearrangement Work may be reduced to a minimum, and that services rendered by those parties will not be unnecessarily interrupted.

In the event interruption to underground or overhead utility services results from an accidental breakage or from being exposed or unsupported, immediately alert the occupants of nearby premises as to any emergency that the accidental breakage may create at or near such premises.  Then notify the Engineer and the owner or operator of the utility facility of the disruption and cooperate with the said utility owner or operator in the restoration of service.  If water service is interrupted, perform the repair work continuously until the service is restored unless the repair work is performed by the local governmental authority.  Do not begin Work around fire hydrants until the local fire authority approves provisions for continued service.

107.17  Furnishing Right-of-Way.  The Department is responsible for securing all necessary Right-of-Way in advance of construction.  The Bid Documents will indicate any exceptions.  The Department will notify all prospective Bidders in writing before the date scheduled for receipt of Bids regarding the specific dates certain parcels will be made available to the Contractor.

107.18  No Waiver of Legal Rights.  The following Department actions do not waive the Department’s rights or powers under the Contract, or any right to damages herein provided:

A.      Inspection by the Engineer or by any of Engineer’s duly authorized representatives.

B.      Any order, measurements, or certificate by the Director, or Department representatives.

C.      Any order by the Director or Department representatives for the payments of money or the withholding of money.

D.      Acceptance of any Work.

E.      Any extension of time.

F.      Any possession taken by the State or its duly authorized representatives.

The Department will not consider any waiver of a breach of this Contract to be a waiver of any other subsequent breach.

107.19  Environmental Protection.  Comply with all Federal, State, and local laws and regulations controlling pollution of the environment.  Avoid polluting streams, lakes, ponds, and reservoirs with fuels, oils, bitumens, chemicals, sediments, or other harmful materials, and avoid polluting the atmosphere with particulate and gaseous matter.

By execution of this contract, the Contractor, will be deemed to have stipulated as follows:

A. That any facility that is or will be utilized in the performance of this contract, unless such contract is exempt under the Clean Air Act, as amended (42 U.S.C. 1857 et seq., as amended by Pub.L. 91-604), and under the Federal Water Pollution Control Act, as amended (33 U.S.C. 1251 et seq., as amended by Pub.L. 92-500), Executive Order 11738, and regulations in implementation thereof (40 CFR 15) is not listed, on the date of contract  award, on the U.S. Environmental Protection Agency (EPA) List of Violating Facilities pursuant to 40 CFR 15.20.

B. That the firm agrees to comply and remain in compliance with all the requirements of Section 114 of the Clean Air Act and Section 308 of the Federal Water Pollution Control Act and all regulations and guidelines listed thereunder.

C. That the firm shall promptly notify the Department of the receipt of any communication from the Director, Office of Federal Activities, EPA, indicating that a facility that is or will be utilized for the contract is under consideration to be listed on the EPA List of Violating Facilities.

D. That the firm agrees to include or cause to be included the requirements of paragraph 1 through 4 of this Section in every nonexempt subcontract, and further agrees to take such action as the government may direct as a means of enforcing such requirements.

Fording of streams is prohibited.  Causeways for stream and river crossings or for Work below a bridge are permitted provided:

A. The causeway complies with the requirements of the 404 Permit the Department obtained for the Project.

B. The Contractor obtains a 404 Permit from the U.S. Army Corps of Engineers if the Department has not obtained such a permit.  Obtain the 404 Permit prior to beginning construction of the causeway.  The Department does not guarantee that the Contractor will be able to obtain a 404 Permit.

Comply with all current provisions of the Ohio Water Pollution Control Act, (OWPCA), (ORC Chapter 6111).  The Department will obtain a storm water permit under the OWPCA provisions when the plan work acreage requires a permit.    Apply for a permit to cover operations outside the Project limits shown on the plans as required by the OWPCA provisions.  When the Department has not applied for a permit on the Project and a permit is required under the provisions of the OWPCA because of the total area of the Contractor’s work, apply for, obtain, and comply with the required permit for both the Work within Project limits and the Contractor’s work.

The Department has obtained the required permits from the U.S. Army Corps of Engineers and Ohio EPA for Work in the “Waters of the United States” and isolated wetlands under ORC Chapter 6111.  Comply with the requirements of these permits.

When equipment is working next to a stream, lake, pond, or reservoir, appropriate spill response equipment is required.  Do not stockpile fine material next to a stream, lake, pond, or reservoir.

Take precautions to avoid demolition debris and discharges associated with the excavation and hauling of material from entering the stream.  Remove any material that does fall into the stream as soon as possible.

When excavating in or adjacent to streams, separate such areas from the main stream by a dike or barrier to keep sediment from entering the stream.  Take care during the construction and removal of such barriers to minimize sediment entering the stream.

Contain, collect, characterize and legally dispose of all waste water and sludge generated during the work. Do not mix waste water with storm water. Do not discharge any waste water without the appropriate regulatory permits.  Manage waste water and sludge in accordance with ORC Chapter 6111 and all other laws, regulations, permits and  local ordinances relating to this waste. Waste water management is incidental to the Work unless otherwise specified in the contract.

Control the fugitive dust generated by the Work according to OAC-3745-17-07(B), OAC-3745-17-08, OAC-3745-15-07, and OAC-3745-17-03 and local ordinances and regulations.  Prior to the initiation of abrasive coating removal, pavement cutting or any other construction operation that generates dust, demonstrate to the Engineer that construction related dust will be controlled with appropriate Reasonable Available Control Measures (RACM) as described in OEPA Engineering Guide #57 (http://epa.ohio.gov/dapc/engineer/eguides.aspx). 

In addition, use dust control measures when fugitive dust creates unsafe conditions as determined by the Engineer.  Perform this work without additional compensation except for Item 616.

Perform open burning according to 105.16.

107.20  Civil Rights.   Comply with Federal, State, and local laws, rules, and regulations that prohibit unlawful employment practices including that of discrimination because of race, religion, color, sex, national origin, disability or age and that define actions required for Affirmative Action and Disadvantaged Business Enterprise (DBE) programs..

107.21  Prompt Payment.  . In accordance with ORC 4113.61, make payment to each subcontractor and supplier within 10 Calendar Days after receipt of payment from the Department for Work performed or materials delivered or incorporated into the Project, provided that the pay estimate prepared by the Engineer includes Work performed or materials delivered or incorporated into the public improvement by the subcontractor or supplier. Promptly release any retainage held, as set forth in any subcontractor or supplier agreement, within 10 days of department's acceptance of the work involving the subcontractor or supplier from whom retainage has been held. For the sole purpose of establishing a time frame for the release of the subcontractor or supplier retainage, acceptance of subcontractor or supplier work will occur when the subcontractor or supplier has complied with the requirements of 109.12.A, B and C.

Also require that this contractual obligation be placed in all subcontractor and supplier contracts that it enters into and further require that all subcontractor and suppliers place the same payment obligation in each of their lower tier contracts.  If the Contractor, subcontractors, or supplier subject to this provision fail to comply with the 10 Calendar Day requirement, the offending party shall pay, in addition to the payment due, interest in the amount of 18 percent per annum of the payment due, beginning on the eleventh Calendar Day following the receipt of payment from the Department and ending on the date of full payment of the payment due plus interest.

Repeated failures to pay subcontractors and suppliers timely pursuant to this subsection will result in a finding by the Department that the Contractor is in breach of Contract and subject to all legal consequences that such a finding entails.  Further, repeated failures to pay timely pursuant to this subsection will result in a lower evaluation score for the Contractor and those subcontractors who are subject to evaluation by the Department.

108  PROSECUTION AND PROGRESS

108.01  Subletting of the Contract.  Perform Work amounting to not less than 50 percent of the Contract Price with its own organization, unless otherwise approved by the Director.  The phrase “its own organization” includes only workers employed and paid directly, inclusive of employees who are employed by a lease agreement acceptable to the Department, and equipment owned or rented with or without operators by the Contractor.  The phrase does not include employees or equipment of a subcontractor, assignee, or agent of the Contractor.  Obtain the Director’s written consent to subcontract, sublet, sell, transfer, assign, or otherwise relinquish rights, title, or interest in the Work.  Provide the Director with a copy of all Disadvantaged Business Enterprise subcontracts.

The Contractor’s percentage of the total Contract Price includes the cost of materials and manufactured products purchased by the Contractor, but not the cost of materials and manufactured products purchased by subcontractors.

The Director will calculate the Contractor’s percentage based on the quantities shown in the Proposal and the unit prices of the contract items to be performed by the Contractor’s organization.  If the Contractor performs only a portion of a contract item, then the Director will determine the proportional value administratively on the same basis.  The Director will follow this procedure even when the part not subcontracted consists only of the procurement of materials.  However, if a firm both sells the materials to the Contractor and performs the Work of incorporating the materials into the Project, then the Department will consider these two phases in combination and as a single subcontract.  If an affiliate of the firm either sells the materials or performs the Work, the Department may refuse approval.  An affiliate is one who has some common ownership or other close relation to said firm.

Use actual subcontract prices for calculating compliance with any Disadvantaged Business Enterprise (DBE) percentage subcontracting obligations.  If only a part of a contract item is sublet, then determine its proportional value administratively on the same basis.  The Director will follow this procedure even when the part not sublet consists only of procuring materials.  However, if a firm both sells the materials to the Contractor and performs the work of incorporating the materials into the Project, then the Department will consider these two phases in combination and as a single subcontract.  If an affiliate of the firm either sells the materials or performs the Work, the Department may refuse approval.

108.02  Partnering.  It is the intent of the Department to partner every project.  The purpose of Partnering is to develop a proactive effort and spirit of trust, respect, and cooperation among all stakeholders in a project.  Partnering does not affect the terms and conditions of the Contract. The Partnering process in this section is Self-facilitated Partnering performed by the Project personnel.  Costs associated with the Self-facilitated Partnering process are incidental to the Contract.

A.      Preconstruction Meeting. Meet with the Engineer for a Preconstruction Meeting before beginning the Work. At or before the meeting, submit the initial progress schedule to the DCA. Prepare the schedule according to 108.03. 

Furnish a list of proposed subcontractors and material suppliers at or before the Preconstruction Meeting. If the Contractor fails to provide the required submissions at or before the Preconstruction Meeting, the Engineer may order the meeting suspended until they are furnished. Do not begin the Work until the meeting is reconvened and concluded or the Engineer gives specific written permission to proceed.

B.      Initial Partnering Session.  In conjunction with the Engineer, determine whether the Initial Partnering Session will be conducted as part of the Preconstruction Meeting or as a separate meeting.    Partnering shall have its own agenda with specific time set aside to develop the necessary partnering protocols.  Develop the Partnering agenda with the Engineer. 

Identify and invite all stakeholders necessary to make the Project successful including utility companies, other transportation entities (i.e., railroads), community leaders, all Project participants including subcontractors. 

During the Initial Partnering Session, consider developing Partnering teams consisting of Department and Contractor senior personnel and Project personnel.  Consider the following items for discussion:

1.      Identifying and developing a consensus on project goals consistent with the contractual obligations, including specific goals concerning safety, quality, schedule, and budget.

2.      Deciding how the teams will measure progress on Project goals.

3.      Identifying any potential risks to the Project’s success, mitigation strategies and an implementation plan for the appropriate strategies.

4.      Defining key issues, project concerns, joint expectations, roles of key partnership leaders, lines of decision making authority, and share relevant information to help determine the scope of the Partnering efforts.

5.      Identifying any opportunities for project enhancement, enhancement strategies and a specific action plan for implementing strategies.

6.      Developing a communication protocol to enhance communication on the Project

7.      Developing an issue identification and resolution process that identifies and attempts to resolve issues at the level closest to the work. The issue identification and resolution process will develop all the necessary steps for issue elevation including Notice and Mitigation defined in 108.02.F and the Dispute Resolution and Administrative Claims Process defined in 108.02.G. 

C.      Progress Meetings.  Hold monthly Progress Meetings unless the frequency is otherwise determined at the Preconstruction Meeting.  Coordinate with the Engineer to determine agenda topics prior to each meeting.  The purpose of Progress Meetings is to keep open communication between the Contractor and the Engineer.  The senior personnel team is encouraged to participate in all Progress Meetings.  Include Partnering as an agenda item at the Progress Meetings.

D.      Post-milestone Meeting.  In conjunction with the Engineer, determine whether the Post-milestone Meeting will be conducted as part of the Progress Meeting or as a separate meeting for multi-year, multi-phase, or projects with critical items of work or milestone dates.  Consider discussing and updating items from the Initial Partnering Session in addition to items specific to the Project.  All stakeholders should be invited to attend.

E.      Partnering Monitoring.  Monitor the progress of the Partnering relationship based on the goals decided during the Initial Partnering Session.  On-line surveys of Project participants may be used to monitor progress on Project goals and help identify issues as they arise.   The on-line surveys are consistent with the Department’s Partnering Project Rating Form which is located on the Division of Construction Management’s Partnering website:

http://www.dot.state.oh.us/Divisions/ConstructionMgt/Pages/Partnering.aspx

F.      Mitigation and Notice.  Mitigation of any issue, whether caused by the Department, Contractor, third-party or an intervening event, is a shared contract and legal requirement.  Mitigation efforts include, but are not limited to, re-sequencing work activities, acceleration, and substitution of materials.  The Contractor and Engineer must explore and discuss potential mitigation efforts in a timely manner.

1.      Contractor Initial Oral Notification.  Provide immediate oral notification to the Engineer upon discovering a circumstance that may require a revision to the Contract Documents or may result in a dispute. Upon notification, the Engineer will attempt to resolve the identified issue as quickly as possible.

2.      Contractor Written Early Notice.  If the Engineer has not resolved the identified issue within 2 working days after receipt of oral notification, provide written notice to the Engineer of any circumstance that may require a revision to the Contract Documents or may result in a dispute. This early notice must be given by the end of the second working day following the occurrence of the circumstance.

The Engineer and Contractor shall maintain records of labor, equipment, and materials used on the disputed work or made necessary by the circumstance. Such records will begin when early notice is received by the Engineer. Tracking such information is not an acknowledgement that the Department accepts responsibility for payment for this disputed work.

If an issue is not resolved through the initial mitigation efforts, either abandon or escalate to the Dispute and Administrative Claims Process defined in 108.02.G.

G.      Dispute Resolution and Administrative Claims Process.  Whenever an issue is elevated to a dispute, the parties shall exhaust the Department’s Dispute Resolution and Administrative Claim process as set forth below prior to  filing an action in the Ohio Court of Claims. The following procedures do not compromise the Contractor’s right to seek relief in the Ohio Court of Claims.

All parties to the dispute must adhere to the Dispute Resolution and Administrative Claim process. Do not contact Department personnel who are to be involved in a Step 2 or Step 3 review until a decision has been issued by the previous tier. Department personnel involved in Step 2 or Step 3 reviews will not consider a dispute until the previous tier has properly reviewed the dispute and issued a decision.

Failure to meet any of the timeframes outlined below or to request an extension may terminate further review of the dispute and may serve as a waiver of the Contractor’s right to file a claim.

Disputes and claims by subcontractors and suppliers may be pursued by the Contractor on behalf of subcontractors or suppliers.  Disputes and claims by subcontractors and suppliers against the Department but not supported by the Contractor will not be reviewed by the Department. Disputes and claims of subcontractors and suppliers against the Contractor will not be reviewed by the Department.

Continue with all Work, including that which is in dispute. The Department will continue to pay for Work.

The Department will not make the adjustments allowed by 104.02.B, 104.02.C, and 104.02.D if the Contractor did not give notice as specified in 108.02.F.1 and 108.02.F.2. This provision does not apply to adjustments provided in Table 104.02-2.

1.      Step 1 (On-Site Determination).  The Engineer will meet with the Contractor’s superintendent within two (2) working days of receipt of the Contractor Written Early Notice set forth in 108.02.F.2.  They will review all pertinent information and contract provisions and negotiate in an effort to reach a resolution according to the Contract Documents.  The Engineer will issue a written decision of Step 1 within fourteen (14) calendar days of the meeting.  If the dispute is not resolved either abandon or escalate the dispute to Step 2.

2.      Step 2 (District Dispute Resolution Committee).  Each District will establish a District Dispute Resolution Committee (DDRC) which will be responsible for hearing and deciding disputes at the Step 2 level.  The DDRC will consist of the District Deputy Director, District Construction Administrator and the Planning and Engineering Administrator or designees (other than the project personnel involved). 

Within seven (7) calendar days of receipt of the Step 1 decision, submit a written request for a Step 2 meeting to the District Construction Administrator (DCA).  The DCA will assign the dispute a dispute number.  Within fourteen (14) calendar days of receipt of the request for a Step 2 meeting, submit the Dispute Documentation as follows:

a)      Submit three (3) complete copies of the documentation of the dispute to the DCA. 

b)      Identify the Dispute on a cover page by county, project number, Contractor name, subcontractor or supplier if involved in the dispute, and dispute number.

c)      Clearly identify each item for which additional compensation and/or time is requested.

d)      Provide a detailed narrative of the disputed work or project circumstance at issue. Include the dates of the disputed work and the date of early notice.

e)      Reference the applicable provisions of the plans, specifications, proposal, or other contract documents in dispute.  Include copies of the cited provisions in the Dispute Documentation.

f)      Include the dollar amount of additional compensation and length of contract time extension requested.   

g)      Include supporting documents for the requested compensation stated in number six (6) above.

h)      Provide a detailed schedule analysis for any dispute involving additional contract time, actual or constructive acceleration, or delay damages.  At a minimum, this schedule analysis must include the Schedule Update immediately preceding the occurrence of the circumstance alleged to have caused delay and must comply with accepted industry practices. Failure to submit the required schedule analysis will result in the denial of that portion of the Contractor’s request.

i)       Include copies of relevant correspondence and other pertinent documents.

Within fourteen (14) calendar days of receipt of the Contractor’s Dispute Documentation the DDRC will conduct the Step 2 meeting with Contractor personnel who are authorized to resolve the dispute.  The DDRC will issue a written decision of Step 2 within fourteen (14) calendar days of the meeting.  If the dispute is not resolved, either abandon or escalate the dispute to Step 3.

3.      Step 3 (Director’s Claims Board Hearing or Alternative Dispute Resolution).  Submit a written Notice of Intent to File a Claim to the Dispute Resolution Coordinator in the Division of Construction Management within fourteen (14) calendar days of receipt of the Step 2 decision.  Include the Contractor’s request for either: 1) a Director’s Claim Board hearing on the claim or 2) an acceptable Alternative Dispute Resolution (ADR) practice. 

The dispute becomes a claim when the Dispute Resolution Coordinator receives the Notice of Intent to File a Claim.

a)      Director’s Claims Board Hearing. The Director’s Claims Board (the Board) will consist of the Deputy Director of the Division of Construction Management, Deputy Director of Engineering and a District Construction Engineer from a district not involved in the claim or designees.  A representative from the Division of Chief Legal Counsel and Equal Opportunity may be present to observe the hearing.  The Director or designee will be responsible for deciding claims.

Submit six (6) complete copies of the Claim Documentation to the Dispute Resolution Coordinator within thirty (30) calendar days of receipt of the Notice of Intent to File a Claim.  This timeframe may be extended upon mutual agreement of the parties and with approval of the Dispute Resolution Coordinator. 

In addition to the documentation submitted at Step 2:

i.        Enhance the narrative to include sufficient description and information to enable understanding by a third party who has no knowledge of the dispute or familiarity with the project. 

ii.       Certify the claim in writing and under oath using the following certification:

“I, (Name and Title of an Officer of the Contractor) certify that this claim is made in good faith, that all supporting data is accurate and complete to the best of my  knowledge and belief, and that the claim amount accurately reflects the contract amendment for which (Contractor Company name) believes the Department is liable.”

Sign and date this claim certification and have the signature notarized pursuant to the laws of the State of Ohio.           The date the Dispute Resolution Coordinator receives the certified claim documentation is the date of the Department’s Receipt of the Certified Claim for the purpose of the calculation of interest as defined in 108.02.G.4. The Dispute Resolution Coordinator will forward one (1) complete copy of this documentation to the District.

Within thirty (30) calendar days of the District’s receipt of the Contractor’s Claim Documentation, the District will submit six (6) complete copies of its Claim Documentation to the Dispute Resolution Coordinator.  In the event that the Contractor is granted a time extension for the submission of its Claim Documentation, the District will be granted an equal time extension for submission of its Claim Documentation.  At a minimum, the District’s Claim Documentation should include:   

i.        An overview of the project.

ii.       A narrative of the disputed work or project circumstance at issue with sufficient description and information to enable understanding by a third party who has no knowledge of the dispute or familiarity with the project. 

iii.      The dates of the disputed work and the date of early notice. 

iv.     References to the applicable provisions of the plans, specifications, proposal, or other contract documents.  Copies of the cited provisions shall be included in the claim document.

v.      Response to each argument set forth by the Contractor. 

vi.     Any counterclaims, accompanied by supporting documentation, the District wishes to assert.

vii.    Copies of relevant correspondence and other pertinent documents.

Within fourteen (14) calendar days of receipt of the District’s Claim Documentation, the Dispute Resolution Coordinator will forward one (1) complete copy to the Contractor and will schedule a hearing on the dispute. 

Once a hearing date has been established, both the Contractor and District shall provide the Dispute Resolution Coordinator with a list of names of persons who may be presenting information at the hearing.  Unless otherwise permitted by the Board, the exchange of documentation and all disclosures specified in this step of the process shall be completed at least fourteen (14) calendar days prior to the hearing. 

Upon request or at the Board’s discretion, the Board may delay the hearing one (1) time to allow more time for review and requests for more documentation.

The Board will hear the entire claim on behalf of the Director.  The Board may have technical advisors at the hearing for assistance in reviewing the claim. The Contractor and District will each be allowed adequate time to present their respective positions before the Board.  The Contractor and District will also each be allowed adequate time for one (1) rebuttal limited to the scope of the opposing party’s presentation.  The Contractor’s position will be presented by a Contractor’s representative who is thoroughly knowledgeable of the claim.  Similarly, the District’s position will be presented by a District representative who is thoroughly knowledgeable of the claim.  Each party may have others assist in the presentation.

The Board may, on its own initiative, request information of the Contractor in addition to that submitted for the hearing. If the Contractor fails to reasonably comply with such request, the Board may render its decision without such information.

Upon completion of the hearing and consideration of any additional information submitted upon request, the Board will submit a written recommendation on the disposition of the claim to the Director.  The Director or designee will ratify, modify, or reject the recommendation of the Board and render a decision within sixty (60) calendar days of the hearing.  Within thirty (30) calendar days of receipt of the Board’s decision, either accept or reject the decision in writing.  In the event the Contractor fails to do so, the Board may revoke any offers of settlement contained in the decision. 

The decision of the Director is the final step of the Department’s Dispute Resolution Process and may not be appealed within the Department.  The Director is not bound by any offers of settlement or findings of entitlement made during Steps 1 and 2 of the Dispute Resolution Process.

b)      Alternative Dispute Resolution (ADR). In lieu of the Board hearing, the Contractor may opt to proceed through an Alternative Dispute Resolution (ADR) Process.  The Department will then choose either binding arbitration as defined by ORC 5525.23 or mediation in the manner in which those methods are practiced by the Department and allowed by law. 

The Dispute Resolution Coordinator will coordinate the agreement of the parties to the ADR method, and the selection of a neutral third party or technical expert. The fees of the neutral third party or technical expert will be shared equally between the Department and the Contractor.  The Dispute Resolution Coordinator will obtain a written agreement, signed by both parties, that establishes the ADR process.  The neutral third party or technical expert will have complete control of the claim upon execution of the ADR agreement.

4.      Interest on Claims.  The Department will pay interest in accordance with ORC Section 5703.47 on any amount found due on a claim which is not paid within 30 days of the Dispute Resolution Coordinator's Receipt of the Certified Claim.

H.     Post Construction Meeting.  The District will conduct a Post Construction Meeting with the Contractor prior to the project finalization. The District will invite the design agency and any other stakeholders deem necessary including utility companies, other transportation entities (i.e. railroads), community leaders, all Project participants including subcontractors performing critical work to attend this meeting.

 Consider the following items for discussion:

1,      Project Safety.

2.      How were the goals evaluated or measured?

3.      How were foremen/ workers involved in the Partnering process?

4.      How were the subcontractors involved in the Partnering process?

5.      How were relationships with key stakeholders managed?

6.      Teambuilding activities or unique motivational activities.

I.       Partnering Close-Out Survey.  Complete the final Partnering evaluation to get participants’ feedback and improve the Partnering process.  The Partnering Close-Out Survey is located on the Division of Construction Management’s Partnering website:

http://www.dot.state.oh.us/Divisions/ConstructionMgt/Pages/Partnering.aspx

108.03  Prosecution and Progress.  Start the Work according to 108.02.  Notify the Engineer at least 24 hours before starting the Work.  If the prosecution of the Work is suspended, notify the Engineer a minimum of 24 hours in advance of resuming operations.

Pursue the Work diligently and continuously as to complete the Project by the Completion Date.

A.      Progress Schedule.

1.      General.  Furnish a bar chart progress schedule to the District Construction Engineer for review at or before the Preconstruction Meeting.  The Engineer will review the schedule and within 14 calendar days of receipt, will either accept the schedule or provide the Contractor with comments.  Acceptance of the schedule does not revise the Contract Documents.  Provide clarification or any needed additional information within 10 days of a written request by the Engineer.  The Department will withhold Estimates until the Engineer accepts the schedule.  The Engineer will not measure or pay for the preparation of the schedule and schedule updates directly, but the cost of preparing and updating the schedule is incidental to all Contract Items.     

a.      Include the following Administrative Identifier Information:

(1)     Project Number

(2)     County

(3)     Route Number

(4)     FHWA Number

(5)     PID Number

(6)     Contract Number

(7)     Date of Contract

(8)     Completion Date

(9)     Contractor's Name

(10)  Contractor's Dated Signature

(11)  ODOT's Dated Acceptance Signature

Provide a working day schedule that shows the various activities of Work in sufficient detail to demonstrate a reasonable and workable plan to complete the Project by the Completion Date.  Show the order and the sequence for accomplishing the Work.  Describe all activities in sufficient detail so that the Engineer can readily identify the Work and measure the progress of each activity.  The bar chart schedule must reflect the scope of work, required phasing, maintenance of traffic requirements, interim completion dates, the Completion Date, and other project milestones established in the Contract Documents.  Include activities for submittals, working and shop drawing preparation, submittal review time for the Department, material procurement and fabrication, and the delivery of materials, plant, and equipment, and other similar activities.  The schedule must be detailed on letter or legal sized paper.

b.      Activity requirements are discussed in further detail as follows:

(1)     Activity Description.  Assign each activity an unambiguous descriptive word or phrase.  For example, use "Excavate Area A," not "Start Excavation."

(2)     Activity Original Duration.  Indicate a planned duration in calendar days for each activity.  Do not exceed a duration of 20 working days for any activity unless approved by the Engineer.  Do not represent the maintenance of traffic, erosion control, and other similar items as single activities extending to the Completion Date.  Break these Contract Items into component activities in order to meet the duration requirements of this paragraph.

2.      Early Completion Schedule.  An Early Completion Schedule is defined as a baseline schedule or update schedule which anticipates completion of all work prior to the Completion Date established by the contract documents and the Contractor submits as an Early Completion Schedule.  In the event that an Early Completion Schedule is accepted, the Engineer will initiate a change order amending the Completion Date to the finish date shown on the accepted Early Completion Schedule.  The amended Completion Date will be effective upon execution of that change order and all contract provisions concerning the Completion Date such as incentives, disincentives, excusable delays, compensable delays, and liquidated damages will be measured against the amended Completion Date. The Contractor may elect not to execute the change order amending the Completion Date; however, in so doing, the Contractor waives its rights to delay damages in meeting the projected early Completion Date.

3.      Updated Progress Schedule.  Submit an updated progress schedule when ordered by the Engineer.  The Engineer may request an updated progress schedule when progress on the work has fallen more than 14 calendar days behind the latest accepted progress schedule.  Information in the updated schedule must include a "% work completed" value for each activity.

4.      Recovery Schedule.  If the progress schedule projects a finish date for the Project more than 14 calendar days later than the Completion Date, submit a revised schedule showing a plan to finish by the Completion Date.  The Department will withhold Estimates until the Engineer accepts the revised schedule.  The Engineer will use the schedule to evaluate time extensions and associated costs requested by the Contractor.

108.04  Limitation of Operations.  Limit operations to prevent unnecessary inconvenience to the traveling public.  If the Engineer concludes that the extent of the Contractor’s Work unnecessarily inconveniences the public or concludes limiting operations are necessary to protect the existing or new construction from damage, the Engineer will require the Contractor to finish portions of Work in progress before starting new Work.

108.05  Character of Workers Methods and Equipment.  Provide personnel with sufficient skills and experience to perform assigned tasks.

Ensure that no debarred individuals listed on the Federal website: www.epls.gov or State debarment list at the website: www.dot.state.oh.us/divisions/contractadmin/ act in any ownership, leadership, managerial, or other similar position that could influence the operations of an entity doing business with the Department.

If the Engineer gives written notification that specific Contractor or subcontractor personnel are improperly performing the Work, intemperate, disorderly, or creating a hostile work environment, remove the identified personnel from the Project.  Do not allow removed personnel to return to the Project without the Engineer’s approval.

The Engineer may suspend the Work by written notice under this subsection for the following reasons:

A.      The Contractor does not furnish sufficient skilled and experienced personnel to complete the Project by the Completion Date.

B.      The Contractor does not remove personnel from the Project as directed in writing by the Engineer.

Use equipment of sufficient size and mechanical condition to complete the Project by the Completion Date.  Ensure that the equipment does not harm the roadway, adjacent property, other highways, workers, or the public.

If the Contract Documents do not prescribe the methods and equipment required to accomplish the Work, determine the methods or equipment necessary to complete the Work according to the Contract.

If the Contract Documents specify methods and equipment to perform the Work, use such methods and equipment, unless others are authorized by the Engineer.  Obtain the Engineer’s written approval before substituting alternate methods or equipment.  To obtain the Engineer’s approval, submit a written description of the alternate methods and equipment proposed and an explanation of the reasons for making the change.  The Engineer’s approval of the substitute methods and equipment does not relieve the Contractor of the obligation to produce Work according to 105.03.  If after trial use of the substituted methods or equipment, the Engineer determines that the Work does not conform to the Contract Documents, then complete the remaining Work using the specified methods and equipment.  Remove all deficient Work and replace it according to the Contract Documents, or take such other corrective action as directed by the Engineer.  The Engineer’s authorization to substitute alternate methods and equipment will not change the basis of payment for the construction items involved or the Contract Time.

108.06  Determining a Time Extension to the Completion Date and Payment for Excusable Delays.

A.      General.  The Department will only extend the Completion Date if an excusable delay, as specified in 108.06.B or 108.06.D, delays Work on the critical path shown on the accepted progress schedule and impacts the Completion Date.  The critical path is defined as; the longest path of activities in the project that determines the project schedule completion date.  The activities that make-up the critical path of activities are the “Critical Activities.”  Any extension of the Completion Date will be executed by a change order.

Mitigation of any delay, whether caused by the Department, Contractor, third-party or an intervening event, is a shared contract and legal requirement.  Mitigation efforts include, but are not limited to, re-sequencing work activities, acceleration, and continuation of work through an otherwise planned shutdown period.  The Contractor and Engineer must explore and discuss potential mitigation efforts in a timely manner. 

The Department will not evaluate a request for extension of the Completion Date unless the Contractor notifies the Engineer as specified in 108.02.F. Notification shall be in writing to the Engineer within 30 days following the termination of the event giving rise to the request and shall be accompanied by supporting analysis and documentation.

The Engineer will evaluate the Contractor’s analysis and determine the time extension due, if any.  The Engineer will measure all time extensions in Calendar Days.  For delays measured in Workdays, the Engineer will convert Workdays to Calendar Days by multiplying by 1.4 for a 5-day work week or less; 1.2 for a 6-day work week; and 1 for a 7-day work week; and extend the Completion Date by the resulting number of Calendar Days plus any holidays the Contractor does not normally work that occur in the extension period.  When the conversion of Workdays to Calendar Days results in a decimal of 0.5 or greater, the Engineer will round the number of Calendar Days to the next highest whole number.  When the conversion results in a decimal less than 0.5, the Engineer will delete the decimal portion of the Calendar Days.

The Engineer will not grant an extension of time for delays incurred from December 1 to April 30 unless the Contractor’s accepted progress schedule depicts work on the critical path occurring during this period.

The Engineer may order the Contractor to continue Work after November 30 and compensate the Contractor for costs incurred due to cold weather Work.

The Contractor’s plea that insufficient time was specified is not a valid reason for an extension of time.

The Department will relieve the Contractor from associated liquidated damages, as specified in 108.07, if the Engineer extends the Completion Date under 108.06.A.

The extended Completion Date shall then have the same standing and effect as though it was the original Completion Date.

If the Contractor contends that an excusable delay is also compensable, as specified in 108.06.D, submit a detailed cost analysis of the requested additional compensation along with the request for extension of Completion Date.

B.      Excusable, Non-Compensable Delays.  Excusable, non-compensable delays are delays that are not the Contractor’s or the Department’s fault or responsibility.  The Engineer will not grant additional payment for excusable, non-compensable delays.

The following are excusable, non-compensable delays:

1.      Delays due to floods, tornadoes, lightning strikes, earthquakes, or other cataclysmic phenomena of nature.

2.      Delays due to weather as specified in 108.06.C.

3.      Extraordinary delays in material deliveries the Contractor or its suppliers cannot foresee or avoid resulting from freight embargoes, government acts, or area-wide material shortages.  Delays due to the Contractor’s, subcontractor’s, or supplier’s insolvency or mismanagement are not excusable.

4.      Delays due to civil disturbances.

5.      Delays from fires or epidemics.

6.      Delays from labor strikes that are beyond the Contractor’s, subcontractor’s, or supplier’s power to settle and are not caused by improper acts or omissions of the Contractor, subcontractor, or supplier.

7.      Added quantities that delay an activity on the critical path.

8.      All other delays not the Contractor’s and Department’s fault or responsibility.

C.      Extension to the Completion Date for Weather or Seasonal Conditions.  A weather day is defined as a workday that weather or seasonal conditions reduced production by more than 50 percent on items of work on the critical path. Submit the dates and number of weather days in writing to the Engineer at the end of each month.  In the event the Contractor fails to submit weather days at the end of each month the Engineer will determine the dates and number of weather days from project records.  

Delays caused by weather and seasonal conditions should be anticipated and will be considered as the basis for an extension of time when the Contractor’s accepted progress schedule depicts Work on the critical path and the actual workdays lost exceeds the number of work days lost each month as determined by Table 108.06-1.

Table 108.06-1

Month

Number of Workdays

Lost Due to Weather

January

8

February

8

March

7

April

May

June

July

August

September

October

November

December

6

5

5

4

4

5

6

6

6

The Engineer will not consider weekends and holidays as lost workdays unless the Contractor normally works those days or unless the Engineer directs the Contractor to work those days.

D.      Excusable, Compensable Delays.  Excusable, compensable delays are delays that are not the Contractor’s fault or responsibility, and are the Department’s fault or responsibility or are determined by judicial proceeding to be the Department’s sole responsibility or are the fault and responsibility of a local government.  For the following excusable, compensable delays, the Engineer will extend the Completion Date if the conditions specified in 108.06.A are met:

1.      Delays due to revised Work as specified in 104.02.B, 104.02.D, or 104.02.F.

2.      Delays due to utility or railroad interference within the Project limits.

3.      Delays due to an Engineer-ordered suspension as specified in 104.02.C.

4.      Delays due to acts of the government or a political subdivision other than the Department; however, these compensable delay costs are limited to escalated labor and material costs only, as allowed in 109.05.D.2.b and 109.05.D.2.d.

5.      Delays due to the neglect of the Department or its failure to act in a timely manner.

Compensation for excusable, compensable delays will be determined by the Engineer according to 109.05.D.

E.      Non-Excusable Delays.  Non-excusable delays are delays that are the Contractor’s fault or responsibility.  All non-excusable delays are non-compensable.

F.      Concurrent Delays.  Concurrent delays are separate critical delays that occur at the same time.  When a non-compensable delay is concurrent with a compensable delay, the Contractor is entitled to additional time but not entitled to additional compensation.

108.07  Failure to Complete on Time.  If the Contractor fails to complete the Work by the Completion Date, then the Director, if satisfied that the Contractor is making reasonable progress, and deems it in the best interest of the public, may allow the Contractor to continue in control of the Work.  The Department will pay the Contractor for Work performed on the Project less any liquidated damages incurred.

If the Work is not completed by the Completion Date and the Director permits the Contractor to remain in control, prosecute the Work at as many different places, at such times, and with such forces as the Director requests.  Provide a written plan for the completion of the Work.

For each calendar day that Work remains uncompleted after the Completion Date, the Department will deduct the sum specified herein from any money due the Contractor, not as a penalty, but as liquidated damages.  The Director will adjust the Completion Date or other contractually mandated dates for delays specified in 108.06.B.7 and 108.06.D. 

Permitting the Contractor to continue and complete the Work or any part of the Work after the Completion Date, or after extensions to the Completion Date, will in no way operate as a waiver on the part of the Department of any of its rights under the Contract.

The Director may stop deducting liquidated damages when:

A.      The Work is substantially complete and the project is available for use as intended by the contract.

B.      The Contractor is diligently pursuing the remaining Work.

C.      The Work remaining will not interfere with the intended use of the project and will not impact traffic. For the limited purposes of assessing liquidate damages, the closing of a shoulder is not considered an impact upon traffic.   

D.      All contract safety items are complete and operational. These safety items include but are not limited to signs, pavement markings, guardrail, attenuators, and signals. Raised pavement markers (RPM) are required safety items if the roadway section involved had RPMs before the project started.

E.      Deemed reasonable and appropriate by the District Deputy Director.

Table 108.07-1  SCHEDULE OF LIQUIDATED DAMAGES

Original Contract Amount

(Total Amount of the Bid)

Amount of Liquidated

Damages to be

Deducted for Each

Calendar Day of

Overrun in Time

From More Than

To and Including

$0.00

$500,000

$500

$500,000

$2,000,000

$1,000

$2,000,000

$10,000,000

$1,500

$10,000,000

$50,000,000

$2,600

Over $50,000,000

$3,200

108.08  Unsatisfactory Progress and Default of Contractor.  The Director will notify the Contractor in writing of unsatisfactory progress for any of the following reasons:

A.      The Contractor has not commenced the Work by the dates established in the schedule.

B.      The Contractor does not proceed with the Work in a manner necessary for completion of the Project by the Completion Date.

C.      The Contractor is performing the Work improperly.

D.      The Contractor abandons, fails, or refuses to complete the Work.

E.      Any other reason the Director believes jeopardizes completion of the Work by the Completion Date.

If the Contractor does not respond to the satisfaction of the Director, the Director may declare the Contractor in default and may notify the Contractor and Surety that the responsibility to complete the Work is transferred to the Surety.  Upon receipt of this notification, the Contractor’s right to control and supervise the Work will immediately cease.  In such a case, the Director will proceed as specified in ORC 5525.17.  The defaulted Contractor will not be compensated for costs resulting from the default and is not eligible to be retained by the Surety to complete the Work.  If it is determined that the Department’s default of the Contractor according to 108.08 is wrongful, then the default will revert to a termination of the Contract according to 108.09.

108.09  Termination of the Contract for Convenience of the Department.  The Director may terminate the Contract at any time for the convenience of the Department.  The Department will compensate the Contractor according to 109.04 and 109.05 for termination of the Contract for the convenience of the Department.  This subsection is subject to the provisions of ORC 5525.14.

108.10  Payroll Records.  Keep payroll records as specified in ORC 4115.07 or as required by Federal law.

Authorized representatives of the Director may inspect the certified payroll and other payroll records.  Upon completion of the Work and before receiving the final estimate and when required by ORC 4115.07, submit an affidavit stating that wages have been paid according to the minimum rates specified in the Contract Documents.

109  ACCEPTANCE, MEASUREMENT, AND PAYMENT

109.01  Measurement of Quantities.  The Department will measure the quantities of Work and calculate payments based on the method of measurement and basis of payment provisions provided in these Specifications. When the following units of measure are specified, the Department will measure quantities as described below unless otherwise specified in the Contract Documents. The accuracy of individual pay item estimate payments will be one decimal more accurate than the unit of measure denoted for the pay item.

Lump Sum.  Not measured.  Describes payment as reimbursement for all resources necessary to complete the Work.  When a complete structure or structural unit is specified as the unit of measurement, the unit will include all necessary fittings and accessories.

Each.  Measured by the number of individual items of Work completed.

Foot (Meter).  Measured parallel to the longitudinal base or foundation upon which items are placed, or along the longitudinal surface of the item. Measured vertically to the nearest 0.1 foot (0.01 m), with a minimum vertical measurement of 1 foot (0.10 m), at each unit.

Square Yard or Square Foot (Square Meter).  Measured by a two-dimensional area method on the surface of the item.

M Square Feet.  One thousand square feet.

Cubic Yard (Cubic Meter).  Measured by a three-dimensional volume method.  Measure all “loose material” or material “measured in the vehicle” by the cubic yard (cubic meter).  Haul material “measured in the vehicle” in approved vehicles and measure in the vehicle at the point of delivery.  For this purpose, use approved vehicles of any type or size satisfactory to the Engineer, provided the vehicle’s bed is of such type that the actual contents are readily and accurately determined.  Unless all approved vehicles on a job are of uniform capacity, each approved vehicle must bear a legible identification mark indicating the specific approved capacity.  The Inspector may reject all loads not hauled in such approved vehicles.

Cubic Yard (Cubic Meter) for Asphalt Concrete.  Measure as specified in 401.21.

Acre (Hectare).  Measured by a two-dimensional area method on the surface to the nearest 0.1 acre (0.05 ha).

Pound (Kilogram).  Measured by actual item net weight avoirdupois (mass).

Ton (Metric Ton).  The term “ton” means the short ton consisting of 2000 pounds avoirdupois.  The term “metric ton” means 1000 kilograms.  Weigh all materials that are proportioned by weight on accurate and approved scales that are operated by competent, qualified personnel at locations approved by the Engineer.  However, car weights will not be acceptable for materials to be passed through mixing plants.  If trucks are used to haul material being paid for by weight, weigh the empty truck at least once daily and as the Engineer directs and only if the weight of the truck is used in determining the ticket weight.  Place a plainly legible identification mark on each truck bearing the weight of the truck.

For Work on a tonnage basis, file with the Engineer receipted freight bills for railroad shipments and certified weight-bills when materials are received by any other method, showing the actual tonnage used.  For Work on a volume basis, itemize evidence of the volume used.

Gallon (Liter).  Measured by actual item liquid volume.  The Department will measure the following materials by the gallon (liter) at the following temperatures:

Temperatures

Items

60 °F (16 °C)

Creosote for Priming Coat, Creosote Oil, Creosote Solutions for Timber Preservatives, Asphalt Primer for Water-proofing, and Liquefier

100 °F (38 °C)

RC, MC Asphalt Emulsions, CBAE, Primer 20, and Primer 100

300 °F (149 °C)

Asphalt Binder

Measure tank car outage of asphalt material at its destination before any material has been removed from the tank car according to Supplement 1060.

Convert the net weight of asphalt material shipments to gallons (liters) at the specified pay temperature according to Supplement 1060.

Convert the gallons (liters) at the measured temperature to gallons (liters) of asphalt material at the specified pay temperature according to Supplement 1060.

M Gallon.  One thousand gallons.

Thousand Board Feet, MBF (Cubic Meter).  Measure timber by MBF (cubic meter) actually incorporated in the structure.  Base the measurement on nominal widths, thicknesses, and the extreme length of each piece.

Standard Manufactured Items.  When standard manufactured items are specified such as fence, wire, plates, rolled shapes, pipe conduit, etc., and these items are identified by size, unit weight, section dimensions, etc., such identification will be to nominal weights or dimensions set by the industry.

109.02  Measurement Units.  The Department will measure using either English or metric units as indicated in the Contract Documents.  Use the Tables 109.02-1 and 109.02-2 to convert units when required.  If Tables 109.02-1 and 109.02-2 do not provide a required factor, then use the appropriate factor provided in the IEEE/ASTM SI 10.

Table 109.02-1  English to SI (Metric) Conversion Factors

Symbol

When You Know

Multiply By

To Find

Symbol

Length

mil

mils

25.4

micrometers

µm

in

inches

25.4

millimeters

mm

ft

feet

0.3048

meters

m

yd

yards

0.9144

meters

m

mi

miles

1.609347

kilometers

km

Area

in²

square inches

645.16

square millimeters

mm²

ft²

square feet

0.09290304

square meters

m²

yd²

square yards

0.8361274

square meters

m²

ac

acres

0.4046873

hectares

ha

ac

acres

4046.873

square meters

m²

mi²

square miles

2.589998

square kilometers

km²

Volume

fl oz

fluid ounces

29.57353

milliliters

mL

gal

gallons

3.785412

liters

L

ft³

cubic feet

0.02831685

cubic meters

m³

yd³

cubic yards

0.7645549

cubic meters

m³

Mass

oz

ounces

28.34952

grams

g

lb

pounds

0.4535924

kilograms

kg

T

2000 pounds

0.9071847

metric tons

t

Temperature

°F

Fahrenheit

C = (F-32)/1.8

Celsius

°C

Illumination

fc

foot-candles

10.76391

lux

lx

fl

foot-lamberts

3.426259

candelas per
square meter

cd/m²

Force and Pressure or Stress

lbf×ft

pounds-force foot

1.355818

newton meter

N×m

lbf

pounds force

4.448222

newtons

N

lbf/ft²
(psf)

pounds force per
square foot

47.88026

pascals

Pa

lbf/in²
(psi)

pounds force per
square inch

0.006894757

megapascals

MPa

Table 109.02-2  SI (Metric) to English Conversion Factors

Symbol

When You Know

Multiply By

To Find

Symbol

Length

µm

micrometers

0.03937

mils

mil

mm

millimeters

0.03937

inches

in

m

meters

3.28084

feet

ft

m

meters

1.093613

yards

yd

km

kilometers

0.62137

miles

mi

Area

mm²

square millimeters

0.00155

square inches

in²

m²

square meters

10.76391

square feet

ft²

m²

square meters

1.19599

square yards

yd²

ha

hectares

2.4710437

acres

ac

m²

square meters

0.000247

acres

ac

km²

square kilometers

0.3861

square miles

mi²

Volume

mL

milliliters

0.033814

fluid ounces

fl oz

L

liters

0.264172

gallons

gal

m³

cubic meters

35.31466

cubic feet

ft³

m³

cubic meters

1.30795

cubic yard

yd³

Mass

g

grams

0.035274

ounces

oz

kg

kilograms

2.204622

pounds

lb

t

metric tons

1.1023114

2000 pounds

T

Temperature

°C

Celsius

F = 1.8C + 32

Fahrenheit

°F

Illumination

lx

lux

0.09290304

foot-candles

fc

cd/m²

candelas per
square meter

0.29186352

foot-lamberts

fl

Force and Pressure or Stress

N×m

newton meters

0.7375621

pounds-foot force

lbf ft

N

newtons

0.22480892

pound force

lbf

Pa

pascals

0.02088543

pounds force per
square foot

lbf/ft²
(psf)

MPa

megapascals

145.03774

pounds force per
square inch

lbf/in²
(psi)

109.03  Scope of Payment.  Payment of the Contract Price is full compensation for all resources necessary to complete the Contract Item and maintain the Work. Assume liability for risk, loss, damage, or expense resulting from the Work.  The Contract Price and Contract Time shall only be changed by written Change Order or as determined by the Department in writing in accordance with the contract documents.

109.04  Compensation for Altered Quantities, Eliminated Items or Termination of the Contract for Convenience of the Department.  If the agreed quantities of contract items vary from the quantities in the Contract, the Department will make payment at the original Contract unit prices for the agreed quantities of Work. 

A.      If an item is eliminated in accordance with 104.02.E or the contract is terminated in accordance with 108.09 the Department will pay the following in addition to that provided by 104.02.D:

1.      Restocking charges supported by paid invoices and an additional 5 percent markup on the compensation for overhead and profit.

2.      The cost of material transferred to the Department or a local government agency in lieu of restocking or disposal.  The allowed compensation is the paid invoice cost plus 15 percent markup, but no more than the unit bid price for the reference number involved.

3.      Hauling costs, if not included in restocking charges, for returned material and for material delivered to the Department.

B.      If the project is terminated for convenience of the Department, the Department will negotiate compensation with the Contractor for actual costs incurred as a result of the termination. The Department will pay for Extra Work as stipulated in approved Extra Work Change Orders or written authorizations subject to the limitations set forth in ORC 5525.14.  Such authorizations for emergencies and to avoid Project delays are in advance of an approved Extra Work Change Order and commit the Department only to the terms of the authorizations.  The Department will pay for Extra Work after the approval of the subsequent Change Order.

109.05  Changes and Extra Work. 

A.      General.  If the Department revises the Contract under: 104.02, 105.07, 105.10, 105.13, 107.10, 107.14, 107.15, 108.09, 109.06, or 109.07, the Department will pay for changes and Extra Work with a Change Order using the sequence specified in 109.05.B through 109.05.E.

In establishing the method of payment for contract changes or extra work orders, force account procedures shall only be used when strictly necessary, such as when agreement cannot be reached with the contractor on the price of a new work item, or when the extent of work is unknown or is of such character that a price cannot be determined to a reasonable degree of accuracy. The reason or reasons for using force account procedures shall be documented.

Unless otherwise stated in 109.05, the compensation provided in 109.05.B through 109.05.E constitutes payment in full for all changes and Extra Work completed by original Contract Price, agreed unit price, agreed lump sum price, and for work performed on a force account basis, including:

1.      Administration.

2.      Superintendence.

3.      Project and field office overhead.

4.      Home office overhead.

5.      Use of tools and equipment for which no rental is allowed.

6.      Profit.

7.      Taxes other than sales tax.

8.      Premiums on insurance including additional premiums for Commercial General Liability Insurance required by 107.12.B and any additional coverage carried by the Contractor or subcontractor, excluding pollution and railroad General Liability Insurance.  The Department will pay the Contractor’s pollution and railroad liability insurance premiums, if required by the contract,  by a separate Change Order for the cost of the premium without any markup.  When the Contractors or subcontractors basic rate for General Commercial Liability Insurance required by 107.12.B is greater than 5 percent of payroll, the Department will pay directly without markup the portion of the premium in excess of 5 percent and provide copies of paid premiums.

Sales tax will not be allowed on any item for which tax exemption was obtained.

B.      Negotiated Prices.  Negotiated prices for changes and Extra Work shall be comparable to prices that would have resulted from a competitive bid contract.  The Engineer and Contractor will negotiate agreed unit or lump sum prices using one or more of the following methods:

1.      Original Contract prices for similar work but adjusted for:

a.      increased or decreased material costs specified in 109.05.C.3.

b.      increased or decreased labor costs specified in 109.05.C.2

c.      increased or decreased equipment costs specified in 109.05.C.4

Adjustments of these prices for inflation or markup for subcontractor work is not allowed.

2.      State-wide average unit price awarded for the item or items as listed in the Department’s annual “Summary of Contracts Awarded.”  These prices may be adjusted for inflation using factors issued by the Office of Construction Administration.  No markup for subcontractor work is allowed.

3.      Average price awarded on three different projects of similar work and quantity.  These prices may be adjusted for inflation using factors issued by the Office of Construction Administration.  No markup for subcontractor work is allowed.

4.      Prices computed by the Office of Estimating.

5.      Cost analysis of labor, material, equipment, and markups as allowed in 109.05.C.

6.      For the cost of compensable delays as defined in 108.06, prepare a cost analysis as allowed by 109.05.D.

Provide proposed pricing and cost justification for changes or Extra Work within 5 business days after the Department’s request.  The Department will respond within 5 business days after receipt of the Contractor’s proposal.  The Department and the Contractor can mutually agree to extend these 5-day time limits.

If the Department negotiates with the Contractor but does not agree on a price adjustment, the Engineer may direct the Contractor to perform all or part of the revised Work under force account. 

C.      Force Account.

1.      General.  The Engineer may direct the Contractor to perform the revised Work under force account.  Submit a written proposal and estimated costs for the Work, including the planned equipment, materials, labor, a work schedule.

The Department will pay the Contractor as specified in 109.05.C as full compensation for performing the force account Work.  The Project and Contractor personnel will document the labor and equipment used on the force account work on a Daily Force Account Record.  At the end of each Workday, the Project and Contractor personnel will compare and sign the Daily Force Account Record. The Department will make no force account payment before the Contractor submits an itemized statement of the costs for that work.

The Engineer will examine and, if found to be acceptable, approve all rates and costs submitted by the Contractor.

Provide the following content in itemized statements for all force account work:

a.      Name, classification, date, daily hours, total hours, rate, and amount for all labor.

b.      Designation, dates, daily hours, total hours of actual operation and idle time, Blue Book rate with reference or category, and amount for each unit of equipment and the applicable Blue Book hourly operating cost for each unit of equipment and invoices for all rental equipment.  The designation includes the manufacturer’s name or trademark, model number, and year of manufacture.

c.      Quantities of materials and prices.

d.      Transportation charges on materials, free on board (F.O.B.) at the job site.

e.      Cost of workers’ compensation insurance premiums, all applicable insurance premiums, unemployment insurance contributions, and social security tax and fees or dues required by a collective bargaining agreement.  Express each of these items of cost as a percentage of payroll, except fees or dues, which should be expressed as a cost per hour.

f.       Documentation showing payment for all surveying, professional, or similar specialized Work not normally a part of a Department contract.

g.      If materials are taken from Contractor’s stock and original receipted invoices for the materials and transportation charges do not exist, provide an affidavit and certify all of the following:

(1)     The materials were taken from the Contractor’s stock.

(2)     The quantity shown was actually used for the force account work.

(3)     The price and transportation costs represent the actual cost to the Contractor.

h.      Documentation showing payment to trucking firms and owner-operators.  Submit documentation showing owner-operations status.  When the trucking is subject to prevailing wage, submit payroll and equipment usage records according to 109.05.C.1.a, 109.05.C.1.b, and 109.05.C.1.e.

i.       Provide “receipted invoices” for all costs substantiated by an invoice. 

If only part of the expenditure represented by an invoice is applicable to force account work, or if the invoice represents expenditure for more than one item of work, clearly indicate the actual amount of expenditure applicable to each item of work. 

2.      Labor.  The Department will pay the wages and fringe benefits currently in effect for each hour the Work is performed by all labor employed in the Work and all foremen in direct charge of the specific operation.  The Department will pay an additional 38 percent markup on these wages and benefits.  “Fringe benefits” are the actual costs paid to, or on behalf of, workmen by reason of health and welfare benefits, pension fund benefits, or other benefits, when such amounts are required by prevailing wage laws or by a collective bargaining agreement or other employment contracts generally applicable to the classes of labor employed on the Project.

The Department will pay the actual itemized cost, without markup, of the following payroll taxes and legally required insurances:

a.      Social Security Tax.

b.      Medicare Tax.

c.      Ohio Workers’ Compensation Premiums.

d.      State and Federal Unemployment Insurance.

e.      Longshore and Harborworkers’ Compensation Insurance for work from a barge or ship, or unloading material from a barge or ship.

Provide itemized statements in addition to the documentation requirements for all labor including the name, classification, date, daily hours, total hours, rate, and amount.  If any person is paid more than the one rate, a separate listing shall be made for that person for each rate paid.  Provide itemized statements for  Ohio Workers’ Compensation insurance premiums, all applicable insurance premiums, State and Federal Unemployment Insurance contributions, and Social Security Tax and fees or dues required by a collective bargaining agreement.  Express each of these items of cost as a percentage of payroll, except fees or dues, which shall be expressed as a cost per hour.

Instead of itemizing the cost of Social Security Tax, Ohio Workers’ Compensation, and State and Federal Unemployment Insurance, the Contractor may elect to receive as compensation for these payroll taxes and premiums, an amount equal to 22 percent of the paid wages.  If the Contractor pays fringes directly to the worker in lieu of paying into a fringe benefit program, then the Department will treat these fringe payments as paid wages when calculating the allowed 22 percent compensation.

The Department will pay, without markup, the actual itemized cost of fees and dues paid to labor unions or to business associations when they are based on payroll hours and required by a collective bargaining agreement.

The Department will not pay for wages or benefits for personnel connected with the Contractor’s forces above the classification of foreman that have only general supervisory responsibility for the force account work.

If the foreman or timekeeper is employed partly on force account work and partly on other work, the Contractor shall prorate the number of hours between the force and non-force account work according to the number of people on each task as shown on payrolls.

The Department will pay the prevailing wage and fringe rates that apply to the Project for the classifications required for Extra Work.  The Contractor must provide payroll records for pay rates higher than the prevailing wages and establish that the higher than prevailing rates are paid for original Contract Work.  The Department will pay for foremen and time keepers not covered by prevailing wages not more than the salaried rate they receive when engaged in original Contract Work.

The Department will pay actual costs for subsistence and travel allowances when such payments are required by the collective bargaining agreement or other employment contracts applicable to the classes of labor employed on the Project.  The Department will not pay a percent markup on these costs.

3.      Materials.  The Department will pay the Contractor’s actual invoice costs, including applicable taxes and actual freight charges, for Engineer approved materials the Contractor uses in force account Work.  The Department will pay an additional 15 percent markup on these costs.

Freight or hauling costs charged to the Contractor and not included in unit prices shall be itemized and supported by invoices.  The cost of owned or rented equipment used to haul materials to the project is not part of the materials cost.  Such equipment, when used for hauling materials, shall be listed under cost of equipment.

Provide itemized statements in addition to the documentation requirements for all equipment including the quantity and price of each material and transportation charges free on board (F.O.B.) at the job site.  Attach invoices to support the quantities of materials used, unit prices paid and transportation charges.     If the Contractor uses materials from the Contractor’s stock and original receipted invoices for the materials and transportation charges do not exist, the Department and the Contractor will agree on a price that represents the actual cost to the Contractor.  Provide an affidavit and certify all of the following:

a.      The materials were taken from the Contractor’s stock.

b.      The quantity shown was actually used for the force account work.

c.      The price and transportation costs represent the actual cost to the Contractor.

Do not incorporate materials into the Work without a price agreement.

4.      Equipment.

a.      General.  The Department will pay the Contractor’s costs for equipment the Engineer deems necessary to perform the force account work for the time directed by the Engineer or until the Contractor completes the force account Work, whichever happens first.  The Department will pay the Contractor the established rates for equipment only during the hours that it is operated, except as otherwise allowed elsewhere in these Specifications.  The Department will pay for non-operating hours at the idle equipment rate as specified in 109.05.C.4.c.  Report equipment hours to the nearest 1/2 hour.  The established equipment rates in these Specifications include compensation for overhead and profit except as otherwise specified.

The Department will pay for use of Contractor-owned equipment the Engineer approves for force account Work at established rates.  The Department will pay the rates, as modified in 109.05.C.4.b, given in the Rental Rate Blue Book for Construction Equipment (Blue Book) published by Equipment Watch, a unit of Interec Publishing, a PRIMEDIA Company.

Provide, and the Engineer will confirm, the manufacturer’s ratings and manufacturer-approved modifications required to classify equipment for rental rate determination.  For equipment with no direct power unit, use a unit of at least the minimum recommended manufacturer’s rating.

The Department will not pay rental for small tools or equipment that show a daily rate less than $5.00 or for unlisted equipment that has a value of less than $400.

Tool trucks will be allowed for compensation if they are used at the force account site.  Only the tools used from the tool truck will be allowed for compensation.  Tools in the tool truck that are not used in the force account work will not be compensated.  A tool trailer that remains at the Contractor’s office or yard will not be allowed on the force account work.  Tool trailers that are taken to the force account site will be allowed for compensation along with the tools used on the force account work that were taken from the trailer.

Treat traffic control devices used in Maintaining Traffic and owned by the Contractor as owned equipment.  Allowed rates for common traffic control devices and concrete barrier that are not listed in the Blue Book will be as determined by the Department.

Use Engineer approved equipment in good working condition and providing normal output or production.  The Engineer may reject equipment not in good working condition or not properly sized for efficient performance of the Work.

For each piece of equipment used, whether owned or rented, provide the Engineer with the following information:

(1)     Manufacturer’s name or trademark.

(2)     Equipment type.

(3)     Year of manufacture.

(4)     Model number.

(5)     Type of fuel used.

(6)     Horsepower rating.

(7)     Attachments required, together with their size or capacity.

(8)     All further information necessary to determine the proper rate.

(9)     Dates, daily hours, total hours of actual operation and idle time,

(10)  Blue Book rate with reference or category,

(11) Amount

(12)  Applicable Blue Book hourly operating cost

(13)  Invoices for all rental equipment.

b.      Hourly Owned Equipment Rates.  The base rate for the machine and attachments represent the major cost of equipment ownership, such as depreciation, interest, taxes, insurance, storage, and major repairs.  The hourly operating rate represents the major costs of equipment operation, such as fuel and oil lubrication, field repairs, tires, expendable parts, and supplies.

For all equipment used on force account work, determine, and have the Department confirm, the hourly owned equipment rates as follows:

HOER = [RAF ´ ARA ´ (R / 176)] + HOC

Where:

                HOER =  hourly owned equipment rate

                    RAF =  regional adjustment factor shown in the Blue Book

                    ARA =  age rate adjustment factor shown in the Blue Book

                          R =  current Blue Book monthly rate

                   HOC =  estimated hourly operating cost shown in the Blue Book

However, compensation for equipment normally used on a 24 hours per day basis will not exceed the monthly rate plus adjustments and operating costs.

The rate adjustment factor assigned to any attachment will be the yearly factor as determined for the base equipment.

When multiple attachments are included with the rental equipment, only the attachment having the highest rental rate will be eligible for payment, provided that the attachment has been approved by the Engineer as being necessary to the force account Work.

When a piece of owned equipment is not listed in the Blue Book, use the rate for similar equipment found in the Blue Book or use 6 percent of the purchase price as the monthly rate (R) and add the hourly operating rate found in the Blue Book for similar equipment of the same horsepower.

For equipment brought to the Project exclusively for force account work and on the Project for less than a month, multiply the monthly rate (R) by the factor listed below:

Table 109.05-1

Working Hours

Factor

Less than or equal to 8.0

2.00

8.1 to 175.9

2.048 - (hours/168)

176 or greater

1.00

The term “WORKING HOURS,” as used in Table 109.05-1, includes only those hours the equipment is actually in operation performing force account work; apply the factor, as determined above, to these actual working hours only.  Calculate compensation for any idle time according to 109.05.C.4.c without application of the factor.

The Department will pay as working equipment for the entire Workday equipment used intermittently during the Workday.  The following criteria qualify for intermittently used equipment:

(1)     Equipment dedicated to the force account exclusively all day and not used on bid work.

(2)     Equipment works before and after the intermittent idle period and its total working time during the Workday is at least 2 hours.

Equipment that is captive to the force account work (i.e.  it must remain at the force account site),  but does not qualify for intermittently used owned equipment, is paid as idle equipment according to C&MS Section 109.05.C.4.c. for the time it is not working.

c.      Hourly Idle Equipment Rate.  For equipment that is in operational condition, on site, and necessary for force account Work, but is idle, the Department will pay an hourly idle equipment rate.  The procedure to determine the hourly idle equipment rate for Contractor owned equipment is as follows:

HIER = RAF ´ ARA ´ (R / 176) ´ (1/2)

Where:

              HIER =  Hourly idle equipment rate.

               RAF =  Regional adjustment factor shown in the Blue Book.

               ARA =  Age rate adjustment factor shown in the Blue Book.

                   R =  Current Blue Book monthly rate.

If rented equipment necessary for force account work is idle, the Department will pay the Contractor for the actual invoiced rates prorated for the duration of the idle period.  The actual invoiced rates must be reasonably in line with the Blue Book rates and approved by the Engineer.  The Department will pay a 15 percent markup for overhead and profit for the actual invoiced rates during the idle period.

The Department will not pay idle owned equipment costs for more than 8 hours in a 24-hour day or 40 hours in a week.

The Department will not pay for inoperable equipment.

The Engineer may order specific equipment to the site up to 5 days before its planned usage.  If this equipment is not used for other work, the Department will pay for it as idle equipment until used.

The Department will pay for the cost of idle owned or rented equipment when the Work was suspended for the convenience of the State.  The Department will not pay the cost of idle equipment when the Work was suspended by the Contractor for the Contractor’s own reasons.

The Department will only pay for the number of Calendar Days during the existence of the suspension.  The Department will not compensate the Contractor for days that the Engineer determined were lost to weather.

The Department will only pay for equipment physically located at the Project site that was received to prosecute the scheduled work during the delay.

Compensation for idle equipment will stop at the completion of the force account Work or at the end of the suspension of Work.

d.      Rented Equipment.  The Department will pay a 15 percent markup for overhead and profit for all rented equipment, its corresponding Blue Book hourly operating costs, and State and Local sales taxes.

(1)     Equipment Rented Solely for Force Account Work.  If the Contractor rents or leases equipment from a third party exclusively for force account Work, the Department will pay the actual invoiced amount.  The actual invoiced rates must be reasonably in line with the Blue Book and approved by the Engineer.  The Department will pay a 15 percent markup for overhead and profit for all rented equipment paid for by the actual invoices.  Add the Blue Book hourly operating cost to the marked up actual invoiced rates.

(2)     Equipment Rented for Original Contract Work, but Used for Force Account Work.  If the Contractor uses rented equipment currently on the Project for original Contract Work to perform force account Work, then determine the hourly outside-rented equipment rate as follows:

HRER = (HRI ´115%) + HOC

Where:

                 HRER =  hourly rented equipment rate

                      HRI =  hourly rental invoice costs prorated for the actual number of hours that rented equipment is operated solely on force account work.  Use a monthly invoice rate divided by 176, a weekly invoice rate divided by 40, or a daily invoice rate divided by 8.

                   HOC =  hourly operating cost shown in the Blue Book

The Department will not compensate for rental rates that exceed the Blue Book rates unless approved in advance of the Work by the Engineer.

e.      Moving of Equipment.  The Department will also pay for the time required to move needed equipment to the location of the force account work and to return it to its original location.  The Department will pay for loading and transportation costs instead of moving time if equipment is moved by means other than its own power.  Moving time back to the original location or loading and transportation costs will not be allowed if the equipment is used at the site of the force account work on contract items or related work.

The Department will consider the actual cost of transferring the equipment to the Project and returning it to the original location as an additional expense and pay for it as specified, for equipment moved on the Project exclusively for force account work.

The Engineer will confirm the original location of the equipment before the Contractor moves and uses it for force account work.

If the equipment is transported by a common carrier, the allowance is the invoiced amount paid for the freight plus 15 percent.  However, if the Contractor’s forces transport the equipment, the allowable compensation will be Blue Book rate of the hauling unit and hourly Blue Book operating cost plus the driver’s wages and the cost of loading and unloading the equipment calculated according to 109.05.C.2.

5.      Foreman’s Transportation.  The Department will pay the Blue Book rate for every hour the foreman’s truck is on the force account site or moving to or from the site.  This rate includes equipment cost, fuel and lubricants, overhead, profit, and mobile phone or two-way radios.

6.      Subcontract Work.  For Work performed by an approved subcontractor, the Department will pay an amount to cover administrative costs of 8% on the first $10,000 of work and 5% for work in excess of $10,000 as provided in 109.05.C.2 through 109.05.C.5. No additional mark-up is allowed for work of a sub-subcontractor or trucking services employed by a subcontractor.

7.      Final Adjustment to Premium for Contract Bonds.  The final bond premium amount for the payment and performance bonds will be computed based on the actual final contract value.  For the purpose of computing a bond premium adjustment the actual final contract value is defined as the whole sum of money, excluding any bond premium adjustment, which is passed from the department to the contractor as a result of the completion of the Work.  If the actual final contract value is different from the original contract value, the premium shall be adjusted accordingly; either by refund of part of the original bond premium by the contractor if the original contract value is larger than the actual final contract value; or by payment of additional bond premium by the department if the original contract value is smaller than the actual final contract value.  Additional payment by the department or refund by the contractor will be based on the difference between the invoiced bond premium for the original contract value and the invoiced bond premium for the actual final contract value without any markup.  A final bond premium adjustment will not be made when the actual final contract value differs from the original contract value by less than $ 40,000.00.

8.      Trucking.

a.      Trucking firms and owner operators not subject to prevailing wage will be paid at the invoiced cost plus 8% on the first $10,000 of trucking and 5% for trucking in excess of $10,000 to cover administrative costs.  

b.      Trucking that is subject to the prevailing wage law will be compensated according to 109.05.C.1, 109.05.C.2, 109.05.C.4, 109.05.C.6, 109.05.C.10, and 109.05.C.11.

Provide documentation showing payment to trucking firms and owner-operators and owner-operations status.  When the trucking is subject to prevailing wage, submit payroll and equipment usage records according to 109.05.C.2 and 109.05.C.4.

9.      Professional and Specialized Work.  The following work, when performed by a firm hired by the Contractor, is paid at the reasonable and fair market invoiced cost plus a 5 percent markup.  The markup is limited to $10,000 for all the work performed by the firm.

a.      Surveying.

b.      Engineering design.

c.      Specialized work that is not normally part of a Department Contract and is not normally subject to prevailing wage.

d.      Installation, periodic maintenance, and removal of traffic control devices under Item 614 performed by a traffic control service or rental company, provided the workers are not on the Project full-time. Maintenance of Traffic services performed by LEO.

e.      Other professional or specialized work not contemplated at the time of Bid.

Provide documentation showing payment for professional and specialized Work.

10.    Payment for Force Account Work.  Submit an analysis of estimated cost prepared in accordance with 109.05C for work that will be performed on a force account basis.  Attach an original affidavit to the analysis stating:

“Labor rates shown are the actual rates paid for labor, unit prices for materials and rates for owned and rented equipment have been estimated on the basis they are not in excess of those charged in the area in which the work will be performed.”

The Engineer will process an Estimated Cost of Force Account (ECFA) if the amount of the force account work is likely to be greater than $100,000 and is expected to take more than two weeks to complete.  The Engineer will process an Actual Cost of Force Account (ACFA) to make any necessary adjustment between the ECFA and the final itemized costs for the force account work.

For force account work estimated to be less than $100,000 and anticipated to require less than two weeks to perform, the Engineer will process an Actual Cost of Force Account (ACFA) at the conclusion of the work.   

Submit biweekly itemized statement of costs prepared from the Daily Force Account Records to the Engineer as the work is being performed.  The Engineer will process estimates as the force account work is performed.  Payment will only be made upon receipt of the Contractor’s itemized statement of costs.

Upon conclusion of the work performed by an ECFA or work performed by an ACFA submit an itemized statement of the actual costs prepared from the Daily Force Account Record and utilizing the Department’s electronic template titled “Electronic Force Account.”  Submit a compact disk (CD), labeled with the contractor’s name and the project number, and a hard copy of the “Electronic Force Account.”  The “Electronic Force Account” template can be downloaded from the following website: 

www.dot.state.oh.us/divisions/constructionmgt/admin/pages/default.aspx

The Engineer may approve an alternative electronic template provided all calculations and printouts are equivalent to those generated by the “Electronic Force Account” template. 

Attach an original affidavit to the hard copy stating:

“The name, classification, total hours worked and rates paid each person listed on the Summary of Actual Cost are substantiated by actual records of persons employed on the force account work. All unit prices for materials and rates for owned and rented equipment listed on the Summary of Actual Costs are substantiated by actual records of materials and equipment actually used in performance of the force account work and the price of any owned equipment not previously agreed upon does not exceed prices charged for similar equipment in the area in which the work was performed.”

Daily Force Account Records signed by both the Department and Contractor will govern over other Department and Contractor records subject to the following:

a.      When the Contractor is subject to a Union Contract that requires a minimum number of paid hours, the compensation will be for the verified contract minimum hours.

b.      Material quantity disagreements will be resolved by field measurements of the installed quantities or the Engineer’s estimate of the amount of temporary or un-measurable material used.  The Engineer may also review and consider the Contractor’s material invoices and material certifications to make the final determination.

In the event the Contractor declines to sign the Daily Force Account Record, the Department’s records shall govern.  Any resulting dispute must be pursued in accordance with 108.06.G.

D.      Delay Costs.

1.      General.  If the Department agrees that it has caused a delay, the Department will pay for the costs specified in 109.05.D as allowed by 108.06.D, unless these costs have been previously paid as listed in 109.05.B or 109.05.C.  Such payment constitutes full compensation for any and all delay costs

The Department will make no payment for delays occurring during the period from December 1 to April 30 unless the Contractor’s approved progress schedule depicts critical Work occurring throughout this period.

The Department will not pay for delay costs until the Contractor submits an itemized statement of those costs.  Provide the content specified in 109.05.C.1, for the applicable items in this statement and as follows:

a.      Proof of cost of Superintendent, or other project staff salaries, wages, and payroll taxes and insurance.

b.      Proof of cost of office rent, utilities, land rent, and office supplies.

c.      Proof of escalated cost for labor and material.

d.      Proof of material storage costs.

2.      Allowable Delay Costs

a.      Extended Labor.  Compute labor costs during delays as specified in 109.05.C.2 for all non-salaried personnel remaining on the Project as required under collective bargaining agreements or for other Engineer-approved reasons.

b.      Escalated Labor.  To receive payment for escalated labor costs, demonstrate that the Department-caused delay forced the Work to be performed during a period when labor costs were higher than planned at the time of Bid.  Provide adequate support documentation for the costs, allowances, and benefits specified in 109.05.C.2.   The Department will pay wages and fringes with a 20 percent mark-up to cover administrative costs.

c.      Idle Equipment or Equipment Demobilization.  The Department will pay the Contractor according to 109.05.C.4.c for idle equipment, other than small tools, that must remain on the Project during the delays.  The Department will pay the Contractor’s transportation costs to remove and return equipment not required on the Project during the delays.  No other equipment costs are recoverable as a result of delay.

d.      Material Escalation or Material Storage.  The Department will pay the Contractor for increased material costs or material storage costs due to the delay. Obtain the Engineer’s approval before storing materials due to a delay. Payment will be based upon the accepted quantity of work performed during the period for which escalated costs have been approved. The Department will pay increased material costs with an 8 percent mark-up to cover administrative costs and any material waste inherent to the Work. 

e.      Field Overhead.  The Department will pay any Contractor or subcontractor for field overhead costs which include the cost of supervision, field office and office supplies, and utilities for which payment is not provided for in 109.05.D.2.f, during a delay period provided all of the following criteria are met:

(1)     The Contractor or subcontractor has incurred an excusable, compensable delay that delays the Work at least 10 Calendar Days beyond the original Completion Date.  These days are cumulative throughout the project.

(2)               The delay for which payment of field overhead is sought is only due to delays defined in 108.06.D.2, 108.06.D.3, 108.06.D.5 or for delays due to revised Work as specified in 104.02.B or 104.02.F.

The Department will pay the salary and fringes plus a 5 percent markup for field personnel identified in Table 109.05-4.

Table 109.05-4

Original Contract Amount

Field Personnel

Up to $5,000,000

One Superintendent

$5,000,001 to $50,000,000

One Superintendent,

One Assistant Superintendent or One Engineer, One Clerk

Over $50,000,000

 One Superintendent,

One Assistant Superintendent,

One Engineer,

One Clerk

Superintendent’s transportation is compensable at the same rate allowed for foreman’s transportation in Section 109.05.C.5, which includes the cost of mobile communication devices. The allowed hours are when the superintendent is at the project site.

Superintendent’s subsistence, provided this is the company’s terms of compensation to such employees, as documented by the Contractor’s written company policy or contracts with their employees.

The Contractor’s or subcontractor’s field office costs include field office trailers, tool trailers, office equipment rental, temporary toilets, and other incidental facilities and supplies.  Compute these costs on a Calendar Day basis.  Owned trailers are paid at the Blue Book rate.  Rented trailers are paid at the invoiced cost plus a 15 percent markup.  Rented office space, toilets, and office equipment are allowed a 5 percent markup.  Purchased office supplies are allowed a 5 percent markup.

Office utilities include, but are not limited to, telephone, electric, water, and natural gas.  Compute these costs on a Calendar Day basis and allow a 5 percent markup.

f.       Home Office Overhead.  The Department will pay the Contractor for home office overhead, unabsorbed home office overhead, extended home office overhead, and all other overhead costs for which payment is not provided for in 109.05.D.2.e, including overhead costs that would otherwise be calculated using the Eichleay formula or some other apportionment formula, provided all of the following criteria are met:

(1)     The Contractor has incurred an excusable, compensable delay that delays the Work at least 10 Calendar Days beyond the original Completion Date.  These days are cumulative throughout the project.

(2)     The delay for which payment of home office overhead is sought is only due to delays defined in 108.06.D.2, 108.06.D.3 and 108.06.D.5.

Any subcontractor that has approved C-92’s for subcontracted work totaling $4,000,000 or more is eligible for reimbursement of home office overhead provided the criteria set forth in 109.05.D.2.f.(1) and 109.05.D.2.f.(2) are met.

Payment will be made for every eligible day beyond the original contract completion date at the rate determined by 109.05.D.2.f.i.  Payment for eligible days occurring during an unanticipated construction period will be calculated in accordance with 109.05.D.2.f.ii.  Payment for eligible days occurring during an unanticipated winter period will be calculated in accordance with 109.05.D.2.f.iii.

(i)      Home Office Overhead Daily Rate

Calculate the home office overhead daily rate using the following formula:

Daily HOOP = (A × C)/B

Where:

                   A = original contract amount

                   B = contract duration in Calendar Days

                   C = value from Table 109.05-5

Table 109.05-5

Original Contract Amount

C

Up to $5,000,000

0.08

$5,000,001 to $25,000,000

0.06

Over $25,000,000

0.05

   Daily HOOP = home office overhead daily rate

Contract duration term, B, includes every Calendar Day from the execution of the Contract, unless otherwise specified by the Director, to the original Contract Completion Date.

When the Contractor requests home office overhead compensation for a subcontractor, use the above formula to calculate the subcontractor’s Daily HOOP; however, in the subcontractor calculation, A is equal to the subcontractor’s portion of the original contract amount as determined by the sum of all approved C-92’s issued for the subcontracted work.

(ii)    Home Office Overhead Payment for an Unanticipated Construction Period

Calculate the home office overhead payment for an unanticipated construction period occurring between May 1 and November 30 using the following formula:

CP HOOP = Daily HOOP × D

Where:

                   D = sum of all excusable, compensable delays in Calendar Days minus the sum of all delays due to 108.06.D.1 and 108.06.D.4 in Calendar Days

   Daily HOOP = daily home office overhead rate

      CP HOOP = home office overhead payment for an unanticipated construction period occurring between May 1 and November 30

The excusable, compensable delay term, D, is the additional, unanticipated extended period for work performed between May 1 and November 30 in Calendar Days.

(iii)   Home Office Overhead Payment for an Unanticipated Winter Period

Calculate the payment for home office overhead for an unanticipated winter period occurring between December 1 and April 30 using the following formula:

WP HOOP = Daily HOOP × F × D/E

Where:

                   D =  sum of all excusable, compensable delays in Calendar Days minus the sum of all delays due to 108.06.D.1 and 108.06.D.4 in Calendar Days

                   E =  sum of all excusable, compensable delays in Calendar Days plus the sum of all excusable, non-compensable delays in Calendar Days

                   F = 151 for a non leap year or 152 for a leap year

   Daily HOOP = daily home office overhead rate

     WP HOOP = home office overhead payment for an unanticipated winter period occurring between December 1 and April 30

Payment for Home Office Overhead for an unanticipated winter period will not be made when the value of the remaining work is below the lesser of $500,000.00 or 10 percent of the estimated final contract value.

(iv)   Total Home Office Overhead Payment

Calculate the total home office overhead payment using the following formula:

Total HOOP = CP HOOP + WP HOOP

Where:

      CP HOOP = home office overhead payment for an unanticipated construction period occurring between May 1 and November 30

     WP HOOP = home office overhead payment for an unanticipated winter period occurring between December 1 and April 30

   Total HOOP = total home office overhead payment

E.      Changes in Materials.  Changes in material specifications that result in increased cost to the Contractor are compensated by lump sum adjustment to the reference number. The allowed compensation is equal to the invoice supported material cost increase plus 15 percent markup for profit and overhead.

Material cost savings resulting from a specification change shall be credited to the project by a lump sum adjustment to the reference number plus a 15 percent markup if the originally specified material has not been ordered.

If the original material was ordered before the Contractor was informed of the change, the savings markup allowed is 2.5 percent in order to exclude profit on the original bid price and pay only for incurred overhead. 

109.06  Directed Acceleration.  The Engineer may order the Contractor to accelerate the Work to avoid delay costs or to complete the Project early.  The Director and the Contractor will negotiate acceleration costs.

109.07  Inefficiency.  The Department will compensate the Contractor for inefficiency or loss of productivity resulting from 104.02 Revisions to the Contract Documents.  Use the Measured Mile analysis comparing the productivity of work impacted by a change to the productivity of similar work performed under un-impacted conditions to prove and quantify the inefficiency.

109.08  Unrecoverable Costs.  The Contractor is not entitled to additional compensation for costs not specifically allowed or provided for in 109.05 including, but not limited to, the following:

A.      Loss of anticipated profit.

B.      Consequential damages, including loss of bonding capacity, loss of bidding opportunities, insolvency, and the effects of force account work on other projects, or business interruption.

C.      Indirect costs.

D.      Attorney’s fees, claim preparation expenses, and the costs of litigation.

109.09  Estimates.  If satisfactory progress is being made, the Contractor will receive monthly payments equaling the Work and materials in place. The monthly payment is approximate, and all partial estimates and payments are subject to correction in the Final Estimate and payment. Payment for Work and materials shall not, in any way, prevent later rejection when defective Work or material is discovered, or constitute acceptance under 109.11 or 109.12.

Except for estimates generated during Project finalization, the Department will not pay an estimate until the Contractor certifies to the Engineer that the work for which payment is being made was performed in accordance with the contract. Certification will be made on forms provided by the Department.

The Department may pay estimates twice each month if the Engineer concludes the amount of work performed is sufficient.

No estimate or payment shall be construed as acceptance of defective Work or improper materials.

The Department will not pay the adjusted final estimate until the Contractor remedies all defective Work and accepted Work damaged by the Contractor’s operations.

Interest will be paid in accordance with ORC 126.30 when warranted.

109.10  Payment for Delivered Materials.  The Department will pay, up to 75 percent of the applicable contract item, for the invoiced cost of the delivered and approved materials before they are incorporated in the Work, if the approved materials are delivered, accepted, and properly stored on the project or stored in acceptable storage places in the vicinity of the Project.

The Department will pay for the cost of approved materials before they are incorporated in the Work when asked by the Contractor, if the Engineer determines that it is not practical to deliver the material to the Project site.  This provision applies only to bulky materials that are durable in nature and represent a significant portion of the project cost, such as aggregates, steel, and precast concrete.  The Department will not pay delivered materials on small warehouse items or for plant materials.

109.11  Partial Acceptance.  Upon completion of a portion of the Work, the Contractor may request acceptance of a completed  portion of the Work. 

A.      An inspection may be performed on a completed portion of the project roadway section provided:

1.      All safety items are in place including permanent pavement markings.

2.      Traffic is in its final pattern.

3.      A completed portion of the project constitutes a completed geographic section of the project or a direction of traffic on a divided highway.

4.      Is in accordance with other contract provisions.

B.      An inspection may be performed on a completed bridge provided:

1.      All work on the bridge and approaches are complete, including all safety items and permanent pavement markings.

2.      The Contractor will not return to the bridge for any work except as allowed in 4.

3.      Traffic is in its final pattern.

4.      Painting of structural steel is either completed or scheduled to be performed.

5.      Is in accordance with other contract provisions.

The Final Inspector will grant written partial acceptance for that portion of the Work or reject the Contractor’s request.  Such written partial acceptance will designate what portion of the Work is accepted, the date of acceptance, and the warranty provisions started by the partial acceptance.

Partial acceptance will relieve the Contractor of maintenance responsibility for the designated portion of the Work.  This does not relieve the Contractor of responsibility to correct defective Work or repair damage caused by the Contractor or waive any other remedy to which the Department is entitled at law or in equity.

109.12  Final Acceptance..

A.      Final Inspection.  The Department will perform a Final Inspection for the sole purpose of relieving the Contractor of maintenance responsibility for the Work.

The Final Inspection shall be a limited visual review of the Work and shall only serve as the Department’s verification that the Work appears substantially complete.  Final Inspection does not waive any available rights or remedies of the Department, nor divest the Contractor of any responsibility for compliance with the contract or liability for damages.

Notify the Engineer when the Project is complete and all of the Engineer’s punch list items are complete.  If the Engineer agrees the Project is complete, then within 10 business days the District Final Inspector will inspect the Work and categorize it as one of the following:

1.      Unacceptable or not complete.

2.      Substantially complete with punch list items found by the Final Inspector.

3.      Substantially complete.

If the Final Inspector finds the Work substantially complete or substantially complete with punch list items, then the Contractor’s maintenance responsibilities end on the day of the Final Inspection, except for any maintenance related to unfinished punch list items.  This does not relieve the Contractor of responsibility to correct defective Work or repair damage caused by the Contractor or waive any other remedy to which the Department is entitled at law or in equity.  The Final Inspector will issue a Final Inspection Report that will document the findings of the inspection and start any warranty period.

B.      Punch List.  The Final Inspector will issue to the Contractor a written punch list of work required as a condition of acceptance.  The Final Inspector’s punch list will stipulate a reasonable time to complete the required Work.  Failure of the Contractor to complete the punch list items by the stipulated time will result in the assessment of fifty percent of the Liquidated Damages according to 108.07 for each Calendar Day for every day beyond the stipulated time the punch list work remains incomplete and beyond the revised Completion Date.

C.      Finalization.  The Contractor shall accept the final quantities as determined by the Engineer or provide a written notice indicating the reason for disagreement within 30 Calendar Days of receiving the Engineer’s list of final quantities. The prescribed 30 Calendar Day period can be modified by mutual agreement of the Contractor and the District Construction Engineer. If no notice of disagreement is received, then the final payment will be based on the Engineer’s list of final quantities.

Supply all documents necessary for Project finalization within 60 Calendar Days from the date that the Work is physically complete. These documents include:

1.      Delinquent material certifications.

2.      Delinquent certified payrolls or required revised payrolls.

3.      Wage affidavit required by ORC Chapter 4115 on projects without any Federal funding.

4.      Delinquent force account records.

5.      If applicable, DBE affidavits.

6.      Any other document required to complete finalization of the project.

Failure to submit these acceptably completed documents will result in an administrative fee of $100 per Calendar Day for every day that any of the required documents remain delinquent, starting 30 Calendar Days after receipt of written notification from the Engineer of a document deficiency.

D.      Final Payment.  Final payment is based on:

1.      The agreed final quantities or as determined by the Engineer if agreement is not possible, no compensation for unauthorized work is allowed.

2.      Finding of substantial completion  by the Final Inspector.

3.      Receipt of acceptable finalization documents.

4.      Contractor certification that the Work was performed in accordance with the contract.

E.      Completion of Contract and Continuation of Contractor’s Responsibility.  The Contract is complete, except for items covered by the required bonds, when the Contractor receives final payment.  The DCA will issue a letter confirming completion of the contract, noting any exception as provided in Items 659 and 661 and any warranty.   The date the final payment is approved by the District constitutes acceptance for the purpose of ORC 5525.16.  Neither Completion of the Contract nor substantial completion relieves  the Contractor of any responsibilities to properly perform or correct the Work or to repair damage or waives any remedies to which the Department is entitled at law or in equity.

200  EARTHWORK

ITEM 201  CLEARING AND GRUBBING

201.01  Description

201.02  General

201.03  Clearing and Grubbing

201.04  Scalping

201.05  Method of Measurement

201.06  Basis of Payment

201.01  Description.  This work consists of clearing, grubbing, scalping, removing trees and stumps, and removing all vegetation and construction debris from the limits shown on the plans, except such objects that are to remain or are to be removed according to other items of work.

Use removed or excavated materials in the work when the material conforms to the specifications; if not then recycle, burn, or dispose of the material according to 105.16 and 105.17.

201.02  General

A.      Remove or save all trees, shrubs, and plants as designated on the plans.  Preserve all vegetation and objects not designated for removal.  Paint cut or scarred surfaces of trees or shrubs selected for retention according to 666.04.

B.      In order to retard and prevent the spread of destructive insects, including the emerald ash borer and Asian longhorned beetle, limit the movement of regulated articles according to Ohio Administrative Codes 901:5-56 and 901:5-57.  Observe requirements for handling and transporting of regulated articles in quarantined areas as defined by the Ohio Department of Agriculture (www.agri.ohio.gov).

The following are considered regulated articles and are subject to the quarantine established by the Ohio Department of Agriculture:

1.      Deciduous trees of any size.

2.      Deciduous limbs and branches

3.      Any cut non-coniferous (non-evergreen) firewood.

4.      Deciduous tree bark and deciduous tree wood chips larger than 1 inch (25 mm).

5.      Deciduous logs and lumber with the bark, outer inch of sapwood, or both attached.

6.      Any item made from or containing deciduous tree wood capable of spreading emerald ash borer or Asian longhorned beetle.

7.      Any means of conveyance capable of spreading emerald ash borer or Asian longhorned beetle.

Follow all other federal and state emerald ash borer and Asian longhorned beetle quarantines.

C.      Restrictions on when the Contractor may perform the clearing and grubbing work are located in other parts of the Contract Documents.

201.03  Clearing and Grubbing.  Clear and grub all trees and stumps marked for removal and all surface objects, brush, roots, and other protruding obstructions not designated to remain, except for special treatments listed below:

A.      In locations to be seeded, remove stumps at least 6 inches (150 mm) below ground surface.

B.      In unseeded areas to be rounded at the top of backslopes, cut the stumps flush with or below the surface of the final slope line.

C.      The Contractor may leave undisturbed stumps and roots, and nonperishable solid objects 6 inches (150 mm) above the existing ground surface in the plan embankment construction locations when both of the following conditions are true:

1.      The embankment height is greater than 9 feet (3 m) as measured vertically from the existing ground surface to the proposed ground surface, and

2.      The slope of the existing ground is 8:1 or flatter.

D.      In locations outside of the construction limits of the cut and embankment areas not to be seeded, the Contractor may leave sound stumps 24 inches (0.6 m) above the existing ground surface.

Except in areas to be excavated, backfill stump holes and other holes created by removing obstructions with Item 203 embankment material.  Place and compact according to Item 203.

Remove low hanging, unsound, or unsightly branches on trees or shrubs designated to remain.  Trim branches of trees extending over the roadbed to provide a clear height of 20 feet (6 m) above the roadbed surface.

Dispose of debris contaminated with garbage, solid waste, or hazardous waste or material according to other contract items.

201.04  Scalping.  Scalping includes removing surface material such as roots, sod, grass, residue of agricultural crops, sawdust, and decayed vegetable matter.  The depth of scalping does not include topsoil or other material below the scalping operation.  The Engineer will not require areas to be scalped in the plan embankment construction locations when both of the following conditions are true:

1.      The embankment height is greater than 9 feet (3 m) as measured vertically from the existing ground surface to the proposed ground surface, and

2.      The slope of the existing ground is 8:1 or flatter. 

Scalp all other areas where excavation or embankment is required.

201.05  Method of Measurement.  The Department will measure by one of the following methods:

If Clearing and Grubbing is specified in the Contract, the Department will not measure the area cleared and grubbed.

If Item 201 Tree Removed or Item 201 Stump Removed is specified in the Contract, the Department will measure trees and stumps designated for removal according to the following table.

TABLE 201.05-1

Tree or Stump Diameter

Pay Item Designation

Over 12 inches to 24 inches

18-inch size

Over 24 inches to 36 inches

30-inch size

Over 36 inches to 60 inches

48-inch size

Over 60 inches

60-inch size

Over 0.3 m to 0.6 m

0.5 m size

Over 0.6 m to 0.9 m

0.8 m size

Over 0.9 m to 1.5 m

1.2 m size

Over 1.5 m

1.5 m size

The Department will measure the diameter of trees at a height of 54 inches (1.4 m) above the ground.  Trees 12 inches (0.3 m) and less in diameter are classified as brush.  The Department will measure stumps by taking the average diameter at the cutoff.

201.06  Basis of Payment.  If Item 201 Clearing and Grubbing is specified in the Contract, the Department will pay for all work described, including backfilling holes, scalping, and removing all trees and stumps, at the lump sum price bid.  If Item 201 Tree Removed or Item 201 Stump Removed is specified in the Contract, the Department will consider the remaining work described incidental and will not pay for performing this work directly.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

201             Lump Sum                      Clearing and Grubbing

201             Each                                Tree Removed, ___ Size

201             Each                                Stump Removed, ___ Size

ITEM 202  REMOVAL OF STRUCTURES AND OBSTRUCTIONS

202.01  Description

202.02  General Construction Requirements

202.03  Structures Removed

202.04  Pipe Removal

202.05  Pavement, Walks, Curbs, Steps, Gutters, or Traffic Dividers Removed

202.06  Buildings Demolished

202.07  Septic Tanks and Privy Vaults Removed

202.08  Underground Storage Tanks Removed

202.09  Guardrail and Fence Removed

202.11  Manhole, Catch Basin, and Inlet Removed

202.12  Manhole, Catch Basin, and Inlet Abandoned

202.13  Method of Measurement

202.14  Basis of Payment

202.01  Description.  This work consists of removing, entirely or in part, and disposing of all buildings, fences, guardrails, structures, old pavements, abandoned pipe lines, storage tanks, septic tanks, privy vaults, and other obstructions not designated or permitted to remain, except for utilities and obstructions to be removed and disposed of under other items in the Contract.  This work also consists of backfilling the resulting trenches, holes, and pits, and salvaging designated materials.

When specific pay items for removal of structures and obstructions are not listed in the Contract Documents, perform this work under Item 203.

202.02  General Construction Requirements.  Raze, remove, and dispose of all buildings and foundations, structures, fences, guardrails, old pavements, abandoned pipe lines, storage tanks, septic tanks, privy vaults, and other obstructions within the Right-of-Way, except for utilities and those items where other provisions have been made for removal.  Remove and store, at the specified locations within the Project limits, or reuse all designated salvageable materials.

The Department will take ownership of all salvageable items specified for storage.  Reuse all salvageable items specified for reuse on the project.  When the Contract Documents do not indicate for storage or for reuse, take ownership of the material.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

Do not remove any item in use by traffic until after making arrangements to accommodate traffic.

When backfilling is required, backfill the resulting cavities, voids, or trenches with either Item 203 embankment material or Item 611 Structural Backfill Type 1 or 2.  Use Item 611 Structural Backfill when the removed item is under the proposed pavement or paved shoulder and when the site limits the use of compaction equipment larger than an 8-ton (7 metric tons) roller; otherwise the Contractor may use Item 203 embankment material.  Place and compact the embankment or Item 611 Structural Backfill according to 203.

For backfilled areas outside the plan construction limits, provide a final grade that presents a neat, well-drained appearance that conforms to the final topography and prevents water from draining onto adjacent properties.

202.03  Structures Removed.  Remove bridges, culverts, and other structures indicated for removal in the Contract Documents.  If within a stream, remove the substructures of existing structures, including piling, down to the proposed stream bottom.  For those parts outside the stream, remove substructures to a minimum of 1 foot (0.3 m) below proposed ground surface.  Remove, as necessary, those portions of existing structures that lie entirely or partially within the limits for a new structure to accommodate the construction of the proposed structure.

Where alteration of an existing structure requires removal of portions of the structure, remove those portions with sufficient care as to avoid damage to the remaining portion of the structure.  In case of damage to the existing structure, repair or replace the structure at no expense to the Department.

If removing a bridge or portion of a bridge with an asphalt wearing course, remove the wearing course separately before removing the bridge or portion of the bridge.

Backfill the cavity created by the removal item according to 202.02, except when the cavity lies within the limits of subsequent excavation or other work. 

202.04  Pipe Removal.  Remove and reuse, store, or dispose of pipe, or culvert as specified in the Contract Documents.

If removing an existing concrete waterline pipe that was constructed before 1980, it may be an asbestos pipe.  Test the pipe by using a Department prequalified environmental consultant to determine if it is an asbestos pipe.  If it is determined that the pipe is asbestos, then a certified asbestos Contractor must perform the removal. Dispose of all asbestos pipe at a solid waste facility that is licensed by the Local Health Department and permitted by the OEPA.

Seal openings left in walls of manholes or catch basins that are to remain in place, and remove and dispose of pipe headwalls.

If an adjacent existing pipe is encountered during removal operations and the pipe is inactive or is to be abandoned, plug or seal the remaining ends of the pipe before proceeding with backfilling operations.  Perform plugging by using approved precast stoppers.  Perform sealing by using masonry bulkheads.

Remove a sufficient section of the pipe to allow the Engineer to determine the quality of the pipe and the possibility of its removal without damage to pipe specified for reuse or storage.  If the Engineer determines the pipe is salvageable, carefully remove the remainder of the pipe to avoid breaking or damaging the pipe.  Transport and store the removed pipe, as necessary before relaying.  Replace sections of pipe lost or damaged by negligence or by use of improper methods at no additional cost to the Department.  Clean all pipe before reusing.  Remove salvageable pipe under Item 202 Pipe Removed for Reuse or Storage.

If the Engineer determines the pipe is unusable, take ownership of the pipe, and dispose of or recycle it according to 202.02.  Remove unusable pipe under Item 202 Pipe Removed.

Before backfilling the trench, excavate the caved material, as necessary.

Backfill trenches resulting from the removal of pipe according to 202.02, except when the trench lies within the limits of subsequent excavation or other work. 

202.05  Pavement, Walks, Curbs, Steps, Gutters, or Traffic Dividers Removed.  As designated, remove and dispose of the existing wearing course, concrete base course, concrete pavement, asphalt wearing course on brick or concrete base, concrete walks, concrete steps, concrete gutters, stone or concrete curbs, and concrete traffic dividers.  If removing only a portion of an existing pavement, walk, step, gutter, curb, or traffic divider, saw or otherwise cut a neat joint at the removal limit if it does not occur at an existing joint.

If Item 202 Pavement Removed is specified in the Contract, remove all asphalt, concrete, or brick from the surface to the bottom of the pavement courses as shown on the plans.  If 202 Base Removed is specified in the Contract, remove the specific layer as shown on the plans.  If Item 202 Wearing Course Removed is specified in the Contract, remove all asphalt from the surface to the top of the concrete or brick or remove the specific layer or layers shown on the plans.

Backfill the cavity created by the removal item according to 202.02, except when the cavity lies within the limits of subsequent excavation or other work.

202.06  Buildings Demolished.  Do not disturb buildings and appurtenances designated for demolition until the Engineer provides a Notice of Possession and Approval to Proceed.  Immediately after receiving approval, schedule and perform the demolition under the Engineer’s direction in order to accommodate utility rearrangements and clearance of structures.  Whether the building is located partially or totally on temporary or permanent Right-of-Way perform the demolition the same.

The Contractor may use buildings located partially on and off the permanent Right-of-Way for storage, office, living quarters, or other purposes.  The agreement shall allow such use during the period of the Contract and save the Department harmless from any claims whatsoever by reason of such use.

Remove foundations; floors; floor slabs; and basement, pit, well, and cistern walls to a minimum of 1 foot (0.3 m) below the grade of the surrounding area.

Completely remove all tanks and clear basements of all materials, debris, appliances, wood or metal partitions, and wood floors so only masonry walls and concrete basement floors remain.  Break up and remove all floor slabs under which a pit, well, cistern, or tank exists.  Break up basement floors to be left in place, and seal remaining drains with masonry or with precast clay or concrete stoppers.

Take ownership of all materials, except those belonging to a public or private utility.  Notify the owners of water, electric, or gas meters when the meters are ready for removal.  Disconnect all utilities according to local requirements.

After completing demolition work and obtaining the Engineer’s approval, immediately backfill the cavity created by the removal item according to 202.02, except when the cavity lies within the limits of subsequent excavation or other work.

202.07  Septic Tanks and Privy Vaults Removed.  Empty all septic tanks and privy vaults.  Dispose of the removed contents in a manner that conforms to the requirements of the State and Local Boards of Health or other authorities having jurisdiction..

Completely remove and dispose of septic tanks and privy vaults located above the subgrade or finished ground surface.  For septic tanks and privy vaults located below the subgrade or finished ground surface, remove tops and walls to a minimum depth of 3 feet (1 m) below subgrade or 1 foot (0.3 m) below finished ground surface.  Break up floors and seal remaining drains with masonry or with precast clay or concrete stoppers.

Backfill the cavity created by the removal, partial removal, or emptying operation according to 202.02, except when the cavity lies within the limits of subsequent excavation or other work.

202.08  Underground Storage Tank Removed.  Remove and dispose of underground storage tanks or regulated underground storage tanks, as designated in the Contract Documents, and according to the requirements of the authorities having jurisdiction.

If Item 202 Regulated Underground Storage Tank Removed is specified in the Contract, remove the tank according to the Bureau of Underground Storage Tank Regulations of the Division of Fire Marshal (BUSTR), Ohio EPA, and all applicable Federal, State, and local regulations.  Removal includes obtaining the required permit, disposing of the tank and its contents, testing the excavated material, and preparing the closure report.  Provide a Certified Tank Installer to supervise the removal.  Provide an independent non-Contractor employee BUSTR inspector or a State Certified BUSTR inspector to perform the BUSTR required inspections.  For tanks containing hazardous substances other than petroleum, use the Ohio EPA regulations in addition to State Fire Marshal regulations.

Completely remove regulated underground storage tank and contents.  Take ownership and dispose of tanks according to 202.02 and the above requirements.  If because of leakage from the tank, any contaminated water or soil disposal or remediation is required, perform the necessary work under other items in the Contract or according to 109.05.

If Item 202 Underground Storage Tank Removed is specified in the Contract, completely remove and dispose of the tank.  Dispose of the removed contents in a manner that conforms to the requirements of the State and local Boards of Health, or other authorities having jurisdiction.

Backfill the cavity created by the removal items according to 202.02, except when the cavity lies within the limits of subsequent excavation or other work.

202.09  Guardrail and Fence Removed.  Carefully dismantle and store existing guardrail (including anchor assemblies and terminal assemblies, and any attached posts, signs, and delineators) and fence when designated for reuse or storage by the Department.  Dispose of wood posts and other materials not considered salvageable according to 202.02.

When fence is designated for replacement, do not remove the existing fence until the replacement material is on site.  Begin the new installation within 7 workdays of beginning the removal process.

When guardrail is designated to be replaced and traffic is being maintained in the adjacent lane, do not leave hazards unprotected except for the actual time required to remove the existing guardrail and install the proposed guardrail in a continuous operation.  Do not remove the guardrail until the replacement material is on the site and ready for installation.  The Engineer will suspend work for failure to comply with this requirement.

Backfill the cavity created by the removal item according to 202.02, except when the cavity lies within the limits of subsequent excavation or other work.

202.11  Manhole, Catch Basin, and Inlet Removed.  Remove existing drainage structures of the types designated for removal.  Take ownership of castings unless otherwise noted on the plans.

Backfill the cavity created by the removal item according to 202.02, except when the cavity lies within the limits of subsequent excavation or other work.

202.12  Manhole, Catch Basin, and Inlet Abandoned.  Remove existing drainage structures of the types designated to be abandoned to a minimum of 1 foot (0.3 m) below the finished subgrade or ground surface.  Do not damage pipes that are to remain.  Take ownership of castings unless otherwise noted on the plans.

Connect existing pipes with new pipe through the structures.  Seal the existing inlet and outlet pipes with precast vitrified or concrete stoppers or with masonry of a type and thickness to fill the inlet or outlet pipe.

After connecting or sealing the existing pipes and removing the walls to the required depth, backfill the remaining cavities according to 202.02.  If using connecting pipes, carefully hand tamp backfill under and around the pipe according to 202.02.

202.13  Method of Measurement.  If the Contract specifies that removal of structures and obstructions is on a lump sum basis, the work will include all structures or obstructions encountered at locations or within areas designated in the Contract Documents.  However, the Department will measure asphalt wearing course removal on a bridge separate from the lump sum item for structure removal.

If the Contract specifies that removal of specific items is on a unit basis, the Department will measure the quantity of each item by the unit stipulated in the Contract. If removal of steps is measured by the foot (meter), the Department will measure the number of feet (meters) along the front edge of each tread.  If the steps have an integral wall, the Department will include the thickness of the integral wall with the tread width measurement.

202.14  Basis of Payment.  Payment is full compensation for all work involved in the removal and storage, reuse, or disposal of structures and obstructions, including excavation and backfill incidental to their removal, removing the contents of the underground storage and septic tanks and the custody, preservation, storage on the Right-of-Way, and disposal as provided in this specification.

For pipe removed and reused or stored, the Department will pay for the accepted work under Item 202 Pipe Removed for Reuse or Storage.  For unusable pipe removed, the Department will pay for the accepted work under Item 202 Pipe Removed.

If the Contract Documents do not include a pay item for  Item 202 Asbestos Pipe Removed, then the Department will pay for removal and disposal of asbestos pipe according to 109.05.

When removed pavement is replaced with embankment material, the Department will pay for the embankment material under the applicable 203 or 204 pay item.  When pipe is removed from beneath existing pavement, the Department will pay for pavement removal under the applicable pay item for pavement removal or excavation, and the Department will pay for new pavement under the applicable pavement pay item.

Include all of the costs and work associated with compliance of the rules or regulations under Item 202 Regulated Underground Storage Tank Removed.  If the underground storage tank is not regulated, the work does not include obtaining inspection services, permits, testing excavated material, or closure reporting and the payment will be under Item 202 Underground Storage Tank Removed.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

202             Lump Sum                      Structure Removed

202             Lump Sum, or                 Portions of Structure
                       Cubic Yard or Pound      Removed
                       (Cubic Meter
                       or Kilogram)

202             Foot (Meter)                    Pipe Removed for Reuse or Storage

202             Foot (Meter)                    Pipe Removed

202             Foot (Meter)                    Asbestos Pipe Removed

202             Square Yard                    Pavement Removed
                       (Square Meter)

202             Square Yard                    Wearing Course Removed
                       (Square Meter)

202             Square Yard                    Base Removed
                       (Square Meter)

202             Square Foot                     Walk Removed
                       (Square Meter)

202             Lump Sum, or                 Steps Removed
                       Foot (Meter)

202             Foot (Meter)                    Curb Removed

202             Foot (Meter)                    Curb and Gutter Removed

202             Foot or                            Gutter Removed
                       Square Yard
                       (Meter or
                       Square Meter)

202             Foot (Meter)                    Curb Removed for Storage

202             Each                                Precast Traffic Divider
                                                               Removed for Reuse or Storage

202             Lump Sum                      Building Demolished

202             Each                                Underground Storage Tank Removed

202             Each                                Regulated Underground
                                                               Storage Tank Removed

202             Each                                Septic Tank Removed

202             Each                                Privy Vault Removed

202             Foot (Meter)                    Guardrail Removed

202             Foot (Meter)                    Guardrail Removed for Reuse or Storage

202             Foot (Meter)                    Fence Removed for Reuse or Storage

202             Each                                Manhole Removed

202             Each                                Manhole Abandoned

202             Each                                Catch Basin or Inlet Removed

202             Each                                Catch Basin or Inlet Abandoned

ITEM 203  ROADWAY EXCAVATION AND EMBANKMENT

203.01  Description

203.02  Material Definitions

203.03  Restrictions on the Use of Embankment Materials

203.04  General

203.05  Embankment Construction Methods

203.06  Spreading and Compacting

203.07  Compaction and Moisture Requirements

203.08  Earthwork Construction Tolerances

203.09  Method of Measurement

203.10  Basis of Payment

203.01  Description.  This work consists of preparing areas upon which embankments are to be placed; excavating for roadways and channels, including the removal of all material encountered not being removed under another item; constructing embankments with the excavated material and material from other approved sources as necessary to complete the planned embankments; furnishing and incorporating all water required for compacting embankment; disposing of unsuitable and surplus material and finishing shoulders, slopes, and ditches.

All excavation is considered unclassified excavation.  If the excavation contains regulated materials such as garbage, solid waste, and hazardous waste or material, the Contract Documents will detail the removal for these items.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material  according to 105.16 and 105.17.

203.02  Material Definitions.

A.      Asphalt Concrete.  Reclaimed asphalt concrete pavement (RACP) that is blended to meet the requirements in 703.16.

B.      Base.  Selected material of planned thickness placed on the subgrade as a foundation for other bases, or asphalt or concrete pavements.  The base is a part of the pavement structure.

C.      Borrow.  Material obtained from approved sources, located outside the construction limits that is required for the construction of the embankment.  When borrow is specified or used, use suitable materials that conform to 203.02.R. 

D.      Compaction Testing.  The Department will perform the compaction testing of embankment and subgrade according to Supplement 1015.

E.      Embankment.  A structure consisting of suitable materials conforming to 203.02.R and constructed in lifts to a predetermined elevation and cross section.

F.      Excavation.  The excavation and disposal of all materials required by the Contract Documents.

G.     Maximum Dry Density.  The maximum dry density is determined according to AASHTO T 99, AASHTO T 272, or Supplement 1015.  The Department will use this maximum dry density for compaction acceptance.

H.     Natural Granular Materials.  Natural granular materials include broken or crushed rock, gravel, sand, durable siltstone, and durable sandstone that can be placed in an 8-inch (200 mm) loose lift.

I.       Natural Soil.  All natural earth materials, organic or inorganic, resulting from natural processes such as weathering, decay, and chemical action.

J.      Optimum Moisture Content.  The water content at which the maximum dry density is produced in an embankment material.  The optimum moisture content is determined according to AASHTO T 99, AASHTO T 272, or Supplement 1015.

K.     Petroleum Contaminated Soil (PCS).  Petroleum contaminated soil (PCS) that is regulated under OAC-1301:7-9-16.

L.      Random Material.  Mixtures of suitable materials that can be placed in 8-inch (200 mm) loose lifts.

M.     Recycled Portland Cement Concrete.  Recycled portland cement concrete (RPCC) that is blended to meet the requirements in 703.16.

N.      Recycled Materials.  Fly ash, bottom ash, foundry sand, recycled glass, tire shreds, or other materials or manufacturing bi-products not specifically named as suitable materials in 203.02.R.

O.     Rock.  Sandstone, siltstone, limestone, dolomite, glacial boulders, brick, and RPCC too large to be placed in an 8-inch (200 mm) loose lift.

P.      Shale.  A fine-grained sedimentary rock formed from the lithification of clay, silt, or mud.  Shale has a laminated structure, which splits easily (is fissile).  For the purpose of this specification, mudstone and claystone are also considered to be shale.  Shale is classified as durable or nondurable according to 703.16.D.

Q.     Slag Materials.  Slag materials include air cooled blast furnace slag (ACBF), granulated slag (GS), open hearth (OH) slag, basic oxygen furnace (BOF) slag, and electric arc furnace (EAF) slag meeting the requirements in 703.16.

R.      Suitable Materials.  All suitable materials are restricted in 203.03. Furnish soil or embankment material conforming to 703.16, when Item 203 Embankment is specified.  Furnish material that conforms to 703.16.B or 703.16.C when Item 203 Granular Embankment is specified.  Furnish material that conforms to 703.16.C when Item 203 Granular Material Types A, B, C, D, E or F are specified.  Do not use recycled materials unless specifically allowed by the Supplemental Specifications.

203.03  Restrictions on the Use of Embankment Materials.  Suitable materials are further restricted as follows:

A.      Use silt identified as ODOT Group Classification A-4b and RACP only if placed at least 3 feet (1 m) below the surface of the subgrade.

B.      Do not place RPCC and RACP in any location where it would inhibit the growth of vegetation.

C.      Do not use any suitable material that cannot be incorporated in an 8-inch (200 mm) lift in the top 2 feet (0.6 m) of the embankment.

D.      Do not use nondurable shale in the top 2 feet (0.6 m) of the embankment that is not completely compacted and pulverized into a soil with 100 percent of the material passing the No. 4 (4.75 mm) sieve.

E.      If using RPCC, OH slag, EAF slag, BOF slags, or blends of these materials, place these materials at least 1 foot (0.3 m) below the flow line of the underdrains.

F.      Do not use RPCC, OH slag, EAF slag, BOF slags, granulated slag, or blends of these materials for underwater applications.

G.      Do not use materials that cannot be satisfactory placed and compacted to a stable and durable condition.

H.     Material excavated in the work that contains excessive moisture is unsuitable for embankment construction unless dried.  Dry or aerate such material before incorporating in the work.  The Contractor may elect to waste this material, instead of drying it.

I.       If Granular Material Type E in 703.16.C is allowed or specified, use a geotextile fabric conforming to 712.09, Type D on the top, bottom, and around the Type E material to prevent piping of the material into the Type E material.

J.       If electing to use PCS, submit the information stated below in a suitable format at least 10 workdays before the intended usage.

1.      Have an independent ODOT consultant pre-qualified in remedial design environmental site assessment review the proposed usage.  The consultant shall provide all documentation used to ensure that the proposed usage obeys all Ohio EPA regulations.  The consultant shall coordinate all EPA required meetings, documentation, and testing requirements.  The consultant shall randomly monitor the construction to ensure that the environmental requirements are carried out on the project.  The consultant shall report any discrepancies to the Department and the Contractor.  The consultant shall certify the report or reports to the Department.

2.      Use PCS that conforms to all current environmental policies, rules, and regulations and the following:

a.      Use PCS material that does not exceed the petroleum constituent concentrations stated below:

Benzene (B)

35 parts per million

Toluene (T)

109 parts per million

Ethyl benzene (E)

32 parts per million

Total Xylenes (X)

165 parts per million

b.      Include test results from BTEX testing by using U.S. EPA test method SW 846, method 8020, or equivalent method.

c.      Perform the tests on every 100 tons (90 metric tons) of PCS used.

203.04  General.  Perform the required clearing and grubbing before starting the excavation, grading, and embankment operations.

Coordinate the clearing and grubbing with the installation of sediment and erosion controls.

Remove all existing pavement before the embankment construction.

Temporarily discontinue operations when the excavating operations encounter remains of prehistoric archaeological sites, historical archaeological sites, or human remains.  The Engineer will contact the Department’s Office of Environmental Services to determine the disposition thereof.  Preserve the artifacts or other archeological items or human remains until a determination as to what the disposition and/or removal of such items is made by the Office of Environmental Services.  Such excavation is considered Extra Work.

If the Contractor encounters any abnormal material such as, but not limited to, drums, tanks, or stained earth or any unusual odors during construction operations, the Contractor shall temporarily discontinue the work in this area, leave equipment in place, cordon off the area, and notify the Engineer.  The area is considered to contain hazardous waste or material and must be handled according to The Construction Inspection Manual of Procedures.  Upon notification by the Engineer to resume work, the Contractor may file for an extension of time according to 108.06.

A.      Drainage and Maintenance of the Work.  Maintain a well-drained embankment and excavation operation.  If trenching for narrow widening and in other areas of the embankment construction, construct ditches of an adequate depth and at frequent intervals across the berm or embankment to maintain drainage.  Deepen side ditches when necessary to ensure thorough embankment or subgrade drainage.

Construct the embankment with sufficient cross-slope to drain in case of rain.

If precipitation saturates the embankment construction, stay off the embankment construction until the embankment dries or stabilizes.  Expedite the construction by removing the saturated embankment or dry the embankment by scarifying, plowing, disking, and recompacting the embankment.

Throughout the embankment construction operation and at the end of each day’s operation, shape to drain, compact, and recompact the work area to a uniform cross section.  Eliminate all ruts and low spots that could hold water.

If using embankment construction or cut areas to haul on, continuously move the hauling equipment around on the area to take advantage of the compactive effort.  Continually re-grade and compact the haul roads and maintain the construction according to 105.13 and 105.14.

Plug and cover the upstream ends of all pipe lines encountered during earthwork operations.

B.      Rock or Shale Blasting Operations.  Conform to Item 208 when blasting.

C.      Slides and Breakages.  Remove all slides and breakages beyond the limits of the planned finished work when caused by improper excavation methods.

D.      Shoulders, Slopes, and Ditches.  When specified, place the topsoil in areas to be seeded or sodded according to Item 659.  Build shoulders to the lines shown on the plans and to the tolerances specified in 203.08.  Reshape shoulders, slopes, and ditches that have been damaged by erosion during construction.

Keep new and existing pavement, and the paved area of the berm clear of earth stockpiles or other berm materials.

E.      Pavement Widening Construction.  Locate sound pavement edges, and cut and trim pavement to a neat line.  Repair and restore damage caused by the equipment or methods.  Include the cost of cutting, trimming, and disposal under Item 203 Excavation.

F.      Borrow.  Unless otherwise designated in the Contract, make arrangements for obtaining borrow and pay all costs involved.  If borrow is specified, use all suitable excavated material in the work prior to using the borrow material.

Place borrow used as embankment according to all the requirements for constructing embankment.

Blade and leave all borrow areas in such shape as to allow accurate measurements after the excavation has been completed.

Notify the Engineer sufficiently in advance of opening any borrow areas so that cross section elevations and measurements of the ground surface after stripping may be taken.

Construct borrow areas that conform to 105.16; clean up the borrow areas according to 104.04.

G.     Staged Construction and Waiting Periods.  If specified in the Contract Documents, control the rate of fill accordingly.  Adhere to the rate of fill and to the waiting periods during the work.

203.05  Embankment Construction Methods.  Embankment construction includes preparing areas upon which embankments are to be placed; placing and compacting approved material within roadway areas where unsuitable material has been removed; and placing and compacting approved material in holes, pits, and other depressions within the roadway.

If scalping is required, scarify, plow, disk, and compact the existing embankment foundation.  Compact the top 8 inches (200 mm) of the foundation to 95 percent of the maximum dry density or to a maximum test section dry density according to Supplement 1015.  If the foundation cannot be compacted, the Department will design replacement material or the Engineer may increase the lift thickness of the next layer of embankment.

The Engineer may increase the lift thickness of the next embankment layer to bridge the soft or wet foundation areas that will not support the weight of the trucks or hauling equipment.  Dump successive loads of rock, durable shale, or granular material in a uniform lift.  Do not exceed the thickness required to support the equipment placing the material.  Manipulate, blade, distribute, level, and doze the material in place until the area is stabilized and material is above the normal water elevation.  Once the bridging has been accomplished, construct the remaining lifts according to 203.06.

If the existing slope is steeper than 8:1, bench into the existing slope as follows:

A.      Scalp the existing slope according to Item 201.

B.      Cut horizontal benches in the existing slope to a sufficient width to blend the new embankment with the existing embankment and to accommodate the placement, and compaction operations and equipment.

C.      Bench the slope as the embankment is placed, and compact into layers.

D.      Begin each bench at the intersection of the existing slope and the vertical cut of the previous bench.  Recompact the cut materials along with the new embankment.

If constructing embankment on only one side of abutments, wing walls, piers, or culvert headwalls, construct the embankment so that the area immediately adjacent to the structure is not compacted in a manner that causes overturning of or excessive pressure against the structure.  If constructing embankment on both sides of a concrete wall, pipe, or box type structure, construct the embankment so that the elevation on both sides of the structure is always approximately the same.

203.06  Spreading and Compacting.  Do not construct frozen embankment material or place embankment material on frozen ground.

Spread all embankment material, except for rock in 203.06.C. and RPCC in 203.06.D, in successive horizontal loose lifts, not to exceed 8 inches (200 mm) in thickness.  Compact all embankment material lifts, except for Type D granular material, Type E granular material, rock and durable shale, to the specified density and moisture controls in 203.07.

When a minimum effective weight requirement is specified in 203.06 or 203.07, the Contractor may use a vibratory roller which meets the requirement using a combination of weight and equivalent centrifugal force from vibration.  In all cases, submit documentation from the manufacturer that shows the roller meets the minimum effective weight requirements.

The Engineer may reduce the minimum number of passes if additional passes are detrimental to compaction or stability.

A.      Soil and Granular Embankment.  For soil or granular material, when a test section is used, use a minimum compactive effort of eight passes with a steel wheel roller having a minimum effective weight of 10 tons (9 metric tons).

Compact Type D and Type E granular material using at least ten passes of a smooth drum vibratory roller having a minimum effective weight of 10 tons (9 metric tons).  Add water to Type D granular material as needed or directed by the Engineer.

B.      Shale.  The Engineer will test shale for durability according to 703.16.D, to determine if compaction testing is required.  For nondurable shale, when a test section is used, use a minimum compactive effort of ten passes with a footed drum roller having a minimum effective weight of 15 tons (14 metric tons) or with rollers meeting the requirements of 703.16.D.

Use water to aid in breaking down large particles and to bring the shale to at least 2 percent above optimum moisture content.

Compact durable shale, as defined in 703.16.D, with a minimum compactive effort of ten passes of a footed drum roller having a minimum effective weight of 15 tons (14 metric tons) or with rollers meeting the requirements of 703.16.D.  When durable shale is mixed with fine material, use fine material that is at least 2 percent above optimum moisture content.  No density testing will be required.  If shale mixtures contain large particles of shale, break down the particles during placement until the voids are filled.

Place and compact shale and rock mixtures using the same procedure as for shale.  Reduce rock size in a shale-rock mixture to less than or equal to 8 inches (200 mm), or separate rock greater than 8 inches (200 mm) from the mixture and use as rock fill.  Use the construction methods for rock when the shale-rock mixture contains less than 15 percent shale.

C.      Rock.  Reduce the rock until it is small enough to be incorporated into the following horizontal lift thickness:  Place rock in a maximum loose lift thickness 6 inches larger than the largest diameter of the rock pieces or 3 feet (1 m), which ever results in the smaller lift thickness.  When placing rock fill within a length of six times the height of the fill at an abutment, place rock fill in loose lifts not to exceed 18 inches (0.5 m).  [For example, if the fill height is 20 feet (6 m), then the rock fill within 120 feet (36 m) of the abutment is placed in less than 18-inch (0.5 m) loose lifts.]

Do not dump the rock, but distribute and place the full width of the lift by blading or dozing to ensure proper placement.  Evenly distribute the larger rocks, and reduce the voids, pockets, and bridging to ensure minimum deformation.  Incorporate smaller rock pieces in the upper portions of each rock lift to fill the voids during this manipulation.

When placing embankment material other than rock on top of the rock lift, level and smooth the rock surface using suitable leveling equipment and evenly distribute the smaller rock, rock spalls, or finer rock fragments.

Roll all rock lift surfaces with eight passes of a vibratory footed drum roller having a minimum effective weight of 10 tons (9 metric tons).

When constructing rock and other embankment materials at approximately the same time, perform the following:

1.      Use the rock at the base of the embankment.

2.      Use rock in the outer portions of the embankment.

3.      Use the larger rocks on the outside side slopes.

4.      Use the other embankment material in the inner portion of the fill.

5.      Keep the top of the other embankment materials higher than the rock.

6.      Construct the other embankment materials to a sufficient width to allow the specified compaction.

7.      When rock is placed on top of other embankment material, construct the other embankment material at a center-to-side slope grade of approximately 4 percent.

D.      Random Materials.  Reduce the random material until it is small enough to incorporate into an 8-inch (200 mm) lift, except for RPCC in 203.06.D.1 through 203.06.D.4.

When using a uniformly graded mixture, use material with a moisture content less than 2 percent below optimum to obtain compaction.  When large pieces are incorporated in the lifts, use fine material with a moisture content less than 2 percent below optimum to obtain compaction.

Compact natural soil and natural granular material blends with RACP or RPCC to the same requirements as a granular embankment in 203.06.

When using RPCC slabs or large RPCC pieces in the embankment construction, conform to the following:

1.      Use natural soil or natural granular material that is less than 2 percent below optimum moisture content in the blend.  Reduce the slabs or pieces to less than 3 ´ 3 feet (1 ´ 1 m) in size and place the blend in a maximum loose lift thickness of 12 inches (300 mm).

2.      Manipulate, level, and distribute the mixture by blading or dozing to fill the voids and pockets, and reduce bridging.

3.      Compact the natural soil or natural granular embankment to the compaction and moisture requirements in 203.07.

4.      When the RPCC slabs or large RPCC pieces consists of more than 50 percent of the embankment lift, place the blended material in maximum loose lifts of 18 inches (0.5 m).  Do not place one slab directly on the other.  Compact, manipulate, level, and distribute as stated in 203.06.D.1 through 203.06.D.3.

E.      Areas Inaccessible to Rollers.  For areas inaccessible to rollers, such as adjacent to culverts, retaining walls, or other structures, construct the embankment in 6-inch (150 mm) horizontal loose lifts.

203.07  Compaction and Moisture Requirements.  Construct all embankments, except rock and durable shale, using moisture and density controls.  Unless otherwise specified in the Contract Documents, the Engineer will perform all compaction tests according to Supplement 1015.

A.      Moisture Controls.  Sprinkle enough water on embankment material that contains too little moisture to wet it to a moisture content needed to meet the density requirements.  Apply the water using tank trucks equipped with suitable sprinkling devices.  Thoroughly incorporate the water into the material by using discs, plows, or other approved equipment.  Continue to water and to manipulate until the required moisture is uniformly distributed throughout the lift.

Before or during compaction, allow the embankment material that contains excess moisture to dry to a moisture content needed to meet the density requirements.  Continue drying until the required moisture is uniform throughout the lift.  However, for material that displays pronounced elasticity or deformation under the action of loaded rubber tire construction equipment or other equipment, reduce the moisture content to secure stability.  Expedite and manipulate the embankment material by drying the wet embankment material by using plows or discs; by adding dry material, lime, or cement; or by other methods.

Do not mix shale in the lifts to reduce the moisture content of the embankment material.

B.      Compaction Requirements.  Compact all embankment materials, except for rock and durable shale, in horizontal lifts to a dry density greater than the percentage of maximum dry density in Table 203.07-1, or to 98 percent of the maximum dry density determined by the test section methods specified in Supplement 1015.

Table 203.07-1  EMBANKMENT COMPACTION REQUIREMENTS

Maximum

Dry Density

[lb/ft³ (kg/m³)]

Minimum Compaction

Requirements in Percent of

Maximum Dry Density

90 to 104.9 (1440 to 1680)

102

105 to 119.9 (1681 to 1920)

100

120 and more (1921 and more)

98

If needed for compaction acceptance, construct a test section using the following:

1.      Use at least the same number of passes and compactive effort used to construct the test section to construct the production embankment areas.

2.      Construct a new test section when the material, supporting foundation, or embankment changes.

3.      Reduce the moisture content if the material becomes unstable.

203.08  Earthwork Construction Tolerances.  Finish the completed excavation and embankment to the cross sections shown on the plans.  Check the excavation and embankment work with templates, slope boards, electronic methods, or other methods specified in Item 623.  The Engineer will allow occasional deviations in the work within the following tolerances:

A.      When topsoil is specified, use the following:

1.      In fill areas, construct the embankment to the bottom of the topsoil depth.

2.      In cut areas, excavate additional depth to allow for the topsoil.

3.      For cuts or fills, the cross sections show the finished grade, which is the top of the topsoil.

B.      For the backslopes (cut slopes), from the back of the ditch to the existing ground, and for the foreslopes (fill slopes), from the edge of the graded shoulder to the bottom of the ditch, do not allow deviations greater than 1 foot (0.3 m) as measured in the horizontal plane.

C.      Do not construct shoulders and ditches less than the horizontal measurement from the centerline or to a higher elevation than shown on the plans.  However, the cross section may vary below the plan grades by less than 1/2 inch (15 mm) at the pavement edge and by less than 2 inches (50 mm) elsewhere.

D.      Construct or fine grade the subgrade to within 1/2 inch (15 mm) of the plan elevation at any location.  Construct or fine grade the subgrade to within 1/2 inch (15 mm) of the plan grade as measured with a 10-foot (3 m) straightedge applied to the surface parallel to the centerline of the pavement.

E.      For all rock or shale cut slopes that do not require control blasting techniques, rake excavate, hoe, ram, or mechanically shape these slopes to obtain a neat and smooth appearance.

203.09  Method of Measurement.  The Department will measure Excavation by the number of cubic yards (cubic meters) of material in the original position, acceptably excavated, using the average end area method.

The Department will measure Embankment; Rock; Granular Embankment; and Granular Material, Type ___ by the number of cubic yards (cubic meters) of material in the final position, acceptably placed, using the average end area method.

Measurement will include overbreakage or slides not attributable to carelessness of the Contractor, embankment settlement caused by soft embankment foundation, unsuitable materials excavated and removed to obtain proper stability in cut sections and in foundation areas for fill sections.

The Department may use three-dimensional measurements where it is impractical to measure material by the cross section method due to the erratic location of isolated deposits.

The Department will not measure excavation or embankment outside plan limits.

The Department will measure Borrow by the cubic yard (cubic meter) or ton (metric ton) as specified in the Contract Documents.

The Contract Documents will specify borrow only when the measurement of the material in its final location by volume is impractical.  For example, this would apply when the borrow material is to be placed in locations that are under water or in locations with extremely soft foundations.  In addition, the Department may specify borrow when additional material is needed and when Item 209 is specified.  In this case, the Department will pay for borrow under 209 Borrow.

The Department will measure the volume of borrow material in a natural formation either by the average end area method or by weight.

Where measurement is by the average end area, the Department will take cross sections after the surface has been cleared and scalped and again after the borrow area excavation has been completed.  The cross sections determine the volume for payment.

Where the total weight is measured and converted to volume, the Department will determine material density in pounds per cubic yard (kilograms per cubic meters) in its original position by a series of representative field measurements made after clearing and scalping have been performed, and as the excavation exposes the borrow material.  Weigh the acceptable material, minus excess moisture, excavated from the borrow area for incorporation into the embankment, and furnish the Department with load slips.  The Department will determine the cubic yards (cubic meters) for payment by dividing the total weight of the borrow material by the average weight per cubic yard (cubic meter) of the undisturbed material.  If the moistures of the in-place borrow site density test material is not within 2 percent of the accepted delivered material, the Department will calculate volume based on the dry densities and weights.

The Department will calculate the volume of borrow from sources other than natural in-place formations, such as processed slag, sand, stone or gravel, and quarry material as follows:  Determine the material in-place compacted density in pounds per cubic yard (kilograms per cubic meter).  The volume paid will be the total weight of the material furnished, minus excess moisture, divided by 95 percent of the average embankment density.  If the moisture content of the accepted in-place density test material is not within 2 percent of the delivered material, the Department will calculate volume based on the dry densities and weights.  Where measurements show that completed embankment exists outside the plan cross sections or outside the allowable tolerances, the Department will multiply the quantity outside plan lines by a shrinkage factor to determine the quantity deducted from the measured borrow quantity.  The shrinkage factor is determined by dividing the volume or weight of the material excavated or used as borrow by the volume or weight of the material compacted in place.

When the measurement is by weight, the Department will accept the material based on the freight bills and weight and volume evidence according to 109.

203.10  Basis of Payment.  If the Contract does not include 201 Clearing and Grubbing or an estimated quantity for 201 Tree Removed or 201 Stump Removed, or an estimated quantity for the pay items under Item 202, the Department will not pay for this work directly but will considered it incidental to pay items under Item 203.

The Department will not pay for additional wasting cost of material excavated in the work that was wasted instead of being dried as detailed in 203.03.H.

If the Contractor elects to use PCS, the Department will not pay for additional work necessary to comply with the requirements specified in 203.03.J.

If during excavation the Contractor encounters remains of prehistoric archaeological sites, historical archaeological sites, or human remains, the Department will pay for such excavation according to 109.05.

If during excavation the Contractor encounters hazardous material or waste, the Department will pay according to 109.05.

If necessary during the construction in 203.03.H, 203.04.A, or 203.07.A, the Department will not pay for removing the saturated embankment or drying the embankment.

If caused by improper excavation methods, the Department will not pay for removing slides and breakages beyond the limits of the planned finished work.  The Department will pay for the removal of slides and breakages beyond the limits of the planned finished work according to 109.05, when there is no Contractor fault or neglect.

If caused by the lack of implementing erosion controls, the Department will not pay for reshaping shoulders, slopes, and ditches damaged by erosion during construction.

If caused by the Contractor’s equipment or methods, the Department will not pay for repairing or restoring damaged areas designated for salvage.

When topsoil is specified, the Department will not make deductions or additions from the earthwork quantities for the topsoil.

The Department will not adjust earthwork quantities when the volume between two consecutive cross-sections differs by less than 5 percent from the plan quantity, unless the difference between the actual quantity and plan quantity is greater than 1000 cubic yards (1000 m³) for all pay items measured by the cubic yard (cubic meter) under Item 203, combined. For quantity differences greater than 5 percent or greater than 1000 cubic yards (1000 m³), submit supporting documentation to the Engineer. However, the Department will adjust earthwork quantities for changes less than 5 percent or 1000 cubic yards (1000 m³) when the change results from the following: undercutting, foundation settlement, changes to grades or slopes, and removing slides. For quantities measured for payment, the Department will use the plan cross sections, corrected for errors, as the original field cross sections.  Additional cross sections may be interpolated from the plans at points necessary to more accurately determine quantities.

The Department will pay according to 109.05 for changes or extra work that increases the haul distance more than 1/2 mile (1 km) to the work detailed in the Contract Documents.  The Department will pay for additional quantities that increase the haul distance 1/2 mile (1 km) or less at the unit bid price.

When specified, the payment for borrow includes all work to complete the embankment construction to the cross sections shown on the plans.  The Department will not make additional payment for the embankment construction of the borrow material.  When borrow is not specified, all work is included in the excavation or embankment pay items.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

203             Cubic Yard                      Excavation
                       (Cubic Meter)

203             Cubic Yard                      Embankment
                       (Cubic Meter)

203             Cubic Yard or Ton          Granular Embankment
                       (Cubic Meter or
                       Metric Ton)

203             Cubic Yard or Ton          Granular Material, Type ___
                       (Cubic Meter or
                       Metric Ton)

203             Cubic Yard or Ton          Borrow
                       (Cubic Meter
                       or Metric Ton)

203             Cubic Yard or Ton          Rock
                       (Cubic Meter
                       or Metric Ton)

ITEM 204  SUBGRADE Compaction and proof rolling

204.01  Description

204.02  Materials

204.03  Compaction of the Subgrade

204.04  Unstable Subgrade

204.05  Rock, Shale, or Coal Subgrade

204.06  Proof Rolling

204.07  Spreading and Placing of Materials

204.08  Method of Measurement

204.09  Basis of Payment

204.01  Description.  This work consists of preparing suitable subgrade material by drying, compacting, proof rolling, and grading.  This work also consists of removing unsuitable subgrade material and constructing new embankment to the limits shown on the plans.

The contract documents provide the anticipated amount of excavation for unsuitable subgrade material which includes unsuitable soil, rock, shale, and coal in the subgrade, and for unstable subgrade material.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

204.02  Materials.  Furnish suitable material conforming to 203.02.R, 203.03, and 703.16, except use soils in the top 12 inches (300 mm) of the subgrade that have a maximum dry density of at least 100 pounds per cubic foot (1600 kg/m³).

Furnish material that conforms to 703.16.B or 703.16.C when Granular Embankment is specified.  Furnish material that conforms to 703.16.C when Granular Material, Type ___ is specified, except do not use RPCC, EAF slag, or BOF slag.

Do not use Granular Material Type D, E, or F in the location where underdrains are to be constructed.

Furnish geotextile fabric that conforms to 712.09, Type D

204.03  Compaction of the Subgrade.  Compact subgrade materials that have a maximum dry density of 100 to 105 pounds per cubic foot (1600 to 1680 kg/m³) to not less than 102 percent of maximum dry density.  Compact all other subgrade materials to not less than 100 percent of maximum dry density.  Determine the maximum dry density using AASHTO T 99, AASHTO T 272, or test section method described in Supplement 1015, according to the Engineer.  The Department may check for compaction before or after the fine grading operation.

If needed for compaction acceptance, use the test section method as follows:

A.      Use a minimum of eight passes with a steel drum roller having a minimum effective weight of 10 tons (9 metric tons).

B.      Use 98 percent of the test section maximum dry density for acceptance of the production subgrade compaction.

C.      Use at least the same number of passes and compactive effort used to construct the test section for the production subgrade compaction.

D.      Construct a new test section when the subgrade material, supporting foundation or embankment material changes.

E.      Reduce the moisture content if the material becomes unstable.  The Engineer may reduce the minimum number of passes if the passes are detrimental to compaction.

Use the moisture controls specified in 203.07.A.

Compact the subgrade under pavements to a depth of 12 inches (300 mm) below the subgrade surface and 18 inches (450 mm) beyond the edge of the surface of the pavement, paved shoulders, or paved medians.  Compact all subgrades under paved driveways, paved mailbox turnouts, curbs and gutters to a depth of 12 inches (300 mm) below the subgrade surface.

Maintain and drain the subgrade according to 203.04.A.

204.04  Unstable Subgrade.  If satisfactory subgrade stability cannot be obtained by moisture control and compaction according to 204.03, the Engineer will direct the Contractor to remove the unstable material and to construct the replacement material to the finished grade within the tolerances specified in 203.08.

Conduct the removal and replacement operations to allow the Engineer to measure the cross-sections before placing the replacement material.

Remove the unstable subgrade material to the depth determined by the Engineer or specified in the Contract Documents.  Replace with suitable material according to 204.07.

204.05  Rock, Shale, or Coal Subgrade.  If an aggregate base is not a part of the pavement design, excavate the subgrade 2 feet (0.6 m) below the final subgrade elevation where rock, shale, or coal is encountered.  If an aggregate base is part of the pavement design, reduce the above 2-foot (0.6 m) excavation depth by the thickness of the aggregate base or bases.  Maintain a total excavation depth of 2 feet (0.6 m) below the bottom of the asphalt or concrete pavement.

Excavate for a width of 1 foot (0.3 m) beyond the shoulders.  Replace with suitable material according to 204.07.

204.06  Proof Rolling.  Test the stability and uniformity of the subgrade compaction by proof rolling.

A.      Use a proof roller conforming to the following:

1.      Four heavy pneumatic tire wheels mounted on a rigid steel frame.

2.      Wheels evenly spaced in one line across the width of the roller.

3.      Wheels arranged so that all wheels carry approximately equal loads when operated over an uneven surface.

4.      A maximum center-to-center spacing between adjacent wheels not exceeding 32 inches (0.8 m).

5.      A body for ballast loading capable of varying the gross load from 25 to 50 tons (23 to 45 metric tons).

6.      Tires capable of operating at inflation pressures ranging from 90 to 120 pounds per square inch (620 to 830 kPa).  Provide a tire pressure gage for measurement before use.

7.      Tires filled with liquid from 90 to 95 percent by volume.

Provide ballast that consist of blocks of known weight, sand bags with a weight of 100 pounds (45 kg), bags of other material of known weight, or other suitable material such that the total ballast weight is readily determinable at all times.  Provide sufficient ballast to load equipment to a maximum gross weight of 50 tons (45 metric tons).

Furnish the Engineer information verifying that the weights and tire pressures can be met.

B.      After compacting the subgrade according to 204.03 and before placing overlying course, proof roll designated subgrade areas.  If proof rolling is performed after the underdrains are installed, do not use the proof roller within 1 1/2 feet (450 mm) of the underdrains.

Ensure that the subgrade moisture content at the time of proof rolling is within 2 percent of the moisture used for acceptance in 204.03.

Adjust the load and tire inflation pressure as directed by the Engineer or according to the following:

1.      For soils classified as A-3, A-4, A-6, or A-7-6, use a 35-ton (32 metric tons) roller with a tire pressure of 120 pounds per square inch (820 kPa).

2.      For granular soils, and soil, rock, and granular mixtures, use a 50-ton (46 metric tons) roller with a tire pressure of 120 pounds per square inch (830 kPa).

3.      When proof rolling areas where unsuitable or unstable subgrade materials have already been excavated and replaced with granular material, use the weight and tire pressure appropriate for the original subgrade material type.

Measure the tire pressure in the presence of the Engineer.  Operate equipment at a speed between 2 1/2 and 5 miles per hour (4 and 8 km/hr).  Adjust the speed to allow the Engineer to measure the deflections, ruts, or elasticity.  Make only one trip of the proof roller over any area. Offset trips to completely cover the subgrade area. 

Where proof rolling indicates areas of unstable subgrade, the Engineer will investigate for the source of the problem.  The Contractor is responsible for all problems found in the materials constructed under the Contract Documents.  Correct all deficiencies found.  Correct the subgrade to a uniform and satisfactory stability as directed by the Engineer.

After proof rolling, check the subgrade for conformance to the plans, and correct all surface irregularities.  Shape the subgrade within the tolerances specified in 203.08.

204.07  Spreading and Placing of Materials.  Place materials, conforming to 204.02, in 8-inch (200 mm) loose lifts.  The Engineer may increase the lift thickness depending on the stability of the bottom of the excavation.  The Engineer may increase the lift thickness up to 24 inches (600 mm) to obtain stability at the top of the lift.  Doze, track, or manipulate the material to maximize the density and stability.  Once stability is achieved, compact according to 204.03.

When specified, place geotextile fabric at the bottom of the cut or at locations designated in the Contract Documents.  Place the geotextile fabric smooth and free of tension or wrinkles.  Fold or cut the geotextile fabric to conform to curves.  Overlap a minimum of 18 inches (450 mm) at the ends and sides.  Hold the geotextile fabric in place with pins or staples.

End dump the suitable material on the geotextile fabric.  Do not operate the equipment directly on the geotextile fabric.  Unless stated otherwise, spread the end dumped material and maintain a minimum lift thickness of 12 inches (300 mm).

When granular material Type E is specified or allowed, use a geotextile fabric on the top, bottom and around the Type E granular material to prevent piping of material into the Type E granular material.  The Engineer may use granular material Type E when excess water is at the bottom of the cut.

204.08  Method of Measurement.  The Department will measure Subgrade Compaction by the number of square yards (square meters) computed from the profile grade and typical sections and actually compacted.  The Department will measure 18 inches (450 mm) beyond the edge of the pavement surface, paved shoulders, and paved medians.  The Department will measure the surface area of the paved driveways, paved mailbox turnouts, curb, and gutter.

The Department will measure Proof Rolling by the number of hours accepted.  The Department will not measure idle time for repairs, servicing, loading and unloading ballast, adjusting tire pressure, bad weather, wet subgrade, usage at times and at locations other than Department directed, and stand-by time to be available when next needed or other cause for stand-by time.

The Department will measure Excavation of Subgrade; Embankment; Granular Embankment; and Granular Material, Type ___ according to 203.09.  All excavation is unclassified.

The Department will measure Geotextile Fabric by the number square yards (square meters) of surface area of geotextile fabric placed.  The Department will not measure the specified lap length.

204.09  Basis of Payment.  The Department will pay according to 109.05 for changes or extra work that increases the haul distance more than a 1/2 mile (1 km) to the work detailed in the Contract Documents.  The Department will pay for additional quantities that increase the haul distance 1/2 mile (1 km) or less at the unit bid price.

If unstable subgrade results from inadequate surface drainage or lack of maintenance, as required by 203.04.A, the Department will not pay for replacing the unstable subgrade and disposing of the removed material.

For problems identified in 204.06 that are the result of soils or conditions at lower elevations than the Contract work, the Department will pay for the corrections.

The Department will pay for the subgrade compaction in areas requiring excavation and replacement in 204.04, 204.05, and 204.07.  The Department will not pay for subgrade compaction in areas stabilized under Item 206.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

204             Square Yard                    Subgrade Compaction
                       (Square Meter)

204             Hour                                Proof Rolling

204             Cubic Yard                      Excavation of Subgrade
                       (Cubic Meter)

204             Cubic Yard                      Embankment
                       (Cubic Meter)

204             Cubic Yard                      Granular Embankment
                       (Cubic Meter)

204             Cubic Yard                      Granular Material Type ___
                       (Cubic Meter)

204             Square Yard                    Geotextile Fabric
                       (Square Meter)

ITEM 205  CHEMICALLY STABILIZED EMBANKMENT

205.01  Description

205.02  Materials

205.03  Submittals

205.04  Construction

205.05  Mixture Design for Chemically Stabilized Soils

205.06  Method of Measurement

205.07  Basis of Payment

205.01  Description.  This work consists of constructing a chemically stabilized embankment by mixing cement, lime, or lime kiln dust into the embankment soil using the method for the specified chemical.

The Contract Documents include an estimated quantity for the specified chemical.

205.02  Materials.  Furnish materials conforming to:

Portland cement....................................................... 701.04

Lime (quick lime)................................................. 712.04.B

Lime kiln dust...................................................... 712.04.C

Furnish water conforming to 499.02.  Furnish suitable natural soil, from on or off the project site, conforming to 703.16 and 203.03.

205.03  Submittals.  Submit, for the Engineer’s acceptance, a report that lists the type of equipment to be used, speed of the intended equipment usage, rate of application of the chemical, and calculations that demonstrate how the required percentage of chemical will be applied.  Submit the report to the Engineer for acceptance at least 2 workdays before the stabilization work begins.

If the pay item for Mixture Design for Chemically Stabilized Soils is included in the Contract Documents, prepare and submit reports according to Supplement 1120.

205.04  Construction.  Perform chemically stabilized embankment work when the air temperature is 40 °F (5 °C) or above and when the soil is not frozen.

Do not perform this work during wet or unsuitable weather.

Drain and maintain the work according to 203.04.A.

A.      Spreading.  If the pay item for Mixture Design for Chemically Stabilized Soils is not included in the Contract Documents, use the following spreading percentage rate for the specified chemical. The percentage is based on a dry density for soil of 110 pounds per cubic foot (1760 kg/m³):

Table 205.04-1

Chemical

Spreading Rate

Cement

6 %

Lime

5 %

Lime Kiln Dust

7 %

Spread the chemical uniformly on the surface using a mechanical spreader at the approved rate and at a constant slow rate of speed.

Use a distribution bar with a maximum height of 3 feet (1 meter) above the ground surface.  Use a canvas shroud that surrounds the distribution bar and extends to the ground surface.

Minimize dusting when spreading the chemical.  Control dust according to 107.17.  Do not spread chemical when wind conditions create blowing dust that exceeds the limits in 107.19.

Do not spread the chemical on standing water.

B.      Mixing.  Immediately after spreading the chemical, mix the soil and chemical by using a power driven rotary type mixer.  If necessary, add water to bring the mixed material to at least optimum moisture content for cement and lime kiln dust, and to at least 3 percent above optimum moisture content for lime.  Continue mixing until the chemical is thoroughly incorporated into the soil, all soil clods are reduced to a maximum size of 2 inches (50 mm), and the mixture is a uniform color.

For areas not under pavements or paved shoulders, the Contractor may use a spring tooth or disk harrow in place of the power-driven rotary type mixer by modifying the above procedure as follows:

1.      Open the soil with a spring tooth or disc harrow before spreading.

2.      Spread the chemical.

3.      Use a minimum disc harrow coverage of ten passes in one direction and ten passes in the perpendicular direction to thoroughly incorporate the chemical into the soil.  Continue mixing until all soil clods are reduced to a maximum size of 1 inch (25 mm) and the mixture is a uniform color.

C.      Compacting.  Construct and compact chemically stabilized embankment according to 203.07, except use 98 percent of the maximum dry density for acceptance.

Determine the maximum dry density for acceptance using the Ohio Typical Moisture Density Curves, the moisture density curves from the Contractor’s mixture design submittal, or the maximum dry density obtained by test section method.

205.05  Mixture Design for Chemically Stabilized Soils.  When included in the plans, perform a mixture design for chemically stabilized soils according to Supplement 1120.

205.06  Method of Measurement.  The Department will measure chemically stabilized embankment by the number of cubic yards (cubic meters) used in the complete and accepted work, as determined by Item 203.

The Department will measure cement, lime, and lime kiln dust by the number of tons (metric tons) incorporated in the complete and accepted work.

205.07  Basis of Payment.  The Department will pay lump sum for all work, labor, and equipment described in 205.05.  The Department will pay two-thirds of the lump sum amount bid when the sampling and testing is complete and the report is accepted by the Department. The Department will pay one-third of the lump sum amount bid when the chemically stabilized embankment is completed and accepted by the Department, and the field verification test results are all submitted.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

205             Cubic Yard                      Cement Stabilized Embankment
                       (Cubic Meter)

205             Cubic Yard                      Lime Stabilized Embankment
                       (Cubic Meter)

205             Cubic Yard                      Lime Kiln Dust Stabilized
                       (Cubic Meter)                  Embankment

205             Ton (Metric Ton)            Cement

205             Ton (Metric Ton)            Lime

205             Ton (Metric Ton)            Lime Kiln Dust

205             Lump Sum                      Mixture Design for Chemically
                                                               Stabilized Soils

ITEM 206  CHEMICALLY STABILIZED SUBGRADE

206.01  Description

206.02  Materials

206.03  Submittals

206.04  Test Rolling

206.05  Construction

206.06  Mixture Design for Chemically Stabilized Soils

206.07  Method of Measurement

206.08  Basis of Payment

206.01  Description.  This work consists of constructing a chemically stabilized subgrade by mixing cement, lime, or lime kiln dust into the subgrade soil using the method for the specified chemical. The Contract Documents include an estimated quantity for the specified chemical.

206.02  Materials.  Furnish materials conforming to:

Portland cement....................................................... 701.04

Lime (quick lime)................................................. 712.04.B

Lime kiln dust...................................................... 712.04.C

Furnish water conforming to 499.02.

For the curing coat, furnish rapid setting emulsified asphalt conforming to 702.04 or the curing materials specified in 451.02.

206.03  Submittals.  Submit, for the Engineer’s acceptance, a report that lists the type of equipment to be used, speed of the intended equipment usage, rate of application of the chemical, and calculations that demonstrate how the required percentage of chemical will be applied.  Submit the report to the Engineer for acceptance at least 2 workdays before the stabilization work begins.

If the pay item for Mixture Design for Chemically Stabilized Soils is included in the Contract Documents, prepare and submit reports according to Supplement 1120.

206.04  Test Rolling.  When specified, test roll prior to chemical stabilization with a proof roller conforming to 204.06. 

206.05  Construction.  Perform chemical stabilization work when the air temperature is 40 °F (5 °C) or above and when the soil is not frozen.  Do not perform this work during wet or unsuitable weather.

A.      Spreading.  Shape the subgrade to the approximate profile grade prior to spreading the chemical so as to permit the construction of a uniformly compacted course of chemically treated soil to the thickness shown on the plans.  The addition of the chemical will raise the subgrade profile approximately 1 inch (25 mm).  Remove this excess material during the fine grading.

If the pay item for Mixture Design for Chemically Stabilized Soils is not included in the Contract Documents, use the following spreading percentage rate for the specified chemical. The percentage is based on a dry density for soil of 110 pounds per cubic foot (1760 kg/m³):

Table 206.05-1

Chemical

Spreading Rate

Cement

6 %

Lime

5 %

Lime Kiln Dust

7 %

Spread the chemical uniformly on the subgrade using a mechanical spreader at the approved rate and at a constant slow rate of speed.

Use a distribution bar with a maximum height of 3 feet (1 meter) above the subgrade.  Use a canvas shroud that surrounds the distribution bar and extends to the subgrade.

Minimize dusting when spreading the chemical.  Control dust according to 107.19.  Do not spread the chemical when wind conditions create blowing dust that exceeds the limits in 107.19.

Do not spread the chemical on standing water.

B.      Mixing.  Immediately after spreading the chemical, mix the soil and chemical as follows. 

1.      Cement or Lime Kiln Dust.  Mix the chemical and soil using a power driven transverse type mixer equipped with a computer controlled volumetric water readout.  Continue mixing until the cement or lime kiln dust is thoroughly incorporated into the soil and is a uniform color.

Do not water during the initial mixing.

Perform the initial mixing so that 60 percent of the soil mixture passes the No. 4 sieve (4.75 mm) and 100 percent passes the 1 inch sieve (25mm), exclusive of aggregate larger than the No. 4 sieve (4.75 mm) size.

After the initial mixing, remix the soil and introduce water through the mixer to bring the mixed material to at least optimum moisture.  Uniformly distribute the water in sufficient quantity to hydrate the cement or lime kiln dust.

If the chemical and soil can be mixed to the required gradation and the water can be added to bring the soil mixture to the required moisture content in one mixing, then only one mixing of the soil, water and chemical is required.

Restrict the addition of water when the moisture content of the soil exceeds 3 percent above optimum moisture.  Add water to the mixed soil within 2 hours after the initial mixing.

Once the water is added to the mixture, complete the mixing, compacting, and shaping within 2 hours from start to finish.

2.      Lime.  Mix the lime and soil using a power driven transverse type mixer equipped with a computer controlled volumetric water readout.  If necessary, add water to bring the mixed material to at least 3 percent above optimum moisture content.  Continue mixing until the lime is thoroughly incorporated into the soil, all soil clods are reduced to a maximum size of 2 inches (50 mm), and the mixture is a uniform color.

After the initial mixing, lightly compact the material to seal it against rain or excessive drying by using a steel wheel or pneumatic tire roller.

Allow the lime and soil mixture to cure (mellow) for a period of not less than 24 hours and not more than 7 days.  If more than 7 days elapse between initial mixing and final mixing, add an additional 0.5 percent of lime during the final mixing.  Furnish the additional lime at no cost to the Department unless the delay beyond the 7-day limit is caused by conditions beyond the Contractor’s control.

Perform the final mixing until the soil mixture is completely pulverized with all clods reduced to a maximum size of 1 inch (25 mm) and at least 60 percent of the clods passing the No. 4 (4.75 mm) sieve, exclusive of aggregate larger than the No. 4 sieve (4.75 mm).  Continue mixing until the lime is uniformly distributed throughout the pulverized soil.

During final mixing, return the mixture to the moisture contents stated above, then shape and compact the mixture.

3.      Mixture Depth Check.  Check the uniformity of the mix by digging trenches or a series of holes at regular intervals for the full depth of treatment and inspecting the color and depth of the exposed material.  Use diluted hydrochloric acid or phenolphthalein to indicate the presence of calcium and ensure that the chemical is mixed to the desired depth.

C.      Compacting.  Start compaction no more than 30 minutes after the final mixing.

Compact all chemically stabilized subgrade to the requirements in 204.03, except use 98 percent of the maximum dry density for acceptance.  Determine the maximum dry density for acceptance by using the Ohio Typical Moisture Density Curves, the moisture density curves from the Contractor’s mixture design submittal, or the maximum dry density obtained by test section method.

Use a vibratory footed roller weighing at least 10 tons (9 metric tons).

Use the moisture controls according to 203.07.A, except ensure that the moisture content at time of compaction is at or above optimum.

Perform the final rolling using a smooth drum roller.  Do not use vibration during the final rolling.

The Contractor may either shape and fine grade the chemically stabilized subgrade before the curing period, or shape the subgrade before the curing period and fine grade after the curing period. If fine grading before the curing period, fine grade the same day as mixing, compacting, and shaping. If fine grading after the curing period, shape the subgrade approximately 1 inch (25 mm) above the profile grade and typical sections. In either case, fine grade the subgrade to the profile grade and typical sections within the tolerances in 203.08.

D.      Curing.  Immediately after the compaction and shaping of the chemically stabilized subgrade, cover the surface with curing coat for curing the chemically stabilized subgrade.  Use a rate of 1 gallon per 30 square feet (1.36 liters per square meter) for emulsions or a rate of 1 gallon per 150 square feet (0.27 liters per square meter)  when the curing materials in 451.02 are used.

Apply the curing coat before the surface dries.  If the curing coat is delayed or the surface starts to dry out, indicated by turning white, apply water for temporary curing until the curing coat can be applied.  Do not apply the curing coat unless the curing coat can set up before it rains.  When the application of curing coat must be delayed, keep the chemically stabilized subgrade wet by using water until the curing coat can be applied.

Cure the chemically stabilized subgrade for at least five days before the placement of the overlying course.

E.      Proof Rolling.  After the curing period, proof roll the chemically stabilized subgrade according to Item 204.

F.      Protection.  Drain and maintain the work according to 203.04.A.

Do not operate any equipment on the chemically stabilized subgrade during the curing period. 

Do not allow the chemically stabilized subgrade to freeze during the cure period.

Cover the completed chemically stabilized subgrade with the aggregate base within 60 calendar days.

206.06  Mixture Design for Chemically Stabilized Soils.  When included in the plans, perform a mixture design for chemically stabilized soils according to Supplement 1120.

206.07  Method of Measurement.  The Department will measure chemically stabilized subgrade by the number of square yards (square meters) computed from the profile grade and typical sections accepted in place.

The Department will measure cement, lime, and lime kiln dust by the number of tons (metric tons) incorporated in the complete and accepted work.

The Department will measure Test Rolling according to 204.08 as specified for Proof Rolling.

The Department will measure Curing Coat by the number of square yards (square meters) computed from the profile grade and typical sections accepted in place.

206.08  Basis of Payment.  The Department will pay lump sum for all work, labor, and equipment described in 206.06.  The Department will pay two-thirds of the lump sum amount bid when the soil sampling and testing is complete and the report is accepted by the Department.  The Department will pay one-third of the lump sum amount bid when the chemically stabilized subgrade is completed and accepted by the Department, and the field verification test results are all submitted.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

206             Square Yard                    Cement Stabilized Subgrade,
                       (Square Meter)                __inches deep

206             Square Yard                    Lime Stabilized Subgrade,
                       (Square Meter)                __ inches deep

206             Square Yard                    Lime Kiln Dust Stabilized
                       (Square Meter)                Subgrade, __ inches deep   

206             Ton (Metric Ton)            Cement

206             Ton (Metric Ton)            Lime

206             Ton (Metric Ton)            Lime Kiln Dust

206             Square Yard                    Curing Coat
                       (Square Meter)

206             Hour                                Test Rolling

206             Lump Sum                      Mixture Design for Chemically
                                                               Stabilized Soils

ITEM 208  rock blasting

208.01  Description

208.02  Regulations on the Use of Explosives

208.03  Product Specifications

208.04  Stabilization

208.05  Blasting Plan Submittal

208.06  Production Holes

208.07  Blasting Test Sections

208.08  Safety Procedures

208.09  Presplitting

208.10  Cushion Blasting

208.11  Sliver Cuts

208.12  Blaster

208.13  Blasting Consultant

208.14  Pre-Blast Condition Survey

208.15  Vibration Control and Monitoring

208.16  Airblast and Noise Control

208.17  Hydrologist

208.18  Flyrock Control

208.19  Public Meetings

208.20  Record Keeping

208.21  Method of Measurement

208.22  Basis of Payment

208.01  Description.  This work consists of using production and controlled blasting techniques to fracture rock or shale and to construct stable final rock cut faces.

Controlled blasting refers to the controlled use of explosives and blasting accessories in carefully spaced and aligned drill holes to produce a free surface or shear plane in the rock along the specified excavation backslopes.  Controlled blasting techniques include presplitting, cushion blasting, and sliver cut blasting.

If the designed cut slope is steeper than 1:1 and deeper than 5 feet (1.5 m), use controlled blasting techniques, even if the main excavation is ripped or excavated. In rare instances, the Department will specify presplitting for 1 to 1 slopes.   For all slopes that do not require controlled blasting techniques, rake, excavate, hoe ram, or mechanically shape these slopes to obtain a neat and smooth appearance.

Production blasting refers to the rock fragmentation blasts resulting from more widely spaced production holes drilled throughout the main excavation area adjacent to the controlled blast line.  Detonate production holes in a controlled delay sequence.

208.02  Regulations on the Use of Explosives.  Perform all blasting operations according to all applicable Federal, State, and local laws and regulations, and the provisions of 107.09.  These regulated blasting operations include but are not limited to the following:

A.      Storage and handling of explosives, blasting agents, and detonators.

B.      Use of explosives in character and amount as allowed.

C.      Storage plan, including the type of magazine or explosive storage facility to be used on the job site.

D.      Record keeping, placarding, safe distances, and all other requirements concerning storage.

E.      Obtaining and displaying magazine permits.

208.03  Product Specifications.  Be aware that delay elements in blasting caps may deteriorate with age.  Aged explosives are known to deliver much less than the rated energy.

If evaporation occurs or if improperly mixed, bulk explosives (such as ammonium nitrate and fuel oil) may not contain the proper amount of diesel oil.  Low diesel oil drastically reduces the energy content of the explosive and commonly produces reddish brown or yellow fumes upon detonation even in dry blast holes.

Use products conforming to manufacturers’ specifications.  Ship the manufacturer recommended expiration dates with the products delivered to the project.  Do not use any blasting product that is either excessively old or in a deteriorated condition.  Cease all work until the product’s age or quality is determined.

208.04  Stabilization.  Remove or stabilize rock along the cut face that is loose, hanging, or creates a potentially dangerous situation during or upon the completion of the excavation in each lift.  Do not drill the next lift until this work is performed.

208.05  Blasting Plan Submittal.  Submit three copies of the Blasting Plan to the Engineer and one copy of the Blasting Plan to the Office of Construction Administration for review at least two weeks before beginning drilling and blasting operations, or at any time the drilling and blasting methods change.  If the drilling and blasting methods change, submit four copies of the changed sections one week prior to the work.

The Blasting Plan shall include, at a minimum, the following:

A.      General details of the drilling and blasting patterns and controls proposed to use for both the controlled and production blasting.

B.      Station limits of proposed shots.  Critical distances to structures.  Place the pre-blast survey limits detailed in 208.14 on the Right-of-Way or plan view sheets.

C.      One plan and section view for each main excavation cut showing the proposed typical range of drill patterns including a range of values for the free face, burden, blast hole spacing, blast hole diameters, blast hole angles, lift heights, and subdrill depths.

D.      A typical loading diagram showing the type and amount of explosives, primers, and initiators and location and depth of stemming.

E.      Typical range of initiator sequence of blast holes including delay times and delay system.

F.      Manufacturers’ data sheets for all explosives, primers, and initiators to be employed.

G.      Use the blaster’s plan form or the blasting plan forms in FHWA Publication FHWA-HI-92-001 Rock Blasting and Overbreak Control.  Adapt these forms to meet the project requirements.

In a subsequent submittal, submit one Detailed Plan for all test sections.  (Submit or fax at least 24 hours before the shot.)  Detail the specific proposed amounts of materials and work described in 208.05.A through 208.05.G above on this Detailed Plan.

The Blasting Plan submittal is for quality control, informational, and record keeping purposes.  The review of the Blasting Plan does not relieve the Contractor of the responsibility for using existing drilling and blasting technology and for obtaining the required results.

If specified in the Contract, use an approved blasting consultant, conforming to 208.13, to assist with the blast design and to ensure that the Blasting Plan is carried out on the project.

208.06  Production Holes.  Perform all production blasting, including blasting carried out in conjunction with the blasting test section requirements of 208.07, according to the following requirements:

A.      Drill the production blast holes on the patterns and to the depths submitted in the Blasting Plan and Detailed Plan, as specified in 208.05, but not exceeding a depth of 60 feet (18 m).  Drill the production blast holes within two blast hole diameters of the staked collar location. If the blaster does not drill the production holes then the blaster shall inspect the holes and review the drilling logs prior to loading the holes.

B.      Deepen or clean-out blast holes if they are plugged or unable to be fully loaded.  Check and measure blast holes before any explosives are loaded into any of the holes to eliminate any safety hazard resulting from drilling near loaded holes.

C.      Maintain a burden distance that is equal to or less than the bench height in order to control the blasting effects.

D.      Drill the row of production blast holes immediately adjacent to the controlled blast line on a plane approximately parallel to the controlled blast line.  Drill the production blast holes no closer than 6 feet (2 m) to the controlled blast line.  Drill the bottom of the production holes no lower than the bottom of the controlled blast holes except by the amount of subdrilling used in the production holes.  Do not exceed 6 3/4 inches (170 mm) in diameter for the production blast holes. Delay the detonation sequence of the production holes toward a free face.

E.      Maintain a stemming depth of at least 0.7 times the burden distance.  If water is present or when blasting within 200 feet (61 m) of a structure, use crushed No. 8 coarse aggregate for holes less than 4 inches (100 mm) in diameter and crushed No. 57 coarse aggregate for holes 4 inches (100 mm) in diameter and larger for the stemming material.  Use the coarse aggregate gradations of Nos. 8 and 57 gradations on Table 703.01-1.  If gravel is used, use crushed material with a minimum of two mechanically fractured faces on 60 percent of the material.  In other locations, the Contractor may use drill cuttings for stemming, if it does not compromise the shot integrity.

F.      Take all necessary precautions in the production blasting to minimize blast damage to the rock backslope.

G.      Drill a line of buffer holes on a parallel plane adjacent to the presplit holes if presplit results are not satisfactory and production holes are damaging the presplit line.  Drill the buffer hole 3 ± 1 inch (75 ± 25 mm) in diameter.  Drill the line of buffer holes approximately 3 feet (1 m) from the presplit line, and space 3 to 5 feet (1 to 1.5 m) center-to-center.  Do not load the buffer holes with more than 50 percent of the full explosive load that could be placed in a 3-inch (75 mm) production hole.  Delay the detonation sequence toward a free face.

208.07  Blasting Test Sections.  Before commencing full-scale blasting operations, demonstrate the adequacy of the proposed Blasting Plan.  Drill, blast, and excavate short test sections to determine which combination of methods, hole spacing, and charge works best.  Use a test section with lengths up to 150 feet (45 m) for presplitting and 120 feet (36 m) for production blasting when field conditions warrant.

Do not exceed a production hole depth of 30 feet (9 m) for the first test section.

Begin the controlled blasting tests for presplitting with the controlled blast holes spaced 36 inches (900 mm) apart, then adjust, if needed, until the spacing for full-scale presplit blasting operations is approved.  A new test section is required to increase the spacing for the presplitting to a maximum of 48 inches (1200 mm).

Perform two test sections on every project.  Use explosive depths greater than 20 feet (6.1 m) for these test sections.  Use one test section for controlled blasting and one test section for production blasting.

Apply the requirements specified for controlled and production blasting operations to the test section blasting.

For controlled blasting and for production blasts within 10 feet (3 m) of the finished slope, do not drill ahead of the test shot area until the test section has been excavated and the results evaluated.  If the test shots are unsatisfactory, revise methods as necessary to achieve the required results.  Unsatisfactory test shot results include an excessive amount of fragmentation beyond the indicated lines and grade, excessive flyrock, or violation of other requirements within Item 208.

If the drilling and blasting methods do not produce the desired result of a uniform slope and shear face, within the tolerances specified, drill, blast, and excavate short sections, not exceeding 150 feet (45 m) in length for a presplit line or 120 feet (36 m) for a production hole line, until a technique produces the desired results.

The blasting consultant shall witness the test sections drilling and loading operations and be present when all test sections are shot.  The time spent witnessing these operations is considered part of the time required to observe the loading, drilling, and blasting operations, as specified in 208.13.

208.08  Safety Procedures

A.      Warnings and Signals.  Establish a method of warning all employees on the job site of an impending blast.

Define the limits of the blasting area where there is a flyrock danger.  Control the access to the blasting area to prevent the presence of livestock or unauthorized persons at least ten minutes before each blast.

Notify all employees in the area that a blast shall be fired with a one minute signal.  After the blast is over, sound an “all clear” signal so all employees in the area understand that all blasting operations are finished.

One minute before the blast, sound three long signals, lasting five seconds, on an air horn or siren.  For the all “clear” signal, sound one long signal, lasting at least five seconds, to indicate that all blasting has ceased.

Fill out the Department’s Blast Site Security Plan Form (CA-EW-11).

B.      Lightning Protection.  Furnish, maintain, and operate lightning detection equipment during the entire period of blasting operations and during the periods that explosives are used at the site.  Use equipment similar or equal to the Thomas Instruments SD250 Storm Alert as manufactured by DL Thomas Equipment, Keene, New Hampshire.  Install the equipment when approved.  If the lightning detection device indicates a blasting hazard potential, evacuate personnel from all areas where explosives are present.  If a lightning detector indicates a blasting hazard, perform the following:

1.      Clear the blasting area of all personnel.

2.      Notify the Engineer of the potential hazards and precautions to be taken.

3.      Terminate the loading of holes and return the unused explosives to the day storage area.

4.      If blast holes are loaded and would pose a hazard to traffic if detonated, close the roads until the lightning hazard has passed.

5.      When the hazard dissipates, inform the Engineer that production blasting can continue.

C.      Check for Misfires.  Observe the entire blast area for a minimum of five minutes following a blast to guard against rock fall before commencing work in the cut.  The five minute delay between blasting and not allowing anyone but the blaster to enter the area is needed to make sure that no misfires have occurred.

During the five minute delay, the blaster is responsible for going into the shot area and checking all the holes to make sure that they have detonated.  If any holes have not fired, the blaster shall handle these misfires before others enter the work area.

Halt the blasting operations if the methods being employed result in the required slopes not being in a stable condition or the safety and convenience of the traveling public is jeopardized.

D.      Misfire Handling Procedures.  If a visual inspection indicates that complete detonation of all charges did not take place, proceed as follows:

1.      If the system was energized and no charges fired for electric systems, test the lead wire continuity before inspection of the remainder of the blast.  For nonelectric systems, check the lead in or tube to make sure that detonation has entered the blast area.

2.      If an inspection of the electrical trunkline or lead in tubing-line indicates that there is a break in the line or if the tubing did not fire, repair the system and refire the blast.  If the inspection indicates that the trunkline has fired, and misfired charges remain, the blaster shall do the following:

a.      Exclude all employees except those necessary to correct the problem.

b.      Close traffic, if a premature explosion could be a hazard to traffic on nearby roads.

c.      Correct the misfire in a safe manner.  If the misfire poses a problem that the blaster cannot safely correct, the Contractor shall call a consultant or an explosive company representative skilled in the art of correcting misfires to correct the problem.

208.09  Presplitting.  Perform all presplitting, including that carried out in conjunction with the blasting test section requirements of 208.07, according to the following requirements:

A.      Completely remove all overburden soil and loose or decomposed rock along the top of the excavation for a distance of at least 30 feet (9 m) beyond the end of the production hole drilling limits, or to the end of the cut, before drilling the presplitting holes.

B.      Remove potentially dangerous boulders or other material located beyond the excavation limits.

C.      Drill the presplit holes 3 ± 1 inch (75 ± 25 mm) in diameter.

D.      Control the drilling operations by using proper equipment and technique to ensure that no hole deviates from the plane of the planned slope by more than 12 inches (300 mm) either parallel or normal to the slope.

E.      Extend presplit holes a minimum of 30 feet (9 m) beyond the limits of the production holes to be detonated, or to the end of the cut as applicable.

F.      Drill the presplit holes for any individual lift to a vertical depth of less than or equal to 30 feet (9 m).  Demonstrate that the blast can stay within the above tolerances and produce a uniform slope.  If more than 5 percent of the presplit holes are misaligned in any one lift, reduce the depth of the lifts until the 12-inch (300 mm) alignment tolerance is met.

G.      If a cut height requires more than one lift or if there is a slope change (for example, when changing from a 1:1 slope to a 0.75:1 slope), use a maximum 2-foot (0.6 m) offset between lifts for drill equipment clearances.  Begin the presplit blast hole drilling at a point that allows for the necessary offsets and adjust to compensate for any drift that may occur in the upper lifts.  Move the controlled blast line back if required to accommodate for these conditions.

H.     The Contractor may drill 2 feet (0.6 m) below ditch bottom to remove the toe berm.

I.       Before placing charges, determine if the hole is free of obstructions for its entire depth.  Exercise all necessary precautions so that the placing of the charges will not cause caving of material from the walls of the holes.

J.       Drill hole conditions may vary from dry to filled with water.  Use whatever types of explosives and blasting accessories necessary to accomplish the specified results.

K.      Use a maximum diameter of explosives that is not greater than one-half the diameter of the presplit hole.

L.      Do not use bulk ammonium nitrate and fuel oil (ANFO) in the presplit holes.

M.     Use only standard explosives manufactured especially for presplitting in the presplit holes.

N.      If using a continuous column cartridge type of explosives with detonating cord, assemble and affix the detonating cord according to the explosive manufacturer’s instructions.  Furnish a copy of the instructions to the Engineer.

O.      The Contractor may make the bottom charge of a presplit hole larger than the line charges but not large enough to cause overbreak.  Place the top charge of the presplitting far enough below the collar, and reduce the charge sufficiently, to avoid overbreaking and heaving.

P.      Stem the upper portion of all presplit holes, from the topmost charge to the hole collar.  Use stemming material conforming to the stemming specified for the production holes in 208.06.

Q.      As long as equally satisfactory presplit slopes are obtained, either presplit the slope face before drilling for production blasting or presplit the slope face and production blast at the same time, provided the presplitting drill holes are fired first.  If required to reduce ground vibrations or noise, delay the presplit holes, except that the hole-to-hole delay must be less than 25 milliseconds.

R.      Do not deviate the presplit slope face more than 1 foot (0.3 m) from a plane passing through adjacent drill holes, except where the character of the rock is such that irregularities are unavoidable.  Measure the 1-foot (0.3 m) tolerance perpendicular to the plane of the slope.  Do not encroach on the roadbed with any portion of the slope.

S.      Use the same diameter and drilled in the same plane and to the same tolerance as the presplit holes when using unloaded and unstemmed guide holes between presplit holes.

T.      Detonate the presplit line before detonating any production holes, except when the closest horizontal distance between the production line and presplit line is greater than 50 feet (16 m).

208.10  Cushion Blasting.  If the horizontal distance from the cut face to the existing rock face is less than 15 feet (4.5 m), the Contractor may use cushion blasting instead of presplitting.  Perform cushion blasting according to 208.09, except as follows:

A.      Detonate along the cut face after the detonation of all production holes.

B.      Between the trim line and the nearest production row, use a difference in delay time of 25 to 75 milliseconds.

208.11  Sliver Cuts.  For sliver cuts, pioneering the top of cuts and preparing a working platform to begin the controlled blasting and drilling operations may require unusual working methods and use of equipment.  Use angle drilled holes or fan drilled holes during the initial pioneering operations to obtain the desired rock face.  Apply the hole diameter requirements for controlled blasting for pioneering work.  Do not exceed a hole spacing of 36 inches (900 mm).

208.12  Blaster.  Use an experienced blaster in charge of all blasting operations.  Use a blaster with at least five years of proven experience in heavy construction or highway rock blasting and with a sufficient amount of proven experience of the type of highway rock blasting required by the Contract.

Before or at the preconstruction conference, submit a resume of the credentials of the proposed blaster.  Include in the resume a list of at least five heavy construction or highway rock blasting projects on which the blaster was responsibly in charge of the rock blasting.  List a description of the projects, with details of the blasting operations.  List the names and telephone numbers of project owners with sufficient knowledge of the projects to verify the submitted information.  Obtain approval of the blaster before beginning any drilling and blasting work.  Allow 30 days for the review of this documentation.  The blaster shall perform the following:

A.      Control the ground vibrations by the use of properly designed delay sequences and by using allowable charge weights per delay.

B.      Base the allowable charge weights per delay on vibration levels that will not cause damage.

C.      Establish the allowable charge weights per delay by carrying out trial blasts and measuring the vibration levels.

D.      Independently measure the vibrations and airblast at the closest structure using the criteria and limits set in 208.15 and 208.16.  Ensure that only trained and certified personnel set up the seismographs.

E.      Use appropriate blast hole patterns, detonation systems, and stemming to prevent venting of blasts and to minimize airblast and noise levels produced by the blasting operations.

F.      Carry out the trial blasts according to the blasting test section requirements of 208.07.

G.      Report the vibrations (velocity and frequency) and airblasts on both seismographs before the next blast.  This report shall denote whether or not these numbers exceeded the allowable set by the vibration specialist.

H.     Modify 208.12.A through 208.12.F above as required to limit ground vibrations and airblast to the levels established by the vibration specialist, and the airblast and noise control specialist.

I. Coordinate and review the blast hole layout and drilling operations.

The blaster, blasting contractor, or the Contractor shall obtain insurance as specified in 107.12.  Present a certificate of insurance 10 days before the blasting operations begin.

208.13  Blasting Consultant.  If specified in the Contract, retain an experienced and recognized blasting consultant to assist in the blast design.  The blasting consultant shall assist in the design of both the controlled and production blasting.

Retain a blasting consultant with at least five years of proven experience in heavy construction or highway rock blasting design and with a sufficient amount of proven experience of the type of highway rock blasting design required by the Contract.  The Contractor shall not use a blasting consultant that is an employee of the Contractor, explosives manufacturer, or explosives distributor.

Before or at the preconstruction conference, submit a resume of the credentials of the proposed blasting consultant.  Include in the resume a list of at least five heavy construction or highway rock blasting projects on which the blasting consultant was responsibly in charge of the rock blasting design.  List a description of the projects, with details of the blast plans and modifications made during the project.  List the names and telephone numbers of project owners with sufficient knowledge of the projects to verify the submitted information.  Obtain approval of the blasting consultant before beginning any drilling and blasting work.  Allow 30 days for the review of this documentation.

The blasting consultant shall observe the loading, drilling, or blasting operations for at least 8 hours per week if these operations are in progress for 40 or more hours per week.  The blasting consultant shall witness the drilling, loading and blasting of the first shot in each major cut.  At a minimum, the blasting consultant shall witness the drilling, loading and blasting of every 20th shot on the project.  The blasting consultant shall write a written report to the Engineer at least once a month detailing the blasting operations.  The time spent writing this report is not considered part of the time required to observe the loading, drilling, and blasting operations.  The Contractor shall coordinate the blasting consultant’s hours with the Engineer.

208.14  Pre-Blast Condition Survey.  If specified in the Contract, conduct a pre-blast survey of any buildings, structures, or utilities within 1500 feet (460 m) or to the nearest structure up to a 1/2-mile (0.8 km) radius of the blasting operations.  Use a greater radius if the structures are potentially at risk from blasting damage.  The Contractor shall use a survey method acceptable to its insurance company.  The Contractor is responsible for any damage resulting from blasting.

If owners or occupants fail to allow access to the property for the pre-blast survey, send a certified letter to the owner or occupant.  Make the notification effort and the certified letter part of the pre-blast survey records.

Submit a copy of the pre-blast survey records to the Engineer before beginning the blasting operations at the critical blasting locations.

Notify occupants of local buildings before the commencement of blasting.

208.15  Vibration Control and Monitoring.  If specified in the Contract, use vibration control and monitoring if blasting near buildings, structures, or utilities that may be subject to damage from blast induced ground vibrations.  The vibration specialist interprets the seismograph records to ensure that the seismograph data is effective in the control of the blasting operations with respect to the existing structures.

Retain an experienced vibration specialist to establish the safe vibration limits.  Use a vibration specialist with at least five years of proven experience in monitoring vibrations on heavy construction or highway rock blasting projects and with a sufficient amount of proven experience of the type of highway rock blasting vibration monitoring required by the Contract.

Use a vibration specialist that is an expert in the interpretation of the vibration data.  The Contractor shall not use a vibration specialist that is an employee of the Contractor, explosives manufacturer, or explosives distributor.

Before or at the preconstruction conference, submit a resume of the credentials of the proposed vibration specialist.  Include in the resume a list of at least five heavy construction or highway rock blasting projects on which the vibration specialist was responsibly in charge of monitoring the rock blasting vibrations.  List a description of the projects, with details of the vibration interpretations made on the project.  List the names and telephone numbers of project owners with sufficient knowledge of the projects to verify the submitted information.  Obtain approval of the vibration specialist before beginning any drilling and blasting work.  Allow 30 days for the review of this documentation.

The vibration specialist shall perform the following:

A.      Monitor each blast with an approved seismograph located between the blast area and the closest structure subject to blast damage.

B.      Use a seismograph capable of recording particle velocity for three mutually perpendicular components of vibration in the range generally found with controlled blasting.

C.      Furnish the data recorded for each shot before the next blast and include the following:

1.      Identification of instrument used.

2.      Name of approved observer and interpreter.

3.      Distance and direction of recording station from blast area.

4.      Type of ground at recording station and material on which the instrument is sitting.

D.      Ensure that the peak particle velocity of each component of the safe limits of the nearest structure subject to vibration damage is not exceeded.

E.      The vibration specialist may elect to summarize and report this information monthly, when the blaster measures the vibration and airblast with its own seismograph and reports the measurements on the vibration specialist’s seismographs.

F.      Establish what vibration limits are being used and explain why they are being used to the Engineer before blasting begins near structures denoted in the pre-blast survey in 208.14.

G.      Stop all operations if the vibration limits are exceeded until the vibration specialist reports to the Engineer that no damage has occurred or will occur and that corrective action has been taken to lower the vibration.

208.16  Airblast and Noise Control.  If specified in the Contract, install an airblast monitoring system between the main blasting area and the nearest structure subject to blast damage or annoyance.

Retain an experienced airblast and noise control specialist.  Use an airblast and noise control specialist with at least five years of proven experience in airblast and noise control on heavy construction highway rock blasting projects and with a sufficient amount of proven experience of the type of rock blasting airblast and noise control monitoring required by the Contract.  Use an airblast and noise control specialist that is an expert in airblast and noise control.  The Contractor shall not use an airblast and noise control specialist that is an employee of the Contractor, explosives manufacturer, or explosives distributor.

Before or at the preconstruction conference, submit a resume of the credentials of the proposed airblast and noise control specialist.  Include in the resume a list of at least five heavy construction or highway rock blasting projects on which the airblast and noise control specialist was responsibly in charge of the airblast and noise control of the rock blasting operations.  List a description of the projects, with details of the airblast and noise control monitoring made on the project.  List the names and telephone numbers of project owners with sufficient knowledge of the projects to verify the submitted information.  Obtain approval of the airblast and noise control specialist before beginning any drilling and blasting work.  Allow 30 days for the review of this documentation.

The airblast and noise control specialist shall perform the following:

A.      Use equipment of the type specifically manufactured for the purpose to make the airblast measurements.  Hold peak overpressure below 134 dB at the nearest structure or other designated location.  Lower the overpressure limit if it proves too high based on damage or complaints.

B.      The airblast and noise control specialist may establish the peak overpressure limits higher than 134 dB.  Submit information explaining why higher limits are needed and are safe to the Engineer before blasting begins near structures denoted in the pre-blast survey in 208.14.

C.      Furnish a permanent signed and dated record of the peak overpressure measurements to the Engineer immediately after each shot or use the same reporting procedures and time frames denoted for vibration in 208.15.

D.      Stop all operations if the overpressure limits are exceeded until the airblast and noise control specialist reports to the Engineer that no damage has occurred or will occur and that corrective action has been taken to lower the airblast.

208.17  Hydrologist.  If specified in the Contract, use a qualified hydrologist to monitor before, during, and after blasting or major excavation the quantity and quality of the water supplies within 1500 feet (460 m) of the blasting or major excavation areas.  The water supplies shall include, but not be limited to, all wells, springs, or other water supplies for human consumption.

Retain an experienced hydrologist.  The Contractor shall not use a hydrologist that is an employee of the Contractor, explosives manufacturer, or explosives distributor.

Before or at the preconstruction conference, submit a resume of the credentials of the proposed hydrologist.  Include in the resume a list of at least five heavy construction or highway projects on which the hydrologist was responsibly in charge of monitoring water quality and quantities.  List a description of the projects, with details of the water monitoring or modeling performed on the projects.  List the names and telephone numbers of project owners with sufficient knowledge of the projects to verify the submitted information.  Obtain approval of the hydrologist before beginning any major excavation, drilling, or blasting work.  Allow 30 days for the review of this documentation.

The hydrologist shall perform, at minimum, all of the following:

A.      Review the available public records, including Ohio DNR well logs, to obtain background information and to identify the locations and geology of water supplies within 1500 feet (460 m) of the blasting areas or major excavations.

B.      Examine private wells, and public and industrial water supplies (as allowed by property owners or occupants), and measure water levels and well depths with a water level meter.  Clean the water level meter before and between each use.

C.      Collect water quality data (pH, e-coli, specific conductivity, turbidity, sulfur, and iron) from private wells, and public and industrial water supplies to determine the major excavation work or blasting effects on the water supplies by using field instruments.

D.      Measure the water quality and water level for a minimum of two times per week for two weeks before, during, and two weeks after major excavation or blasting within 1500 feet (460 m) of the water supplies.

E.      Perform an associated field survey of the locations and elevations of wells and springs.

F.      Evaluate the need for piezometers to monitor the ground water conditions.  Place and monitor the piezometers as necessary.

G.      Provide a monitoring plan report detailing the proposed activities, frequencies, testing, and any recommendations for monitoring the water supplies as detailed in 208.17.A through 208.17.F above.  Submit this report at least 10 days before beginning the scheduled blasting or major excavation.

H.     Provide a monthly report of the conclusions and results of the monitoring plan.

I.       Provide a final report on the final condition or effect of the blasting or major excavation on the water supplies.  Submit this report within 30 days after the blasting or major excavation is completed on the project.

J.       Meet with the Engineer in order to coordinate this work and provide input, update the project schedule, report progress (including completed work and updated schedule), and make recommendations.  Allow for ten meetings.

The Contractor is not responsible for damages to the above denoted water supplies if the blasting or excavation is done according to this specification.  The Contractor is responsible for damage caused by negligence, vibration or noise above the allowable limits, flyrock, or back break.

208.18  Flyrock Control.  Before firing any blast in areas where flying rock may result in personal injury or unacceptable damage to property or the work, cover the rock with blasting mats, soil, or other equally serviceable material to prevent flyrock.

If flyrock leaves the construction site or lands on a traveled road, the Contractor shall cease all blasting operations until the blasting consultant specified in 208.13 reviews the site and determines the cause and solution to the flyrock problem.  Before blasting proceeds, submit a written report addressing the following:

A.      Why the flyrock left the construction site or landed on a traveled road.

B.      What corrective measures were taken to prevent this from reoccurring?

208.19  Public Meetings.  If a blasting consultant, vibration specialist, airblast and noise control specialist, or hydrologist are specified in the Contract, make the consultant, specialists, Contractor’s superintendent and blaster available for one day to prepare for and participate in a public meeting organized by the Engineer and conducted by the Contractor to inform the public about anticipated drilling and blasting operations.  The consultant and specialists shall be prepared to answer any questions dealing with the magnitude of seismic motion, vibrations, airblast overpressure, flyrock, and water problems that may affect the public.

208.20  Record Keeping.

A.      Daily Explosive Material Consumption.  Keep a daily record of the transactions at each storage magazine.  Update inventory records at the close of every business day.  Show on the records the class and quantities received and issued and total remaining on hand at the end of each day.  Check the remaining explosive inventory each day and report any discrepancies that would indicate a theft or loss of explosive material.

B.      Report of Loss.  If a loss or theft of explosives occur, report all circumstances and details of the loss or theft immediately to the nearest Bureau of Alcohol, Tobacco and Firearms, as well as to the local law enforcement authorities and the Engineer.

C.      Daily Drilling and Blasting Logs.  On a weekly basis, provide a daily log of the drilling and blasting operations.  Update the log at the close of each business day. 

Fill out the Department or blaster’s drilling form to document the following: burden, spacing, bench height, hole depth and diameter, and subdrill depth.  Document additional information about the drilling such as voids, mud seams, air pressure loss and lack of cuttings.  The driller shall give this form to the blaster and the Department.

Document on the blasting log the number of blasts, times and dates of blasts, the blasting locations and patterns, and all of the following information:

1.      Station limits of the shot.

2.      Plan and section views of drill pattern including free face, burden, blast hole spacing, blast hole diameters, blast hole angles, lift height, and subdrill depth.

3.      Loading diagram showing type and amount of explosive, primers, and initiators and location and depth of stemming.

4.      Initiators sequence of blast holes including delay times and delay system in each blast hole.

5.      Trade names and sizes of all explosives, primers, and initiators employed.

6.      Signature of the blaster in charge.

7.      Use the blaster’s blasting form or the Blasting Report form in FHWA Publication FHWA-HI-92-001 Rock Blasting and Overbreak Control.  Adapt these forms to meet the project requirements.

The drilling and blasting logs are for quality control, informational, and record keeping purposes.  Review of the blast log by the Engineer does not relieve the Contractor of responsibility for the accuracy and adequacy of the drilling and blasting log.

D.      Video Recording of Blasts.  Record video of each blast.  Index the recordings in a manner that permits easy and correct identification of each blast.  Submit copies of the blast recordings on a weekly basis.  If submitting the video recordings as electronic data files, furnish them in a video format acceptable to the Engineer and capable of being viewed on the Department’s computers.

208.21  Method of Measurement.  The Department will measure Presplitting by the number of square yards (square meters) along the slope face of the cut.  The horizontal measurement will begin at the first hole and end at the last hole of the cut, and the vertical slope measurement will be along the sloped drill hole.

208.22  Basis of Payment.  The Department will not make separate payment for the production blasting operations.  Payment for the production blasting is incidental to the other work items in the Contract requiring blasting.  The Department will pay for additional excavation volume resulting from the 2-foot (0.6 m) offsets at the Contract unit price for Item 203 Excavation.  The Department will pay for the removal of this material beyond the excavation limits under 109.05.

The Department will pay lump sum for all work for the Pre-Blast Condition Survey, Blasting Consultant, Airblast and Noise Control, Vibration Control and Monitoring, and Hydrologist.  The same person or consultant may perform the pre-blast survey, vibration control and monitoring, airblast and noise control, and the work required of the hydrologists.  The Department may make intermediate payments based on the percentage of the work completed for Pre-Blast Condition Survey, Blasting Consultant, Airblast and Noise Control, Vibration Control and Monitoring, or Hydrologist.

Payment for guide holes is incidental to Presplitting.  Payment for all of controlled blasting is included in the payment for Presplitting.

The Department will pay for stabilization under 109.05 if caused by geology.  The Department will not pay for stabilization if caused by the Contractor’s blasting operations.

The Department will pay for the placement and monitoring of piezometers according to 109.05.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

208             Square Yard                    Presplitting
                       (Square Meter)

208             Lump Sum                      Pre-Blast Condition Survey

208             Lump Sum                      Blasting Consultant

208             Lump Sum                      Airblast and Noise Control

208             Lump Sum                      Vibration Control and Monitoring

208             Lump Sum                      Hydrologist

Item 209  LINEAR GRADING

209.01  Description

209.02  Materials

209.03  Construction Requirements

209.04  Ditch Cleanout

209.05  Reshaping Under Guardrail

209.06  Preparing Subgrade for Shoulder Paving

209.07  Grading Tolerances

209.08  Method of Measurement

209.09  Basis of Payment

209.01  Description.  This work consists of performing linear grading within the specified alignment detailed in the Contract Documents and within the grading tolerances.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

209.02  Materials.  Furnish suitable materials as defined in 203.02.R.

209.03  Construction Requirements.  Construct embankment and subgrade work according to Items 203 and 204.

When off-project-limit embankment material is needed for the work, an estimated quantity for Item 209 Borrow will be specified in the Contract Documents.

209.04  Ditch Cleanout.  Reestablish the cross-section of the existing ditch.  Use the required embankment material to fill the eroded conditions.  The compaction requirements specified in Item 203 do not apply.

209.05  Reshaping Under Guardrail.  Reshape graded shoulders at locations were the existing guardrail is removed or where the new guardrail is to be erected to ensure a smooth drainable surface free of all irregularities.

209.06  Preparing Subgrade for Shoulder Paving.  Prepare the subgrade for shoulder paving by excavating the existing shoulder material to the depth shown in the plan.  Trim unsound or broken edges of asphalt concrete or concrete pavement to a line established by the Engineer.  Remove any unstable material and shape and compact the subgrade.

Compact the subgrade according to 204.03.  Backfill areas graded in excess of the depth shown on the plans with Item 617 compacted aggregate at no expense to the Department.

209.07  Grading Tolerances.  Do not encroach on stream channels, impact wetlands, or extend beyond construction limits, Right-of-Way or easement limits.  Do not make alignment or profile grade adjustments that adversely affect drainage.  Construct the work to the tolerances in 203.08.

209.08  Method of Measurement.  The Department will measure Linear Grading, Reshaping Under Guardrail, and Preparing Subgrade for Shoulder Paving by the number of either stations or miles (meters or kilometers) completed and accepted, along each side of the pavement.  The Department will not make deductions for intersections and other gaps.

The Department will measure Ditch Cleanout by the number of feet (meters) measured along the centerline of the ditch.

The Department will measure Borrow according to 203.09.

209.09  Basis of Payment.  The Department will pay according to 109.05 for changes or extra work that increases the haul distance by more than 1/2 mile (1 km) to the work detailed in the Contract Documents.  The Department will pay for additional quantities that increase the haul distance 1/2 mile (1 km) or less at the unit bid price.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

209             Station or Mile                Linear Grading
                       (Meter or Kilometer)

209             Feet (Meters)                   Ditch Cleanout

209             Station or Mile                Reshaping Under Guardrail
                       (Meter or Kilometer)      

209             Station or Mile                Preparing Subgrade for Shoulder Paving
                       (Meter or Kilometer)      

209             Cubic Yard or Ton          Borrow
                       (Cubic Meter

                       or Metric Ton)

250 Pavement repairs

ITEM 251  PARTIAL DEPTH PAVEMENT REPAIR

251.01  Description

251.02  Removal of Existing Pavement

251.03  Placement of Asphalt Concrete

251.04  Method of Measurement

251.05  Basis of Payment

251.01  Description.  This work consists of partial depth removal of existing pavement in areas exhibiting deterioration at the surface, applying tack coat, and placing and compacting asphalt concrete.

251.02  Removal of Existing Pavement.  The Engineer will designate the location and limits of areas to be repaired.  Provide the Engineer with aerosol spray paint to outline those areas for repair.  Provide rectangular repair areas with dimensions as required to envelop surface deterioration.  Unless otherwise specified, extend repair areas the full width of a traffic lane at transverse joints and along portions of longitudinal joints.  Remove pavement to the depth shown on the plans.

Remove the pavement to the specified depth within the designated limits without loosening or otherwise damaging adjacent pavement.  Dispose of removed pavement according to 202.

251.03  Placement of Asphalt Concrete.  Apply 407.02 material to thoroughly coat the exposed surface and to fill cracks and joint openings.

Place and compact approved Item 448 asphalt concrete in one or more lifts as necessary to finish flush with the adjacent pavement surface.

Thoroughly compact the final lift using a Type I pneumatic tire roller that conforms to 401.13.  As the rolling progresses, add additional patching material, as necessary, to produce a smooth surface flush with the existing pavement surface.

Continuously compact each lift while the material is in a workable condition throughout the depth of the lift.

Trim the limits of the repair to form a vertical face 1.5 inches (38 mm) deep from the surface before placing the final asphalt concrete layer adjacent to the existing pavement unless the repair is covered with an overlay within 60 days.

If the Contract does not include resurfacing, seal the perimeter surface of the repaired area by applying a 2 inch (50mm) to 4 inch (100 mm) wide strip of approved 705.04 material or 702.01 approved PG binder.

251.04  Method of Measurement.  The Department will measure the quantity of Partial Depth Pavement Repair by the number of square yards (square meters) or cubic yards (cubic meters) of pavement repaired in the complete and accepted work, calculated using the dimensions established by the Engineer.

251.05  Basis of Payment.  Payment is full compensation for furnishing all materials, including aerosol spray paint, tack coat, asphalt concrete, seal coat, and cover aggregate and for all labor, equipment, and incidentals necessary to complete this work.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

251             Square Yard                    Partial Depth Pavement Repair

                     (Square Meter)

251             Cubic Yard                      Partial Depth Pavement Repair
                       (Cubic Meter)

ITEM 252  FULL DEPTH RIGID PAVEMENT REMOVAL AND FLEXIBLE REPLACEMENT

252.01  Description

252.02  Removal of Existing Rigid Pavement

252.03  Correction of Subgrade

252.04  Placement of Asphalt Concrete

252.05  Method of Measurement

252.06  Basis of Payment

252.01  Description.  This work consists of the full depth removal of existing rigid pavement in areas exhibiting deterioration, correcting the subgrade, placing and compacting asphalt concrete, and restoring the shoulders.

252.02  Removal of Existing Rigid Pavement.  Conform to 255.03, except the last paragraph does not apply.

252.03  Correction of Subgrade.  Shape and recompact the subgrade as the Engineer directs.  Clean all vertical faces of the existing pavement, and coat them with asphalt material according to 401.14.

252.04  Placement of Asphalt Concrete.  Construct the pavement replacement by placing and compacting Item 301 or 448, Type 2 material in two or more lifts according to 401.16.

Thoroughly and uniformly compact the first lift and all intermediate lifts using suitable mechanical compaction equipment operated over the entire replacement area.

Thoroughly compact the final lift using a pneumatic tire roller that conforms to 401.13.  As the rolling progresses, add additional patching material, as necessary, to produce a smooth surface flush with the existing pavement surface.

Continuously compact each lift while the material is in a workable condition throughout the depth of the lift.

Trim the limits of the repair to form a vertical face 1.5 inches (38 mm) deep from the surface before placing the final asphalt concrete layer adjacent to the existing pavement unless the repair is covered with an overlay within 60 days.

If the Contract does not include resurfacing, seal the perimeter surface of the repaired areas by applying a nominal 4 inch (100 mm) wide strip of approved 702.04 asphalt material, RS-1, RS-2, CRS-1, or CRS-2 or 702.01 approved PG binder.

After completing repairs, restore the existing shoulders to the condition that existed prior to the repair work.

252.05  Method of Measurement.  The Department will measure the quantity of Full Depth Rigid Pavement Removal and Flexible Replacement by the number of square yards (square meters) of rigid pavement repaired in the complete and accepted work, calculated using the dimensions established by the Engineer.

The Department will measure the quantity of Full Depth Pavement Sawing by the number of feet (meters) of full depth saw cuts in the complete and accepted work.  The Department will not measure offset saw cuts.  The Department will not measure additional cuts made to facilitate the removal of the pavement

252.06  Basis of Payment.  Payment is full compensation for furnishing all materials, including aerosol spray paint, removing pavement, correcting the subgrade, placing flexible pavement, sealing, and restoring the shoulders and for all labor, equipment, and incidentals necessary to complete this work.

The Department will not pay for removal, disposal, and replacement of pavement damaged adjacent to the repair area.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

252             Square Yard                    Full Depth Rigid Pavement Removal and
                       (Square Meter)                Flexible Replacement

252             Foot (Meter)                    Full Depth Pavement Sawing

ITEM 253  PAVEMENT REPAIR

253.01  Description

253.02  Removal of Existing Pavement

253.03  Placement of Asphalt Concrete

253.04  Method of Measurement

253.05  Basis of Payment

253.01  Description.  This work consists of removing existing asphalt concrete, brick, portland cement concrete, or aggregate pavement courses; shaping and compacting the exposed material; and placing new asphalt concrete pavement or aggregate and asphalt concrete pavement courses.

The plans show details about the repairs and replacement material.

253.02  Removal of Existing Pavement.  The Engineer will designate the location and limits of areas to be repaired.  Provide the Engineer with aerosol spray paint to outline those areas for repairs.  Repair the full depth of the pavement, unless otherwise shown on the plans.

Cut the existing pavement at the limits specified and as necessary to prevent disturbing or undermining the remaining pavement during removal.  Completely remove pavement in the repair area to the specified depth without displacing, undermining, or otherwise damaging the remaining pavement.  Dispose of removed pavement according to 202.

253.03  Placement of Asphalt Concrete.  Shape and compact the exposed underlying material as the Engineer directs.  Before placing asphalt concrete, clean all vertical faces of the existing pavement and coat them with asphalt material according to 401.14.  Place the replacement material in lifts as the Engineer directs.  Thoroughly and uniformly compact each lift using suitable compaction equipment as the Engineer directs.  Finish the final lift flush with the existing pavement surface.

Thoroughly compact the final lift using a pneumatic tire roller that conforms to 401.13.  As the rolling progresses, add additional patching material, as necessary, to produce a smooth surface flush with the existing pavement surface.

Continuously compact each lift while the material is in a workable condition throughout the depth of the lift.

Trim the limits of the repair to form a vertical face 1.5 inches (38 mm) deep from the surface before placing the final asphalt concrete layer adjacent to the existing pavement unless the repair is covered with an overlay within 60 days.

If the Contract does not include resurfacing, seal the perimeter surface of the repaired areas by applying a nominal 4 inch (100 mm) wide strip of RS-1, RS-2, CRS-1, or CRS-2 or 702.01 approved PG binder from certified binder list.

After completing repairs, restore the existing shoulders to the condition that existed prior to the repair work.

253.04  Method of Measurement.  The Engineer will measure the quantity of Pavement Repair by either the number of square yards (square meters) or cubic yards (cubic meters) of pavement repaired in the complete and accepted work, calculated using the dimensions established by the Engineer.  The Engineer will not measure removal and replacement pavement beyond the designated limits.

253.05  Basis of Payment.  Payment is full compensation for furnishing all materials, including aerosol spray paint and replacement and restoration materials; cutting, removing, and disposing of existing pavement; shaping and compacting the exposed underlying material; placing new pavement; and restoring the shoulders and for all labor, equipment, and incidentals necessary to complete this work.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

253             Square Yard                    Pavement Repair
                       (Square Meter)

253             Cubic Yard                      Pavement Repair
                       (Cubic Meter)

ITEM 254  PAVEMENT PLANING

254.01  Description

254.02  Equipment

254.03  Planing

254.04  Surface Patching

254.05  Surface Tolerances

254.06  Method of Measurement

254.07  Basis of Payment

254.01  Description.  This work consists of planing the existing asphalt concrete  and disposing of the cuttings, and, if specified in the Contract, patching the planed surface.

254.02  Equipment.  Use self-propelled planing equipment that has sufficient power and stability to consistently and efficiently meet the requirements of 254.05 and the plans.  Use equipment with either grinding, sawing, or milling type cutters.  Ensure that the cutters are mounted rigidly to the carrier and are adjustable to control the depth of cut and cross-slope.  Accomplish longitudinal planing action by using equipment with a suitable carrier wheelbase or with an automatic control system having an external reference.  Ensure that cross-slope adjustments or automatic controls are capable of producing either a variable or a constant cross-slope, as required.

For small or confined areas, the Contractor may use suitable supplemental equipment or methods approved by the Engineer.

254.03  Planing.  Make one or more planing passes, as necessary, over the designated area to the depth specified in the plans.  Remove irregularities such as bumps, corrugations, and wheel ruts, when required, to establish a new pavement surface elevation or cross-slope.

Remove cuttings from the surface following each pass.  Before opening the completed area to traffic, thoroughly clean the surface of all loose material that would create a hazard or nuisance, or would redeposit into the surface texture.  Dispose of cuttings according to 202.

Implement effective measures to control dust, pavement contamination, and the scattering of loose particles during planing and cleaning operations.

If planing damages the adjacent pavement, repair the damaged area to the Engineer’s satisfaction.  Ensure that the repaired area matches the adjacent pavement in terms of smoothness and mix type.

254.04  Surface Patching.  Patch areas of the planed surface that the Engineer designates that have spalling or dislodged unsound pavement.  Before patching, clean areas of loose material, coat with 407.02 asphalt material, and fill with Item 448, Type 1 material.  Level and compact new material flush to the adjacent planed pavement.

254.05  Surface Tolerances.  Plane the surface free from grooves, ridges, gouges, or other irregularities detrimental to the safe operation of vehicles on the planed surface.

If the Contract specifies planing without resurfacing, plane the surface to a smoothness of 1/8 inch in 10 feet (3 mm in 3 m).  If the Contract specifies resurfacing after planing, plane the surface to a smoothness of 1/4 inch in 10 feet (6 mm in 3 m).  Match the surfaces at the edges of adjacent passes within 1/8 inch (3 mm).  Ensure that the cross-slope of the planed surface is within 3/8 inch in 10 feet (10 mm in 3 m) of the specified cross-slope.

254.06  Method of Measurement.  The Engineer will measure the quantity of Pavement Planing, Asphalt Concrete by the number of square yards (square meters).

The Engineer will measure the quantity of Patching Planed Surface by the number of square yards (square meters).

254.07  Basis of Payment.  The Department will not pay for repairs due to damage caused by planing operations.  If the depth of the planed surfaces is increased by more than 3/8 inches (10 mm) the Department will compensate for the additional work.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

254             Square Yard                    Pavement Planing, Asphalt Concrete
                       (Square Meter)

254             Square Yard
                       (Square Meter)             Patching Planed Surface

ITEM 255  FULL DEPTH PAVEMENT REMOVAL AND RIGID REPLACEMENT

255.01  Description

255.02  Materials

255.03  Removal of Existing Pavement

255.04  Correction of Disturbed Subgrade

255.05  Placing Dowels and Tiebars

255.06  Placement of Portland Cement Concrete

255.07  Wearing Course Replacement

255.08  Opening to Traffic

255.09  Method of Measurement

255.10  Basis of Payment

255.01  Description.  This work consists of full depth removal of existing pavement; removing subbase where specified; compacting the subgrade; furnishing and placing dowels, tiebars, and mesh where specified; placing, consolidating, finishing, and curing new portland cement concrete to the level of the existing portland cement concrete pavement; and restoring affected shoulders.

255.02  Materials.  Furnish materials conforming to:

Concrete, Class QC 1, QC MS, QC FS....................... 499

Curing materials, Type 2.......................................... 705.07

Non-shrink non-metallic grout................................. 705.20

Reinforcing steel ..................................................... 709.00

Preformed elastomeric joint sealer........................... 705.11

Tiebar steel, epoxy coated........................................ 709.00

Dowel bars and basket assemblies.......... 705.01 or 709.13

Expansion shield anchors Type A........................... 712.01

Use epoxy coated Hook bolt, Wiggle bolt, and Coupling.

Select and furnish grout from the Qualified Product List issued by the Laboratory that firmly anchors the dowel or tiebar within 30 minutes.

A.         Rapid Repair Concrete Mix Materials.  If the bid item requires RRCM (Rapid Repair Concrete Mix) do not use the Concrete classes listed above.  Develop a specialized mix design as follows:

Using the following special Rapid Early Repair admixture Systems such as

1.     4 x 4 concrete system 

2.     Rapid -1

3.     Or other manufactured systems acceptable to the Director

Develop a RRCM concrete mix design that will achieve a flexural strength of 400 psi (2.8 MPa) in not less than 4 hours and not more than 6 hours using 6” x 6” (150 mm x 150 mm) beam samples conforming to ASTM C293.

Use cements conforming to 701.02, 701.04 or 701.05

Use fine aggregate conforming to 703.02.A

Use Coarse Aggregate(s) conforming to 703.02.B and 703.13

During the testing of the RRCM mix design develop the mix’s maturity curve according to supplement 1098 using the actual materials that will be used on the project. 

Document and Submit to the Engineer the RRCM mix design results showing flexural strength, time to strength, materials, sources of materials, quantities of materials and batching requirements.

The Engineer will have 10 days review the mix design and accept or reject.

255.03  Removal of Existing Pavement.  The Engineer will locate and mark all areas for repair before the start of diamond sawing.  Provide the Engineer with aerosol spray paint to outline those areas for repair.

Saw cut the existing rigid pavement to the full depth at the limits of the area designated by the Engineer using a diamond saw blade.  Where there is an existing asphalt concrete overlay on top of the concrete pavement to be removed, the Contractor may make either a full depth saw cut through the asphalt concrete overlay and the concrete pavement, or make an offset saw cut through the asphalt concrete overlay.  If making an offset saw cut through the asphalt concrete overlay, remove the overlay as necessary to provide clearance for the full depth saw cut through the concrete pavement.  The Contractor may elect to make additional cuts to facilitate the removal of the pavement.

Remove pavement in the repair area by the lift-out method without damaging or undermining the remaining pavement.  After the repair area is isolated by full depth saw cuts, drill holes through the deteriorated slab, and install lift pins.  Vertically lift the pavement out of the repair area.  Remove loose debris left behind after lift-out using hand methods.  Dispose of removed pavement according to Item 202.

Do not break the pavement and clean out the material using a backhoe unless the Engineer determines that the lift-out method is not feasible due to deteriorated pavement or existing asphalt concrete repairs, or deteriorated concrete pavement.

If the bottom face of the adjacent concrete pavement is deteriorated for a height greater than one-fourth (1/4) the thickness of the rigid pavement, make additional full depth saw cuts as directed by the Engineer along the full width of the lane or lanes to remove the deteriorated areas.  Repair pavement damaged during the pavement sawing or pavement removal according to Item 255 or Item 256.

255.04  Correction of Subgrade.  After removing the existing pavement full depth and before installing dowels or tiebars, shape and recompact the subgrade to the satisfaction of the Engineer.  Replace any subgrade material removed with the existing concrete pavement removal with concrete as part of the rigid pavement replacement.

255.05  Placing Dowels and Tiebars.  Drill dowel and tiebar holes using hydraulic or electric drills without spalling or damaging the existing concrete.  To drill for dowels, use a device capable of drilling a minimum of three holes at a time.  For patches 10 feet (3 m) or greater in length, provide tie bars or wiggle bolts of the size and spaced as shown on the standard construction drawings. Blow clean all drilled holes with oil-free compressed air.  Maintain holes dry and frost free before grouting the dowels or tiebars.  Pneumatically inject grout into the rear portion of the drilled holes.  Use a grout retention disc with a radius slot as shown in the standard drawings to retain the grout within the drilled holes.  Inject grout to fill all voids behind the grout retention disc and until grout extrudes through the radius slot.  Insert dowels and tiebars through the grout retention disc while the disc is placed flush with the sawed edge of pavement and aligned with the drilled hole.  Insertion of the dowels and tiebars shall force the grout out of the radius slot in the grout retention disc.  Hold dowel bars in proper alignment until the grout has hardened.

255.06  Placement of Portland Cement Concrete.  Do not place any portland cement concrete for rigid pavement replacement until the grout around the dowel or tiebar has hardened. Coat dowel bars with bond breaking material conforming to 451.08.B.  Place portland cement concrete according to 451.06.  Use forms at the shoulder.  Cast each patch in one continuous operation.  Consolidate the concrete around the perimeter of the patch and within the limits of the patch area using an internal type vibrator.  Use approved internal type vibrators capable of visibly affecting the concrete for a distance of 12 inches (0.3 m) from the vibrator head.

When using RRCM concrete install maturity sensors to measure the maturity of each day’s placement according to supplement 1098.  If RRCM placement from one location to another is delayed by more than 1 hour treat the delayed placement as a new day’s placement and install additional maturity sensors according to 1098.

Ensure that batch tickets of the delivered RRCM conform to the accepted mix design. Assure the

1.       water/cementitious ratio is not exceeded

2.       Admixtures are the same brand, type and dosage as the approved design.

3.       Aggregates, cementitious materials

4.       Air content

Screed repairs less than 12 feet (3.7 m) in length parallel to the centerline.  Screed repairs 12 feet (3.7 m) in length and longer perpendicular to the centerline.

While the concrete is still in a plastic state, test the surface for trueness and for being flush with the edges of the adjacent slabs using a 10-foot (3 m) straightedge.  Place the straightedge parallel to the pavement centerline with half of the straightedge resting on the existing pavement, and draw the straightedge across the patch to test the patch edges.  Check areas within the patch length in a similar manner.  Where the straightedge does not remain in contact with the existing pavement while drawing it across the patch, correct all high or low areas exceeding 1/8 inch in 10 feet (3 mm in 3 m).  Recheck the concrete surface after making corrections to ensure conformance to the above tolerance.  Make additional checks and corrections until patch is within tolerance.

Texture the new concrete surface similar to that of the surrounding pavement.

Apply the liquid membrane-forming compound conforming to 705.07, Type 2 for curing at a minimum rate of 1 gallon (1 L) of material for each 150 square feet (3.7 m²).

255.07  Wearing Course Replacement. Replace the removed asphalt concrete overlay with Item 301 or 448 Type 2 material as shown on the plans.  Compact these mixtures as approved by the Engineer using any of the roller types specified in 401.13.  Apply Item 407 tack coat to the replacement surfaces.

Trim the limits of the repair to form a vertical face 1.5 inches (38 mm) deep from the surface before placing the final asphalt concrete layer adjacent to the existing pavement.

Before opening the rigid replacement to traffic, restore the shoulders to the original line and grade. Use either aggregate or asphalt concrete as shown on the plans or as the Engineer directs.  Fill the low areas, and compact them flush with the surrounding shoulder.

Seal the perimeter surface of the repaired areas by applying a 2 inch (50 mm) to 4 inch (100 mm) wide strip of approved 705.04 material or 702.01 approved PG binder.

255.08  Opening to Traffic.  Do not open the rigid replacement to traffic until the concrete attains a modulus of rupture of 400 pounds per square inch (2.8 MPa).

For RCCM mixes do not open the rigid replacement to traffic until the RCCM attains a modulus of rupture of 400 pounds per square inch (2.8 MPa) based on maturity testing.

If maintaining traffic in adjacent lanes, schedule work in order to place the concrete in the prepared repair area within 48 hours after removing the existing pavement. In accordance with standard drawing MT-101.90, drums may be used as a separator to the adjacent traveled lane for repairs 60 feet or less in length. If unable to complete placement of the concrete in the exposed repair area by the end of the daily work shift, fill repair areas less than 4 feet from the traveled lane with a temporary patch material suitable to the Engineer or cover unfilled repair areas 10 feet (3 m) or less in length with a steel plate.  Do not leave repair areas unfilled with concrete when work is suspended on weekends or holidays.  If unable to complete placement of the concrete in the exposed repair area before suspending work for a weekend or holiday or within the time specified above, fill the excavation with an asphalt concrete mixture or other suitable temporary patch material with a durable surface as the Engineer directs.  Maintain the temporary patches while they are in service.

255.09  Method of Measurement.  The Department will measure the quantity of Full Depth Pavement Removal and Rigid Replacement by the number of square yards (square meters) repaired in the complete and accepted work.

The Department will measure the quantity of Full Depth Pavement Sawing by the number of feet (meters) of perimeter full depth saw cuts in the complete and accepted work.  The Department will not measure offset saw cuts.  The Department will not measure additional cuts made to facilitate the removal of the pavement.

255.10  Basis of Payment.  Payment is full compensation for furnishing all materials, including paint; developing and testing the concrete mix, removing pavement by any method; removing subbase for undercut replacement; compacting subbase and subgrade; placing rigid pavement, including concrete necessary to replace removed subbase or subgrade; furnishing and placing dowels, tiebars, and mesh; performing maturity testing and acceptance; placing, maintaining, removing, and disposing of temporary patches, and restoring the shoulders.

The Department will not pay for additional concrete sawing and removal depths within 1 inch (25 mm) greater than those shown on the plans.

The Department will not pay for additional work to repair damage caused by pavement sawing or pavement removal.

The Department will include tack coat in the cost of the asphalt concrete.  The Department will pay for asphalt concrete according to Item 301 or Item 448.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

255             Square Yard                    Full Depth Pavement Removal
                       (Square Meter)                and Rigid Replacement, Class ___

255             Foot (Meter)                    Full Depth Pavement Sawing

ITEM 256  Bonded Patching of Portland cement concrete Pavement

256.01  Description

256.02  Materials

256.03  Equipment

256.04  Removal of Unsound Concrete

256.05  Preparation of Patch Area

256.06  Bonding Grout Installation

256.07  Placing Patching Material

256.08  Curing and Loading

256.09  Method of Measurement

256.10  Basis of Payment

256.01  Description.  This work consists of bonded patching of portland cement concrete pavements at spall areas adjacent to cracks or joints or other areas of the pavement as designated by the Engineer.  This work involves removing all loose and unsound concrete and asphalt material patches; removing sound concrete as directed; preparing the surface; applying a bonding grout if required; reconstructing the joint or crack; and mixing, placing, finishing, and curing of the patching material called out in the pay item description.

256.02  Materials.  Furnish materials conforming to:

Portland cement....................................................... 701.05

Fine aggregate.......................................................... 703.02

Coarse aggregate, No. 8 size.................................... 703.02

Curing material........................................................ 705.07

Air-entraining admixture.......................................... 705.10

Quick setting concrete mortar.................................. 705.21

256.03  Equipment.  Use a milling machine, concrete saw, jackhammers, or other approved equipment to remove existing surface material.  Provide oil and moisture free compressed air for cleaning and abrasive blasting the prepared area.  Provide an on-site concrete mixer capable of mixing a minimum of 2-cubic foot (0.06 m³) batches of patching material.  Provide chipping hammers not heavier than the nominal 35-pound (16 kg) class.

256.04  Removal of Unsound Concrete.  The Engineer will locate and mark all areas to be repaired prior to concrete sawing.  Provide the Engineer with aerosol spray paint to outline the areas for repair.  Repair areas will be rectangular or square in shape with dimensions as required to envelope the surface deterioration.

Saw the perimeter of all areas designated for removal to a depth of 1 inch (25 mm) to produce a vertical or slightly undercut face.  Make additional saw cuts as required to facilitate removal.  Remove all unsound concrete, all asphalt material, and all obviously loose and disintegrated concrete within the patch area.  Remove sound concrete where required to achieve the minimum depth within the patch area.  Remove concrete by jack hammering or milling.  The minimum depth of any partial depth repair is 1 1/2 inch (38 mm) except at the perimeter saw cuts.  Operate chipping hammers at an angle of less than 45 degrees measured from the surface of the pavement.  During removal of unsound concrete, remove all pavement reinforcing exposed in the patch areas using a cutting tool or a torch.

256.05  Preparation of Patch Area.  Before applying bonding grout and/or the patching material, abrasive blast the exposed concrete surfaces to which the patching material is to bond until free of loose particles, oil, dust, traces of asphalt concrete and joint sealer, and other contaminates.  Remove all sandblasting residue with compressed air just prior to placing the concrete bonding grout or the patching material.  Do not begin abrasive blasting operations until implementing reasonably available engineering controls to limit fugitive dust that are acceptable to the Engineer.  Conform to State, regional, and local government agency requirements regarding control of dust generated by the blasting operation.  For Types B and C patching materials that do not use water as the activator, perform additional surface preparation according to the patching material manufacturer’s recommendations.

Recreate joints in or along the patch using a joint board that extends below the prepared surface and has a width equal to the existing joint.  One hour after placing the patching material, remove the joint board in a manner that does not damage the patch.

256.06  Bonding Grout Installation.  For bonding Type A patches, use grout that consists of equal parts, by volume, of portland cement and sand, mixed with sufficient water to form a stiff slurry.  Using a stiff brush or broom, apply a thin, uniform coating of grout to the prepared surface.  Scrub the grout onto the dry surfaces of the prepared area to be patched immediately before placing the patching material.  Do not allow excess grout to collect in low spots.  Do not allow the grout to dry before placing the new concrete.  Paint grout over all sawed joints between the new and existing concrete immediately after completing the finishing.

For bonding Types B and C patches, conform to the patching material manufacturer’s recommendations.

256.07  Placement of Patch Material.  Use Type A, B, or C patch material as follows:

A.      Type A.  Provide patch material consisting of one part high early strength portland cement, one and a half parts fine aggregate, and one and a half parts No. 8 coarse aggregate by volume.  Add sufficient air-entraining admixture to maintain an air content of 8 ±2 percent.  Add enough water to obtain the minimum slump practical for placing, and do not allow slump to exceed 4 inches (100 mm).  Mix the materials on site.  Do not use ready-mixed concrete.  Place the concrete mixture in the patch area while the bonding grout is still wet.  Slightly overfill, vibrate, and strike off the concrete.

B.      Type B.  Provide patch material consisting of quick setting concrete mortar 705.21, Type 1 or 2.  Mix and place the mortar according to the manufacturer’s recommendations.  Add coarse aggregate, as needed, according to the manufacturer’s instructions.  Place the concrete mixture in the patch area.  If the manufacturer’s requirements specify using bonding grout, place the concrete mixture while the bonding grout is still wet.  Slightly overfill, vibrate, and strike off the concrete.

C.      Type C.  Provide patch material consisting of a blend of quick setting concrete mortar 705.21, Type 2 and selected aggregates with an activator.  Mix and place these materials according to the manufacturer’s recommendations.  Add coarse aggregate, as needed, according to the manufacturer’s instructions.  Place the concrete mixture in the patch area.  If the manufacturer’s requirements specify using bonding grout, place the concrete mixture while the bonding grout is still wet.  Slightly overfill, vibrate, and strike off the concrete.

Screed patches 12 feet (3.7 m) and less in length parallel to the centerline.  Screed patches over 12 feet (3.7 m) in length perpendicular to the centerline.

While the concrete is still in a plastic state, test the surface for trueness and for being flush with the edges of the adjacent slabs using a 10-foot (3 m) straightedge.  Place the straightedge parallel to the pavement centerline with the ends resting on the existing pavement and draw the straightedge across the patch.  Where the straightedge does not remain in contact with the existing pavement while drawing it across the patch, correct all high or low areas exceeding 1/8 inch in 10 feet (3 mm in 3 m).  Recheck the concrete surface after making corrections to assure that the patch area meets the surface tolerance before the patching material hardens.

Texture the new concrete surface similar to that of the surrounding pavement.

256.08  Curing and Opening to Traffic.  Cure Type A patches according to 451.10, except allow the patch to attain a modulus of rupture of 400 pounds per square inch (2.8 MPa) before opening to traffic.  Cure Types B and C patches according to the manufacturer’s recommendations.

256.09  Method of Measurement.  The Department will measure the quantity of Bonded Patching of Portland Cement Concrete Pavement, Type ___ by the number of square feet (square meters) of the exposed surface of all patches, irrespective of the depth of the patch, repaired in the complete and accepted work.  If the actual measured area of a patch is less than 2 square feet (0.2 m²), the Engineer will increase each such measurement to 2 square feet (0.2 m²).

256.10  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

256             Square Feet                     Bonded Patching of Portland
                       (Square Meter)                Cement Concrete Pavement, Type __

Item 257  Diamond Grinding Portland Cement Concrete Pavement

257.01  Description

257.02  Equipment

257.03  Construction

257.04  Final Surface Finish

257.05  Method of Measurement

257.06  Basis of Payment

257.01  Description. This work consists of diamond grinding and texturing Portland cement concrete pavement longitudinally to substantially eliminate joint and crack faulting and to restore proper riding characteristics to the pavement surface.

257.02  Equipment. Provide grinding equipment that is a power driven, self-propelled machine that is specifically designed to smooth and texture Portland cement concrete pavement with diamond blades or diamond impregnated cylinder rings.  Mount the blades or cylinder rings on an arbor head.  Provide a grinding head at least 3 feet (0.9 m) wide.  Ensure the equipment is capable of grinding the surface in the longitudinal direction without causing spalls or other damage at cracks, joints and other locations.  Ensure the equipment is capable of correcting the pavement profile and providing proper cross slope on the concrete pavement.

Provide equipment with an effective wheelbase of at least 12.0 feet (3.6 m); a set of pivoting tandem bogey wheels at the front of the machine and rear wheels that travel and track in the fresh cut pavement.  Ensure the center of the grinding head is no further than 3.0 feet (0.9 m) forward from the center of the back wheels. Ensure it is also of a shape and dimension that does not encroach on traffic movement outside of the work area.

Furnish and maintain a profiler conforming to Supplement 1058 for daily use during the grinding operations.  Provide all necessary supplies to fully operate and graph the results of testing the ground pavement for smoothness.  The Engineer will verify the profiler according to Supplement 1058.

257.03  Construction. The plans will designate the areas of pavement surfaces to be ground.  Grinding of bridge decks and roadway shoulders will not be required unless indicated on the plans or required to provide drainage.  Perform grinding in a manner that eliminates crack or joint faults while providing positive lateral drainage by maintaining a constant cross-slope between grinding extremities in each lane.  Transition auxiliary or ramp lane grinding as required from the mainline edge to provide positive drainage and an acceptable riding surface.

Ensure the operation results in pavement that conforms to the typical cross-section and the requirements specified for the final surface finish, however, it is the intention of this specification that the faulting at joints and cracks be eliminated and the overall riding characteristics be restored within the limits specified.  To accomplish the smoothness required, grinding may not be required on 100 percent of the pavement surface.

During initial grinding operations, use the profiler to test the pavement surface as soon as the concrete has been ground full lane width.  This initial testing is to aid the Contractor in evaluating the grinding methods and equipment being used.  Subsequent to the initial testing, run daily profiles of each day's grinding the next working day.

Remove all grinding residue.  Remove solid residue before it is blown by traffic action or wind.  Do not allow residue to flow across lanes used by the traveling public or into gutters or drainage facilities.

257.04  Final Surface Finish. Produce a pavement surface that is true to grade with the ground area consisting of a longitudinal corduroy-type texture.  Ensure the peaks of the ridges are approximately 1/16 inch (1.5 mm) higher than the grooves with 53 to 57 evenly spaced grooves per foot (174 to 187 per meter).

Measure the finished pavement surface for riding quality.

Produce a mainline riding surface which does not exceed an IRI of 95 inches per mile (1.50 m/km), nor any localized surface deviations in excess of 0.4 inches in 25 feet (10 mm in 7.6 m), as measured with the approved profiler.  Use equipment conforming to Supplement 1058 and obtain a profile and smoothness measurements using ProVAL and Supplement 1110.  The Engineer will witness the testing of the pavement surface’s wheel paths.  The wheel paths are located parallel to the centerline of the pavement and approximately 3 feet (0.9 m) measured transversely, inside all lane edges.  Maintain the alignment of the profiler with reference to the pavement edge at all times.  Re-grind any 0.10 mile (0.16 km) sections with an IRI greater than 95 inches per mile (1.5 m/km) until the measured IRI is less than 95 inches per mile (1.5 m/km).

Provide the necessary traffic control and survey stationing for initial measurements or any subsequent measurements.  Measure the entire length of pavement, starting and stopping the measuring equipment when any wheel is within 1.0 foot (0.3 m) of any existing pavement, pressure relief joint or approach slab.

Ensure transverse joints and cracks are flush with adjacent surfaces.  The Engineer will visually inspect transverse joints and cracks to ensure that adjacent surfaces are in the same plane.  Adjacent sides of joints or cracks within of 1/16 inch (1.5 mm) of each other will be considered flush.  Ensure the transverse slope of the pavement is uniform to a degree that no depressions or misalignments of slope greater 1/4 inch in 12 feet (6 mm in 3.6 m) are present.  Use a straightedge placed perpendicular to the centerline to measure depressions and misalignments.  Straightedge requirements do not apply outside of area ground.

257.05  Method of Measurement. The Department will measure diamond grinding by the number of square yards (square meters) of pavement ground and accepted.  The quantity of diamond grinding will be determined by multiplying the width specified on the plan by the total length of the finished pavement surface, excluding bridge decks, approach slabs or the 1.0 foot (0.3 m) adjacent to the existing pavement, pressure relief joints, approach slabs and other areas designated by the Engineer.

257.06  Basis of Payment.  Payment is full compensation for furnishing all labor, materials, tools, equipment and incidentals and for doing all work involved in grinding the existing surface, removing residue, cleaning the pavement, and testing with a profiler.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

257             Square Yard                    Diamond Grinding Portland Cement
                       (Square Meter)                Concrete Pavement 

ITEM 258  DOWEL BAR RETROFIT

258.01  Description

258.02  Materials

258.03  Equipment

258.04  Construction

258.05  Method of Measurement

258.06  Basis of Payment

258.01  Description. This work consists of sawing slots across transverse cracks, cleaning the slot, injecting caulking filler, placing a dowel in the slot, and filling the slot with a patching material.

258.02  Materials.  Furnish a one part silicone sealant which does not require a primer for bond to concrete and conforms to the following Table:

Properties

Requirements

Flow, ASTM D5893

0.3 inches(7.6 mm) maximum

Extrusion Rate, C1183 method A

75 to 350 grams/minute

Tack free time @ 77 °F ±3 °F (25 °C ±2 °C) –ASTM C679

20 to 90 minutes

Specific Gravity - ASTM D 792, Method A

1.010 to 1.515

Durometer Hardness - Shore A, cured 7 days @ 77 °F ±3 °F (25 °C ±2 °C) and 45 to 55% R.H.; ASTM D 2240

10 to 25 at 0 °F (-18 °C)

Tensile Stress -@ 150% elongation, 7 day cure @ 77 °F ±3 °F (25 °C ±2 °C) and 45 to 55% R.H.; ASTM D 412, Die C

45 psi (310 kPa) maximum

Elongation - 7 day cure @ 77 °F ±3 °F (25 °C ±2 °C) and 45 to 55% R.H.; ASTM D 412, Die C.

800% minimum

Bond to Concrete Mortar Briquettes - Air cured 12 days @ 77 °F ±3 °F (25 °C ±2°C);[1]

50 psi (345 kPa) minimum

Movement Capability and Adhesion [2]

Extend 100% and compress 50%; No adhesive or cohesive failure after 10 cycles at 0 °F (-18 °C)

Shelf Life

9 months from date of shipment from manufacturer

[1]  Bond to Concrete Mortar Briquettes molded in accordance with AASHTO T 132 sawed in half and bonded with a thin section of sealant and tested in accordance with AASHTO T 132. Briquettes will be dried to constant weight in oven at 212 °F ±9 °F (100 °C ±5 °C).

[2]  Movement Capability and Adhesion: Prepare 1-inch × 2-inch × 3-inch (25 mm × 50 mm × 75 mm ) concrete blocks in accordance with ASTM C 719. A sawed face will be used for bond surface. Seal 2 inches (50 mm) of block leaving 1/2 inch (13 mm) on each end of specimen unsealed. The depth of sealant will be 3/8 inch (10 mm) and the width 1/2 inch (13 mm). Subject sealant to movement in accordance with ASTM C 719. The magnitude of the movement will be as specified, and the rate of extension or compression will be 1/8 inch (3.2 mm) per hour.

Furnish materials conforming to:

Aggregate......................................................... 703.02.A.3

Curing material........................................... 705.07, Type 2

Dowel bars.............................................. 709.13 or 705.01

Dowel bar chairs................ 709.14 or non-metallic material

Preformed filler........................................................ 705.03

Patching material.  Must meet the performance requirements of ASTM C928, Table 1, R3 concrete material with the following exceptions and additions:

.... Final Set Time (ASTM C403)...... 25 minutes minimum

.... Length Change (ASTM C157)

.... @ 4 days........................................... ±0.13% maximum

.... Freeze Thaw Durability Factor (ASTM C666) Procedure A @ 300 cycles or Procedure B @ 350 cycles,

.... Durability Factor:.................................... 90% minimum

Furnish patching material according to the Departments Qualified Products List (QPL)

Mix prepackaged materials that contain all aggregates needed to produce the desired concrete as specified by the manufacturer.  For bagged cementitious materials that need additional aggregates, grade the aggregate according to the patching material manufacturer’s recommendation except ensure that 100% passes the 1/2-inch (12.5 mm) sieve and a minimum of 85 percent, by weight, passes the 3/8-inch (9.5 mm) sieve.

258.03  Equipment. Furnish equipment to create slots that has a power driven gang type assembly, consisting of diamond blade saws, capable of sawing a minimum of three slots at one time to the required dimensions, without damage to the surrounding pavement.

Furnish jack hammers weighing less than 30 pounds (13.6 kg).

Furnish abrasive blast equipment capable of removing the saw slurry or other foreign material from the exposed surfaces leaving a clean, newly exposed concrete surface free of spalls, laitance, and all contaminants detrimental to achieving an adequate bond.  Ensure water blasting pressure with abrasives in the water is 10,000 psi (690 bar) or less.

258.04  Construction. The Engineer will locate and mark cracks to be retrofitted.  Provide the Engineer with aerosol spray paint to mark the cracks to be retrofit.

Cut 2 1/2-inch (65 mm) wide slots into the pavement to a depth which places the center of the dowel at mid-depth in the concrete slab.  Make the slots parallel to the centerline of the pavement.  Make multiple saw cuts parallel to the centerline if necessary to properly remove material from the slot and to provide a level surface for the feet of the dowel bar chairs.  Cut three slots, on one foot (0.3 m) centers, in each wheel path, as shown in the standard drawings.

Do not allow traffic across the crack once the concrete has been removed from the slots until all six retrofit dowel bars are in place, cured and completed.  Do not allow the tires of construction vehicles to travel on slots where concrete has been removed.

Clean the edge of the slots by approved blast methods to produce a rough surface.  Insure any blasting operation does not damage the surrounding pavement.  Do not begin abrasive blasting operations until implementing reasonably available engineering controls to limit fugitive dust that are acceptable to the Engineer.  Conform to state, regional, and local government agency requirements regarding control of dust generated by the blasting operation.

Caulk cracks at the bottom and sides of the slot with an approved silicone sealant in order to prevent any grout from entering the crack.  Apply the sealant with a pressure applicator that forces it into the crack.

Place a 1/2 inch (13 mm) thick preformed filler board to maintain the crack, as shown in the plan details.  Ensure the filler board fits tight around the dowel and to the bottom and edges of the slot.  Maintain the filler board in a vertical position and tight to all edges during placement of the patching material.  Ensure the filler board extends from the bottom of the slot to the surface of the pavement.  If for any reason the filler board shifts during placement of the patching material, redo the dowel bar retrofit at no expense to the Department.

Ensure the dowel bar chair firmly holds the bar centered in the slot.  Obtain the Engineer’s approval before using any dowel bar chairs.  The Engineer will reject any chair design that may allow movement of the bar during the placement of grout.

Use dowel bars 1 1/2 inches (38 mm) in diameter and 18 inches (460 mm) long.  Center the filler board on the dowel.  Coat the dowel bars with a thin uniform coat of new light form oil as a bond-breaking material just prior to installation in the slot.  Place an expansion cap on each end of the dowels prior to installation.  Ensure the expansion caps are tight fitting and made of non-metallic material which will allow 1/4 inch (6 mm) movement at each end of the dowel.

Use two chairs to firmly hold the dowel bar in the slot during placement of the patching material.  Furnish chairs that are a nominal 2 1/2 inches (65 mm) wide and center the dowel bar across the crack.  Ensure the bar varies no more than 1/4 inch (6 mm) from parallel to the pavement surface and the centerline of the pavement.  Just prior to placement of the patching material, make one or more passes of an air blast to provide a dust-free, clean slot to insure an adequate bond of the patching material.

Mix, place, and cure the patching material in accordance with the manufacturer’s recommendations.  Consolidate the patching material using a vibrator approved by the Engineer.  Place the patching material in the slot and finish to produce a smooth, even surface.

Repair any damage to the pavement due to the Contractor’s operation at no expense to the Department.

Cure the patching material for a minimum of four hours before placing any vehicle loads on the repair, or as directed by the Engineer.

258.05  Method of Measurement. The Department will measure the quantity of Retrofit Dowel Bars by the actual number in the complete and accepted work.

258.06  Basis of Payment. Payment is full compensation for furnishing all materials including paint; sawing and cleaning the slots; installing dowel chairs, dowels, bond breaker material, dowel bar end caps, sealant/caulking material, filler material, and patching material.

The Department will not pay for additional work or materials required due to shifting of the filler board.

The Department will not pay for any additional work to repair damage to the pavement caused by the Contractor.

The Department will pay for accepted quantities at the contract unit price as follows:

Item           Unit                                Description

258             Each                                Retrofit Dowel Bar

300 bases

ITEM 301  ASPHALT CONCRETE BASE

301.01  Description

301.02  Composition

301.03  Mixing

301.04  Spreading and Finishing

301.05  Spreading and Surface Tolerances

301.06  Basis of Payment

301.01  Description.  This work consists of constructing a base course of aggregate and asphalt binder, mixed in a central plant and spread and compacted on a prepared surface.

The requirements of Item 401 apply, except as modified by this specification.

301.02  Composition.  Furnish aggregate for the mix that conforms to the following gradation:

Sieve Size

Total Percent Passing

2 inch

(50 mm)

100

1 inch

(25.0 mm)

75 to 100

1/2 inch

(12.5 mm)

50 to 85

No. 4

(4.75 mm)

25 to 60

No. 8

(2.36 mm)

15 to 45

No. 16

(1.18 mm)

10 to 35

No. 50

(300 µm)

3 to 18

No. 200

(75 µm)

1 to 7

Submit for the Laboratory’s approval the desired percentage of the aggregate passing the No. 4 (4.75 mm) sieve and blend of individual components. The Contractor may use reclaimed asphalt concrete pavement according to 401.04.  The Laboratory will establish the required binder content within a range of 4 to 8 percent.  Do not make changes in these JMF values due to unsatisfactory results or other conditions except as authorized by the Laboratory. Obtain a new JMF approval for any desired change to an existing JMF.

301.03  Mixing.  If using a batch plant, use screens with openings of sizes that result in a reasonably balanced separation of the dried and heated aggregate into a minimum of two bins.

301.04  Spreading and Finishing.  Ensure that the maximum compacted depth of any one layer is 6 inches (150 mm).  Ensure that the temperature of the mixture when delivered to the paver is a minimum of 250 °F (120 °C) if a hot mix asphalt and 230 °F (110 °C) if a warm mix asphalt according to 402.04.  Ensure the temperature of the mixture is sufficient for the roller coverage to be effective in compacting the mixture.

301.05  Spreading and Surface Tolerances.  Do not exceed 3/8 inch (10 mm) in surface variation from the testing edge of a 10-foot (3 m) straightedge.  If using Item 301 Asphalt Concrete Base as a subbase for a rigid pavement or base, do not exceed a variation of 1/4 inch (6 mm).

Correct variations in excess of slope or surface tolerances by adding or removing material in a manner satisfactory to the Engineer.  The Contractor may use asphalt concrete approved by the Engineer.

301.06  Basis of Payment.  The Department will pay for accepted quantities, complete in place, at the contract price as follows:

Item           Unit                                Description

301             Cubic Yard                      Asphalt Concrete Base
                       (Cubic Meter)

ITEM 302  ASPHALT CONCRETE BASE

302.01  Description

302.02  Composition

302.03  Mixing

302.04  Spreading and Finishing

302.05  Spreading and Surface Tolerances

302.06  Basis of Payment

302.01  Description.  This work consists of constructing a base course of aggregate and asphalt binder, mixed in a central plant and spread and compacted on a prepared surface.

The requirements of Item 401 apply, except as modified by this specification.

302.02  Composition

A.      General.  Furnish a mixture that conforms to the following gradation:

Sieve Size

Total Percent Passing

2 inch

(50 mm)

100

1 1/2 inch

(37.5 mm)

85 to 100

1 inch

(25.0 mm) [1]

68 to 88

3/4 inch

(19.0 mm) [1]

56 to 80

1/2 inch

(12.5 mm) [1]

44 to 68

3/8 inch

(9.5 mm) [1]

37 to 60

No. 4

(4.75 mm)

22 to 45

No. 8

(2.36 mm)

14 to 35

No. 16

(1.18 mm)

8 to 25

No. 30

(600 µm)

6 to 18

No. 50

(300 µm)

4 to 13

No. 200

(75 µm)

2 to 6

[1]  Provide aggregate to retain a minimum of 7 percent of the material on each of these sieves.  This requirement applies to the gradation of the JMF and the mix production according to Item 403.

In the design of the asphalt concrete base, the requirements of Item 441 apply, except as follows:

The Contractor may use reclaimed asphalt concrete pavement according to 401.04.  Should problems with proper coating or other material issues related to the use of reclaimed asphalt concrete pavement be evident, the Laboratory may limit reclaimed asphalt concrete pavement to 30 percent.  In this case virgin binder content will be adjusted by the Laboratory.

Add hydrated lime in the dry form at a rate of 0.75 percent by the dry weight of aggregate for asphalt concrete base, if antistrip additive is required and hydrated lime is used.

Design the asphalt concrete base to yield 4.0 percent air voids and the following properties:

Property

Acceptable Range of Values

Minimum

Maximum

Binder Content, % of total mix

2.0 [Virgin]

6.0[Total]

Stability, lb (N), 70 blow

3000  (13,345)

--

Flow, 0.25 mm, 70 blow

--

28

Voids in Mineral Aggregate %

12.0

--

Use equipment that meets the requirements of a Level 3 Laboratory as specified in Supplement 1041.  Ensure that the following equipment is designed and manufactured to prepare and test a Marshall specimen with a 6.0-inch (152.4 mm) diameter and a 3.75 ±0.05 inch (95 ±1.3 mm) height:

1.      Specimen mold assembly

2.      Specimen extractor

3.      22.5-pound (10 kg) compaction hammer.

4.      Compaction pedestal specimen mold holder.

5.      Marshall test apparatus.

Produce batches of asphalt concrete base in the amount that will result in a compacted specimen 3.75 ±0.05 inch (95 ±1.3 mm) in height.  This amount is about 4050 grams.

B.      Compaction of Specimens.  Fill the mold with asphalt concrete base by placing approximately one-half of the batch in the mold and spading it vigorously with a heated spatula or trowel 15 times around the perimeter and ten times over the interior.  Place the second half of the batch in the mold and spade the mixture in the same manner.

Compact the specimen on both sides with 70 blows.

C.      Stability Correlation Ratios.  Convert measured stability values for specimens that depart from the standard 3.75-inch (95 mm) thickness to an equivalent 3.75-inch (95 mm) value by multiplying the stability value by the appropriate correlation ratio as follows:

Approximate Thickness of

Specimen, inches (mm)

Correlation

Ratio

3 1/2

(89)

1.12

3 9/16

(90)

1.09

3 5/8

(92)

1.06

3 11/16

(94)

1.03

3 3/4

(95)

1.00

3 13/16

(97)

0.97

3 7/8

(98)

0.95

3 15/16

(100)

0.92

4

(102)

0.90

302.03  Mixing.  Conform to the requirements of 301.03.

302.04  Spreading and Finishing.  Ensure that the compacted depth of any one layer is a minimum of 4 inches (100 mm) and a maximum of 7.75 inches (190 mm).  Ensure that the temperature of the mixture when delivered to the paver is a minimum of 250 °F (120 °C) if a hot mix asphalt and 230 °F (110 °C) if a warm mix asphalt according to 402.04.  Ensure the temperature of the mixture is sufficient for the roller coverage to be effective in compacting the mixture

302.05  Spreading and Surface Tolerances. Conform to the requirements of 301.05.

302.06  Basis of Payment.  The Department will pay for accepted quantities, complete in place, at the contract price as follows:

Item           Unit                                Description

302             Cubic Yard                      Asphalt Concrete Base
                       (Cubic Meter)

ITEM 304  AGGREGATE BASE

304.01  Description

304.02  Materials

304.03  Before Spreading

304.04  Spreading

304.05  Compaction

304.06  Finished Surface

304.07  Method of Measurement

304.08  Basis of Payment

304.01  Description.  This work consists of furnishing, placing, and compacting one or more courses of aggregate on a prepared surface, including furnishing and incorporating all water required for compaction.

304.02  Materials.  Furnish materials conforming to 703.17.

304.03  Before Spreading.  The Engineer will sample the Contractor’s stockpile to determine the initial moisture content to be used for compaction.  The Engineer will develop a moisture-density curve to determine the optimum moisture content.

Use material that has reasonably uniform moisture content.  Ensure the moisture content is not less than 2 percent below the optimum moisture content before spreading.  Add water to the stockpile if necessary to meet this moisture requirement.

Handle the material in a manner to minimize segregation.  If segregation occurs, thoroughly mix or regrade the stockpile.

304.04  Spreading.  Spread the material on the prepared surface.  Do not use frozen material and do not spread on frozen surfaces.

Do not exceed a compacted lift thickness of 8 inches (200 mm) when using vibratory rollers with effective weights greater than 12 tons (11 metric tons).  Do not exceed a compacted lift thickness of 6 inches (150 mm) when using vibratory rollers with effective weights from 10 to 12 tons (9 to 11 metric tons).  Do not exceed a maximum compacted lift thickness of 4 inches (100 mm) when these vibratory rollers are not used.  The effective weight of a vibratory roller is the weight plus the centrifugal force from vibration.  Submit documentation from the manufacturer that shows the vibratory roller meets the minimum effective weight requirements.

Place the material in two or more approximately equal lifts when the specified compacted thickness exceeds the maximum allowed.

Place the material with self-propelled spreading machines capable of placing the material true to line and grade.  Spreading machines such as spreader boxes or pavers are allowed.  Do not use graders or dozers without spreader boxes to spread the material except for areas described in the next paragraph.  Spread the material such that it minimizes segregation and requires minimal blading or manipulation.  The Department may perform in-place gradation testing in areas that are visually segregated according to Supplement 1090.

The Contractor may use hand-placing methods, dozers or graders when the total area of the material is 2000 square yards (1700 m²) or less or in small areas where self-propelled spreading machines are impractical.  Small areas include lane widths less than 12 feet (3.7 m) or lengths less than 1000 feet (305 m).  The Department will not take in-place gradation tests in these small areas.

The Department may test for in-place gradation after spreading but before compaction testing according to Supplement 1090.

304.05  Compaction.  Add water or dry the material to bring it to within 2 percent of the optimum moisture content before compacting.  Maintain the moisture content within this range during all compaction operations.  The Engineer will determine the percentage of moisture to apply or to be dried from the material.  Uniformly apply the water or dry the material throughout the lift and in a manner that does not soften or disturb the lower courses.  Reduce the moisture content if the material becomes unstable during the compaction operation.

Compact each lift of material immediately after spreading.  Use rollers that correspond with the lift thickness as described in 304.04.  The Contractor may use lighter rollers or vibratory equipment in small areas as specified in 304.04 or when heavier rollers are not practical.  Approved compaction equipment may consist of vibratory rollers, static rollers, or vibratory equipment.

At the beginning of the compaction operation, construct a test section according to Supplement 1015.  Use a minimum compactive effort of eight passes to construct the test section.  Use and adjust the vibration on the vibratory rollers to maximize the density and stability.  Construct a new test section when the material changes or when the supporting materials change appreciably.

The Engineer will use 98 percent of the test section maximum dry density for acceptance of the production material.  Use at least the same number of passes and compactive effort used to obtain the test section maximum dry density for the production material.  At a minimum, use eight passes in the production area.  The Engineer may reduce the minimum passes if the passes are detrimental to compaction

The Engineer may check the production material density before or after the finishing operations.

Maintain the surface of each lift during the compaction operations in such a manner that the surface texture is reasonably uniform and the material is firmly keyed.

Cover the aggregate base with the next layer of pavement before the end of the construction season.  If the aggregate base is not covered up, then assume all liability for contamination of, damage to and instability of the base, subgrade and underdrains.

Provide drainage and maintain the material according to 203.04.A.

304.06  Finished Surface.  Ensure that the finished surface does not vary more than 3/8 inch (10 mm) from a 10-foot (3 m) straightedge parallel to the centerline or more than 1/2 inch (13 mm) from a template conforming to the required cross-section.  Furnish straightedges, templates, or other devices satisfactory to the Engineer, and check the surface for conformance with these requirements.

Do not construct the aggregate base at a consistent depth below the required minimum compacted depth thickness.  When the depth is found to be less than the required depth, provide the Engineer with a written corrective action plan for approval.

304.07  Method of Measurement.  The Department will measure Aggregate Base by the number of cubic yards (cubic meters) computed from the profile grade and typical sections, compacted in place.

Where variable depth is specified, the Department will measure the number of cubic yards (cubic meters) of aggregate base by converting from weight using the following conversion factors:

Table 304.07-1

Material

Conversion Factor

Crushed stone

4000 lb/yd³

2375 kg/m³

Crushed gravel

4000 lb/yd³

2375 kg/m³

Crushed slag [1]

   less than 90 lb/ft³ (1450 kg/m³)

3600 lb/yd³

2140 kg/m³

   90 to 100 lb/ft³ (1450 to 1600 kg/m³)

4000 lb/yd³

2375 kg/m³

   more than 100 lb/ft³ (1600 kg/m³)

4500 lb/yd³

2670 kg/m³

Granulated slag

2800 lb/yd³

1660 kg/m³

[1]  Based on average dry rodded weight of standard size of slag aggregates on record at the Laboratory.  The conversion factors listed are the long gradation weights.  These numbers are based on the dry rodded weights of No. 67, 57, or 8 gradation.  The Department will determine slag weights based on weights obtained from the original source.

The Department will verify that the moisture content of the delivered material is less than 2 percent above saturated surface dry (SSD).  If the moisture content is greater than 2 percent above SSD, then the Department will calculate the number of cubic yards (cubic meters) based on the dry density and dry weight.

The Department will determine the pounds per cubic yard (kilograms per cubic meter) for aggregate mixtures by using 100 percent of the test section maximum dry density obtained in 304.05.

304.08  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

304             Cubic Yard                      Aggregate Base
                       (Cubic Meter)

ITEM 305  PORTLAND CEMENT CONCRETE BASE

305.01  Description

305.02  Construction

305.03  Method of Measurement

305.04  Basis of Payment

305.01  Description.  This work consists of constructing a portland cement concrete base on a prepared surface.

305.02  Construction.  The requirements of Item 451 apply, except as follows.

Do not comply with the requirements of 451.08.

Provide dowels at transverse contraction joints in mainline pavement, ramps, acceleration/deceleration lanes, or collector/distributor lanes.  Dowels for contraction joints in concrete shoulders on mainline pavement, ramps, acceleration/deceleration lanes, or collector/distributor lanes are not required unless the contraction joint is located within 500 feet (150 m) of a pressure relief joint.

Do not place construction joints within 6 feet (1.8 m) of another parallel joint.

Modify the curing membrane application rate specified in 451.11 to 200 square feet per gallon (5 m²/L) of treated pavement surface.

Produce a final surface with a uniform, gritty, longitudinal, or transverse texture using a broom drag in either direction.

Ensure that pavement surface variations do not exceed 1/4 inch in 10 feet (6 mm in 3 m).

Impressing station numbers into the plastic concrete as specified in 451.10 is not required.

305.03  Method of Measurement.  The Department will measure Concrete Base by the number of square yards (square meters) completed and accepted in place.  The width equals the base width shown on the typical cross-section of the plans plus additional widening as the Engineer directs in writing.  The Department will field measure the length along the centerline of each roadway or ramp.

305.04  Basis of Payment.  For base found deficient in thickness, the Department will pay a reduced price according to 451.18.A.

The Department will not make additional payment over the Contract unit price for any base with an average thickness in excess of that shown on the plans.

For base found deficient in strength, the Department will pay a reduced price according to 451.18.B and table 451.19-2.  Use the determination and pay procedures for non QC/QA items. 

The Department will pay for accepted quantities at the contract price as follows.

Item           Unit                                Description

305             Square Yard                    Concrete Base
                       (Square Meter)

item 320  RUBBLIZE AND ROLL

320.01  Description

320.02  Materials

320.03  Equipment

320.04  Construction Details

320.05  Method of Measurement

320.06  Basis of Payment

320.01  Description.  This work consists of rubblizing and rolling existing reinforced concrete pavement before placing an asphalt concrete pavement.

320.02  Materials.  Furnish filler aggregate conforming to Item 304.

320.03  Equipment.  Use a self-contained and self-propelled unit of either the resonant frequency type or the multiple head breaker type for rubblizing the concrete pavement.

If using a resonant frequency unit, ensure that it is capable of producing low amplitude, 2000-pound-force (8900 N) blows at a rate of not less than 44 blows per second.

If using a multiple head breaker unit, ensure that it has the capability of rubblizing the full 12-foot (3.6 m) lane width in a single pass.  Ensure the breaking head consists of 12 to 16 hammers, each weighing 1000 to 1500 pounds (450 to 680 kg).  Attach each hammer to a hydraulic lift cylinder that operates as an independent unit, develops 2000 to 12,000 foot-pounds (2700 to 16,000 J) of energy depending on lift height selected, cycles at a rate of 30 to 35 impacts per minute, and has a maximum lift height of 60 inches (1.5 m).

Use a vibratory steel wheel roller having a total weight of not less than 10 tons (9 metric tons).

320.04  Construction Details.  Make a full depth saw cut or cut load transfer devices at existing joints on ramps or mainline where the rubblizing abuts concrete pavement or approach slabs that are to remain in place permanently or temporarily for maintenance of traffic.

Before the rubblizing operations begin, the Engineer will designate a test section.  Rubblize the test section according to this specification.  After rubblizing, excavate a test pit, where the Engineer designates, to check for proper particle size throughout the thickness of the concrete.  Fill in the test pit using the excavated material and additional filler aggregate as necessary.  Compact the test pit as part of the rolling operation.  Excavate at least one test pit, at the location designated by the Engineer, for each production day or every 7040 square yards (5886 m²), whichever is greater.

Adjust the rubblizing procedure to maintain the proper particle sizes.  Control the operating speed of the rubblizing equipment such that: 75% of the rubblized particles above the reinforcing steel are reduced to 3 inches (75 mm) in their largest dimension, 90% of the rubblized particles below the reinforcing steel do not exceed 9 inches (230 mm) in their largest dimension, and no particles exceed 12 inches (300 mm) in their largest dimension.

Before placing the initial asphalt concrete course, compact the rubblized pavement with two passes of the vibratory roller.  Operate the roller in the vibratory mode and at a speed not to exceed 6 feet (1.8 m) per second.

Leave steel reinforcement in place in the rubblized pavement.  However, cut off any exposed steel reinforcement below the surface and remove it from the site.

Fill depressions 1 inch (25 mm) or greater in depth compared to the immediate surrounding area resulting from the rubblizing, the compactive effort, or the steel reinforcement removal, with the filler aggregate.  Strike off excess aggregate level with the surrounding area.  Compact filled depressions with the same roller and compactive effort previously described.

Do not allow traffic on the rubblized pavement before the initial asphalt concrete base and intermediate courses are in place.

Do not allow more than 48 hours to elapse between rubblizing the pavement and placing the initial asphalt concrete course.  However, in the event of rain, the Engineer may waive this time limitation to allow sufficient time for the rubblized pavement to dry to the Engineer’s satisfaction.  If the Engineer waives the time limitation, cease rubblizing the pavement until the Engineer allows paving to resume.

320.05  Method of Measurement.  The Department will measure Rubblize and Roll by the number of square yards (square meters).  The Engineer will use the actual width of the existing concrete pavement and will measure the length along the centerline of each roadway or ramp.

The Department will measure the Filler Aggregate by the number of cubic yards (cubic meters) furnished, placed, and compacted.

320.06  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

320             Square Yard                    Rubblize and Roll
                     (Square Meter)

320             Cubic Yard                      Filler Aggregate
                     (Cubic Meter)

item 321  CRACKING AND SEATING EXISTING Non-
reinforced CONCRETE PAVEMENT

321.01  Description

321.02  Equipment

321.03  Construction Details

321.04  Method of Measurement

321.05  Basis of Payment

321.01  Description.  This work consists of cracking and seating existing non-reinforced concrete pavement or concrete base before placing an asphalt concrete pavement.

321.02  Equipment.  Use devices for cracking the concrete capable of producing the desired crack pattern without extensive spalling or excessive shattering.  Extensive spalling is spalling over 1 1/4 inches (30 mm) in depth.  Do not use whiphammers.

Use watering equipment capable of wetting the cracked surface uniformly to reveal the crack pattern.

Use a 50-ton (45 metric tons) pneumatic tire roller conforming to the requirements of Item 204 for seating the cracked concrete slabs.  Use pneumatic tire towing equipment capable of moving the roller forward and backward along predetermined lines.

321.03  Construction Details.  Demonstrate, to the Engineer’s satisfaction, the ability of the selected equipment and procedures to produce cracking of acceptable quality by cracking at least three, but no more than five, existing concrete slabs.  When cracking the test sections, furnish and apply water to dampen the cracked concrete to enhance visual determination of the cracking pattern.  In addition to 107.07, provide positive provision to contain any flying debris during cracking operations.

Crack existing concrete into nominal 4 ´ 4-foot (1.2 ´ 1.2 m) segments.  In the event existing panels are already cracked into segments, crack these segments further into nominally equal-sized square or rectangular pieces having longitudinal and transverse dimensions not more than 5 feet (1.5 m) and not less than 3 feet (0.9 m), wherever feasible.  Do not allow the cracking equipment to impact the slabs within 1 foot (0.3 m) of another break line, joint, or the edge of the concrete.

Furnish and apply water to a check section at least once each day to verify that a satisfactory crack pattern is being maintained.  Make adjustments to the energy or striking pattern when the Engineer deems it necessary, based on the check sections.

Roll the cracked concrete until the concrete pieces are firmly seated.  Perform rolling with at least two coverages as specified in Item 204.  The Engineer will determine the maximum number of coverages of the roller on the test sections to ensure seating without damage to the concrete.

Before placing the asphalt concrete, remove all loose pieces of broken concrete that are not firmly seated.  Repair all voids, such as spalls, removed loose pieces, joints, or cracks that, in the Engineer’s opinion, will make uniform compaction of the first asphalt concrete course difficult.  Repair voids by applying 407 tack coat, filling with asphalt concrete, and compacting as directed by the Engineer.

Do not allow traffic on the cracked concrete before the initial asphalt concrete base and intermediate courses are in place.

321.04  Method of Measurement.  The Engineer will measure the area of existing non-reinforced concrete pavement or concrete base satisfactorily cracked and seated in square yards (square meters).  The Engineer will measure the actual width of the existing concrete, and will measure the length along the centerline of each roadway or ramp.

321.05  Basis of Payment.  Payment is full compensation for furnishing all labor, equipment, materials, and incidentals necessary to complete this work; for all crack pattern test and check sections including water; and for repairing of joint, cracks, spalls, and voids.

The Department will pay for the accepted quantities at the contract price as follows.

Item           Unit                                Description

321             Square Yard                    Cracking and Seating Existing Non-
                       (Square Meter)                Reinforced Concrete Pavement

400  FLEXIBLE PAVEMENT

item 401  Asphalt Concrete
PAVEMENTS—GENERAL

401.01  Description

401.02  Mix Design and Quality Control

401.03  Materials

401.04  Reclaimed Asphalt Concrete Pavement and Reclaimed Asphalt Shingles

401.05  Mixing Plants

401.06  Weather Limitations

401.07  Notification

401.08  Asphalt Binder

401.09  Aggregate Preparation

401.10  Mixing

401.11  Hauling

401.12  Spreading Equipment

401.13  Rollers

401.14  Conditioning Existing Surface

401.15  Spreading, Finishing and Night Work

401.16  Compaction

401.17  Joints

401.18  Asphalt Binder Compatibility

401.19  Spreading and Surface Tolerances

401.20  Asphalt Binder Price Adjustment

401.21  Method of Measurement

401.22  Basis of Payment

401.01  Description.  This specification is applicable to all types of asphalt concrete pavements irrespective of gradation of aggregate, kind, and amount of asphalt binder, or pavement use.  Deviations from these general requirements are covered in the specific requirements for each type according to the appropriate contract item or items.

Work consists of one or more courses of asphalt concrete constructed on a prepared foundation.  The asphalt concrete consists of a mixture of uniformly graded aggregate and specified type and grade of asphalt binder.

Control all production processes to assure the Engineer that the mixture delivered to the paving site is uniform in composition, conforms to the specification requirements and that the placed mixture is free of any defect (ex.  segregation, tenderness, lack of mixture and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control at project completion.

The asphalt concrete pavement thickness shown on the plans or stated in the Proposal is for the exclusive use in calculating the weight required to be placed per unit of surface area.

401.02  Mix Design and Quality Control. Use an approved Job Mix Formula (JMF). The quality control and acceptance requirements of Item 403 apply unless otherwise specified.

If required to perform the mix design or quality control, provide a laboratory and personnel meeting the requirements of Supplement 1041 to perform mix design and quality control tests.

Calibrate asphalt content nuclear gauges according to Supplement 1043 using personnel with a minimum Level 2 rating according to Supplement 1041.  Mix and test the calibration verification sample with a Department employee present.

Provide and dispose of the solvent used for cleaning the asphalt content nuclear gauge pans.

401.03  Materials.  Furnish materials conforming to:

Asphalt binder

.... (asphalt concrete, 401.14, 401.15)...................... 702.01

Asphalt material (401.14, 401.18)......................................
.............................................. 702.01, 702.04, or 702.13

Aggregates (base courses)....................................... 703.04

Aggregates (intermediate and

.... surface courses).................................................. 703.05

Mineral filler ........................................................... 703.07

Sample aggregate, asphalt binder, asphalt material, and mineral filler according to 106.01.

If 100 percent of coarse aggregate in an asphalt mix design is steel slag, the Contractor may include steel slag as a maximum of up to 50 percent of fine aggregate.  If a steel slag source causes bulking (expansion resulting in flushing or material loss) in asphalt concrete courses, the Laboratory will place limits on the amount of steel slag allowed in a mix design.  Bulking may occur when a large percentage of an asphalt mix design is steel slag aggregate.  Bulking may be shown through testing, such as ASTM D 4792, or through field failure such as, but not limited to, flushing on newer pavement or apparent over-asphalting in production.  The Department may require the steel slag processor at any time to perform additional testing to verify steel slag properties.  Potential pavement performance problems due to poor control of steel slag aggregate include bulking, poor gradation and specific gravity control resulting in highly variable void properties, excess soft pieces resulting in pock marks, flushing, etc.

Take prompt corrective action if mixture delivered to the paving site is not uniform in composition, does not conform to the specification requirements or is not free of any defect (ex.  segregation, tenderness, lack of mixture and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control as determined by the Engineer.  The Engineer will stop conditional acceptance of the asphalt concrete for failure to correct problems.

401.04  Reclaimed Asphalt Concrete Pavement and Reclaimed Asphalt Shingles.  Provide reclaimed asphalt concrete pavement (RAP) and/or reclaimed asphalt shingles (RAS) according to the following requirements when choosing to use the in a mix.  Failure to follow these requirements will result in a rejection of the Contractor QCP (403.03); restriction of any RAP or RAS use at the facility; and/or a change to Unconditional Acceptance at the facility.

Job Mix Formula. The Contractor may use a blend of new materials in combination with RAP obtained from verifiable Department or Ohio Turnpike Commission projects and/or RAS obtained from un-used manufactured shingle waste or used roofing tear-off shingles as listed in Tables 401.04-1 and 401.04-2 and as follows.  If the RAP is not from the above sources or the source is unknown, process and blend the RAP into a single uniform stockpile, test according to Level 3 Asphalt Mix Design requirements and obtain District approval for use. Obtain written Laboratory approval for use of unusually large, old RAP stockpiles of unknown content and/or age.  Include approved methods in the QCP for ongoing processing and testing of these piles.  Ensure no foreign or deleterious material (703.04, 703.05) is present in RAP.  All RAS suppliers must meet the requirements of Supplemental Specification 1116.

Ensure that the JMF falls within the specified limits of the required mix item. Ensure the JMF submittal includes the percentages of RAP, RAS, virgin aggregates, and virgin asphalt binder required for the mix item.  Report all RAP and RAS test results, including binder blend analysis, in the JMF submittal.  Identify the RAP in the JMF submittal as to project origin and mix type(s). Identify the manufactured shingle waste manufacturer source or the approved tear-off RAS processor in the JMF submittal.

Determine RAP properties and uniformity as follows.  Determine the final RAP gradation and asphalt binder content on a minimum of four separate stockpile (or roadway for concurrent grinding) samples all agreeing within a range of 0.4 percent for asphalt binder content and 5 percent passing the No. 4 (4.75 mm) sieve.  If fractionated RAP is used use a suitable sieve for determining gradation uniformity.

Determine RAS properties and usage as follows.  Use no more than 5.0 percent RAS by dry weight of mix. For design assume 18.0 percent available RAS binder.  Determine gradation and specific gravity according to AASHTO PP 53-09,  Section 5 or subsequent AASHTO applicable standard.  Provide the required certification forms in the JMF submittal documenting that the RAS meets AASHTO MP 15-09, sections 3.2 or 3.3 and that RAS from roofing tearoffs conforms to the EPA’s NESHAP, 40 CFR 61 Subpart M, and other applicable agency requirements for asbestos.

RAP and RAS Usage Limits and Requirements. Process and use RAP and RAS as follows.

Process and use RAP by one of the following two methods.  Note on the JMF submittal RAP page which of Method 1 or Method 2 methods described below apply to the RAP.

1.      Method 1 Standard RAP. Include RAP in a JMF submittal according to the Standard RAP/RAS Limits Table 401.04-1 unless specified differently in the applicable mix specification.  For mixes that will contain up to 10 percent RAP the JMF submittal is not required to include the RAP except when a virgin polymer asphalt binder is used in a surface course.  For surface course JMFs having polymer asphalt binder only submit at 0 or 10 percent RAP.    If greater than 20 percent RAP is used in a JMF submittal include an analysis of the recovered asphalt binder and blend according to Level 3 Mix Design procedures to determine the grade of virgin asphalt binder to use.

TABLE 401.04-1  Method 1 – Standard RAP/RAS Limits

Asphalt Mix

Application

Percent RAP by

Dry Weight of Mix

Max.

RAS Usage [1]

Total Virgin Asphalt Binder Content, Min.

Comments

Heavy Traffic Polymer Surface Course

10%

None

5.2

Polymerized binder is virgin. (For non-polymer virgin binder allow 20% max RAP and 5.0 min. virgin.)

Medium Traffic Surface Course

20%

Manufacturing waste only

5.0

Polymer or non-polymer virgin.

Light Traffic Surface Course

20%

Manufacturing waste only

5.2

Polymer or non-polymer virgin.

Intermediate Course

35%

Manufacturing waste and tear-offs

3.0

Any mix type used as an intermediate course.

Base Course 301

50%

Manufacturing waste and tear-offs

2.7

The Laboratory will establish the asphalt binder content.

Base Course 302

40%

(30%)

Manufacturing waste and tear-offs

2.0

A lower RAP limit of 30 percent will be required if poor production mixing or coating is evident.

[1]  No more than 5.0% RAS by dry weight of mix

RAP Processing for Table 401.04-1 Method 1-Standard RAP.  For surface courses process RAP to less than 0.75 inch (19 mm) and place a 0.75 inch (19 mm) screen on the cold feed.  For other courses place a 2-inch (50 mm) screen on the cold feed.  Ensure that the RAP is the proper size to allow for complete breakdown in the plant.  If mixing is incomplete, place a smaller screen on the cold feed.

2.      Method 2 Extended RAP.  Include RAP in a JMF submittal according to the Extended RAP/RAS Limits Table 401.04-2 unless specified differently in the applicable mix specification.  Only use Method 2 with counter flow drum plants or mini-drum batch plant configurations meeting 402.  For mixes that will contain up to 15 percent RAP the JMF submittal is not required to include the RAP unless a virgin polymer asphalt binder is used in a surface course.  For JMFs having polymer asphalt binder do not submit at 1 through 9 percent RAP.

If greater than 25 percent RAP is used in a JMF submittal include an analysis of the recovered asphalt binder and blend according to Level 3 Mix Design procedures to determine the grade of virgin asphalt binder to use.  If the blending shows a grade change is required use a PG64-28 for heavy intermediate courses or PG 58-28 or 64-28 for medium intermediate or base courses.  No grade change is required with RAP at 26 to 40 percent if Warm Mix Asphalt (WMA) technology is used in a manner to maintain the mix temperature below 275 °F (135 °C). Use WMA technology meeting 402.04.  Other WMA technologies must be approved by the Laboratory. If desired, WMA may be used to control plant temperatures when producing mixes using RAP above 40 percent, but a grade change is required if shown necessary by the blending index.

TABLE 401.04-2  Method 2-Extended RAP/RAS Limits

Asphalt Mix

Application

Percent RAP by

Dry Weight of Mix

Max.

RAS Usage [1]

Total Virgin Asphalt Binder Content, min.

Comments

Heavy Traffic Polymer Surface Course

15%

None

5.0

Polymerized binder is virgin. (For non-polymer virgin binder allow 25% max RAP and 4.6 min virgin.)

Medium Traffic Surface Course

25%

Manufacturing waste only

4.8

Polymer or non-polymer virgin.

Light Traffic Surface Course

25%

Manufacturing waste only

5.0

Polymer or non-polymer virgin.

Intermediate Course

40%

Manufacturing waste and tear-offs

3.0

Any mix type used as an intermediate course.

Base Course 301

55%

Manufacturing waste and tear-offs

2.5

The Laboratory will establish the asphalt binder content.

Base Course 302

45%

(35%)

Manufacturing waste and tear-offs

1.8

A lower limit of 35 percent will be required if poor coating is evident. The virgin requirement of 302.02 does not apply.

[1]  No more than 5.0% RAS by dry weight of mix

RAP Processing for Table 401.04-2 Method 2-Extended RAP.  Process RAP by means of fractionation or by additional in line processing.  Include in the QCP additional methods and procedures to dictate how this is to be accomplished at plants.  Specify documentation method for RAP measurement.  Fractionation is the process of creating separate piles of RAP from one pile when split over a specific sieve or sieves.  Test fractionated piles to show uniformity.  For additional in line processing only process RAP from a uniform, tested and approved stockpile by passing the RAP over a double deck screen placed in-line between the RAP cold feed bin and the mixer.  Use a 9/16 inch (14.3 mm) screen for surface and intermediate mixes and a 1.5 inch screen for base mixes.  Do not use concurrent project RAP in a stream process.

3.      RAS Processing and Usage.  Include RAS in a JMF submittal according to the Standard RAP/RAS Limits Table 401.04-1 or Extended RAP/RAS Limits Table 401.04-2 unless specified differently in the applicable mix specification.

Ensure RAS is processed to have 100 percent passing the 1/2 inch sieve and at least 85 percent passing the No. 4 sieve.  Ensure RAS has less than 1.0 percent deleterious materials and 0.1 percent metals by weight.  Do not blend RAS from manufacturing waste and RAS from roofing tearoffs.

Ensure the approved QCP includes RAS usage methods before using RAS. Include in the contractor QCP what contractor requirements apply to the RAS processor.

Introduce and control RAS in asphalt plants in the same manner as RAP is introduced and controlled.  RAS for base courses may be preblended with RAP if using rate control equipment to ensure uniformity of blending and if satisfactory blend and production is achieved. RAS may be preblended with a small amount of virgin aggregate meeting 703.05 to minimize stockpile agglomeration.  Include in the contractor QCP blending equipment type and operation and uniformity testing requirements for preblended RAP and RAS or RAS and virgin aggregate.  Other methods must be approved by the Laboratory.

RAP and RAS QC and Management Requirements. Maintain as part of the QC records the signed certification forms as required in Supplemental Specification 1116.

Always note on the daily quality control report how much RAP and RAS is actually being used.  Apply a tolerance of ± 5.0 percent on the amount of RAP used if needed for a quality control adjustment but do not exceed the limits of Table 401.04-1 or Table 401.04-2, whichever applies.  If this adjustment is not adequate for maintaining control of the mix submit a new JMF for approval.  Do not apply this tolerance to RAS.

Include in the QCP methods to be used to meet Method 1 and Method 2 requirements above and the following requirements:

Provide enough space for meeting all RAP and RAS handling requirements at a hot mix facility.  Provide a clean, graded base for stockpiles that does not collect water.  Test blended RAP and RAS stockpiles to assure uniform gradation and asphalt binder content.  Ensure uniform stockpile properties match the JMF submitted RAP and RAS properties unless the uniform stockpile will be processed into the asphalt plant using plant cold feed in line processing.

If the uniform stockpile will be processed into the asphalt plant using plant cold feed in line processing determine the processed RAP properties for use in the mix design.  Record in the JMF submittal both the uniform stockpile and in line processed RAP properties.

If desired, when applying Method 1 Standard RAP requirements, use concurrent Department project RAP in a stream process in place of stockpiling and testing for uniformity but do so in the following manner.  Concurrent project RAP must be taken from one existing mix type on the concurrent project or two existing mix types if both mix types are taken at the same time in one pass of the milling machine.  Submit a new JMF for each existing mix type on the project (or each milling pass of two types) desired for use as concurrent project RAP.  Include in the QCP methods of validating RAP properties when using concurrent project RAP. If these requirements are not met blend and test for uniformity and apply the stockpile requirements of this specification.

Maintain in the plant lab and control room an up to date and dated site map of all tested and untested RAP and RAS stockpiles.  Give each stockpile a unique identification and identify if RAS piles are from un-used manufactured shingle waste or used roofing tear-off shingles.  Provide in the plant lab RAP and RAS properties for each uniform, blended stockpile cross referenced with its identification. In addition, provide the date the stockpile processing was completed and the stockpile estimated size in tons.  The DET may require RAP and RAS pile staking for failure to maintain the above.  Do not add to a stockpile once it is tested for uniformity.  Provide signage at all uniform stockpiles to inform haulers that uniform piles are not to be added to.

Stockpiles and processing methods are subject to inspection and approval by the DET at any time.  Rejection of stockpiles can occur for the presence of foreign or deleterious materials, lack of uniformity, incomplete mixing in the asphalt mixture, adding to piles, or moving RAP or RAS in a way not traceable through the QCP records and methods.  The Laboratory will resolve disputes over acceptability of RAP or RAS.

401.05  Mixing Plants.  The Department will approve mixing plants before preparation of the mixtures.  Schedule a date with the Department for approval inspection to be at least 1 week before mix production. Do not produce mixtures for projects from un-approved plants.  General requirements for asphalt concrete mixing plants are specified in Item 402.Set the asphalt binder controls for the computerized plant at the virgin asphalt binder content of the JMF at all times unless change is authorized by the Laboratory.

Asphalt mixtures may be produced using the warm mix asphalt method according to 402.04 except as restricted by specification.

401.06  Weather Limitations.  Place asphalt concrete only if the surface is dry and if weather conditions are such that proper handling, finishing, and compaction can be accomplished.  Never place asphalt concrete if the surface temperature is below the minimum established in Table 401.06-1.

Table 401.06-1

Course Thickness

Minimum Surface Temperature

3.0 inches (75 mm) and over

36 °F [1]

(2 °C [1])

1.5 to 2.9 inches (38 to 74 mm)

40 °F

(5 °C)

1.0 to 1.4 inches (25 to 37 mm)

50 °F

(10 °C)

Less than 1.0 inch (25 mm)

60 °F

(16 °C)

Variable Intermediate,
0 to 3.0 inches (0 to 75 mm)

40 °F

(5 °C)

[1]  Instead of 36 °F (2 °C), use a minimum air temperature of 40 °F (5 °C) if paving on an aggregate base or subgrade.

In addition to the above surface temperature requirements, do not place surface courses if the air temperature is less than 40 °F (5 °C).

For Type 1H asphalt concrete or any surface course with a polymer modified asphalt binder, ensure that the surface of the existing pavement is at least 50 °F (10 °C) and the air temperature is at least 50 °F (10 °C).

Do not schedule the placement of any Type 1H asphalt concrete or any surface course with a polymer modified asphalt binder after November 1, regardless of pavement or air temperature.

401.07  Notification.  Notify the Engineer at least 24 hours before starting paving on a project.  After starting paving, if paving operations are stopped for 1 week or more, notify the Engineer at least 24 hours before resuming paving on a project.

Construct longitudinal joints using string line or other controls as a point of reference to provide a straight longitudinal joint. Prior to placing adjacent pavement, trim any locations along the longitudinal joint that deviate horizontally from the point of reference.  Maintain a consistent overlap of 1 inch to 1 ½ inches on adjacent pavement when closing longitudinal joints.

401.08  Asphalt Binder.  Heat the asphalt binder and deliver it to the mixer within the temperature range specified in Table 702.00-1.  Do not use asphalt binder while it is foaming in a storage tank.  Take samples using correct new containers from the binder line between the last piping ‘tee’ and inlet into the plant unless a different storage method requires a different sampling location.

401.09  Aggregate Preparation.  Feed aggregates in their proper proportions and at a rate to permit correct and uniform control of heating and drying.  Remove all aggregates in the plant that will produce a mix outside the temperature limits or that contain excessive moisture or expanding gases causing foaming in the mixture, and return them to the proper stockpiles.

401.10  Mixing.  Maintain the temperature of the mix at the plant within the range set by the Laboratory for the JMF or according to the specification.  The Engineer will determine the required temperature of the mixture on arrival at the project site based on the temperature range set for the mix design and heat losses in transit.

For batch plants, after all of the aggregate is in the mixer, add the asphalt binder in an evenly spread sheet over the full length of the mixer.  The mixing time is defined as the interval between the start of application of the asphalt binder and the opening of the mixer gate.  Discharge all asphalt binder required for one batch in not more than 30 seconds.  After the asphalt binder is added, the Laboratory will establish a minimum mixing time, which will not be less than 30 seconds.

401.11  Hauling.  Use trucks for hauling asphalt concrete that have tight, clean, smooth metal beds from which the entire quantity of mixture is discharged smoothly into the spreading equipment.

Before loading, apply a thin coating of an approved release agent to the inside surfaces of the truck bed to prevent adhesion of mixture to the bed surfaces.  The Laboratory maintains a list of approved release agents.  Do not use fuel oil for this purpose.  Drain truck beds before loading.

Provide a place off the project for cleaning trucks when hauling polymer modified asphalt binder mixes or when excessive sticking of material in truck beds occurs.  If the Contractor does not resolve excessive sticking of material in truck beds in a reasonable time and the sticking is in areas of the truck that would indicate excessive cooling of the mix (front corners, bottom, etc.) due to a long haul, the Engineer will require an insulated bed.  The Contractor may only make changes in policy regarding release agents for beds or other procedure changes for better mix handling at the discretion of the Laboratory.

Equip each truck with a securely fastened, waterproof cover of suitable material to adequately protect the mixture from wind and weather.  At the request of the Engineer, remove covers before dumping into the paver.

If transporting hot asphalt concrete at prevailing air temperatures below 50 °F (10 °C) or if the length of haul exceeds 20 miles (32 km), insulate all truck beds to maintain workable mix temperature, and ensure that all covers are fastened to exclude the wind.  Do not exceed a distance of 50 miles (80 km) from the asphalt concrete plant to the paving site except by specific permission of the Department.

401.12  Spreading Equipment.  Use self-contained spreading equipment of sufficient size, power, and stability to receive, distribute, and strike-off the asphalt concrete at rates and widths meeting the typical sections and other details shown on the plans.  Use spreading equipment that has automatic control systems that maintain the screed in a constant position relative to profile and cross-slope references.  Ensure control of the screed position is reasonably independent of irregularities in the underlying surface and of the spreader operation.  Equip asphalt spreading equipment to prevent the segregation of coarse aggregate from the remainder of the asphalt concrete when the material moves from the hopper to the screed.   Use means and methods approved by the asphalt spreader manufacturer consisting of but not limited to any combination of chain curtains, deflector plates, or other such devices.

For the following asphalt spreaders perform the listed modifications:

A.      Equip Blaw-Knox asphalt spreaders with the Blaw-Knox Materials Management Kit (MMK) or an alternate equivalent kit.  If an alternate kit is used provide documentation showing the Blaw Knox means and methods and that the alternate methods used are equivalent.

B.      Only use Cedar Rapids asphalt spreaders manufactured after 1988.

C.      Equip Caterpillar asphalt spreaders with deflector plates as identified in the Caterpillar December 2000 Service Magazine entitled “New Asphalt Deflector Kit {6630, 6631 or 6640}”.

Provide a letter to the Engineer identifying modified asphalt spreaders to be used and provide a certification statement and signature that the above modifications were implemented on the listed asphalt spreaders.

The Engineer will base final approval of spreading equipment on the demonstrated capability of the equipment to place the mixture to the required cross-section, profile and alignment in an acceptable, finished condition ready for compaction.

Where the use of standard full-scale spreading equipment is impractical due to the size or irregularity of the area to be paved, use specialized equipment or hand methods approved by the Engineer to spread the asphalt concrete.

401.13  Rollers.  Use only steel wheel and pneumatic tire types of rollers meeting the minimum requirements of the following tables.  Conform to manufacturer’s specifications for all ballasting.

table 401.13-1  ROLLER CAPACITY

Roller Type

Maximum Capacity
square yards per hour (m²/hr)

Tandem

700 (600)

Three-Wheel

700 (600)

Trench

15 per inch width (13 per 25 mm width)

Pneumatic Tire, Type 1

1000 (850)

Pneumatic Tire, Type 2

700 (600)

Vibratory, Vibrating Roll

15 per inch width (13 per 25 mm width)

Vibratory, Static Roll (not vibrating)

3 per inch width (3 per 25 mm width)

table 401.13-2  STEEL WHEEL ROLLERS

Roller Type

Three-
Wheel

Tandem

Vibratory
Static

Trench

Total weight, tons
(metric tons)

10

(9)

8 to 12

(7 to 11)

8 to 12

(7 to 11)

Compression rolls, pounds per inch width (kN/m), minimum

300

(53)

200

(35)

120

(21)

300

(53)

table 401.13-3  PNEUMATIC TIRE ROLLERS

Type I

Tire size, minimum

9.00 ´ 20 in (229 ´ 508 mm)

Wheel load, minimum

5000 lb. (2250 kg)

Average tire contact pressure, minimum

85 psi (590 kPa)

Type II

Tire size, minimum

7.50 ´ 15 in (191 ´ 381 mm)

Wheel load, minimum

2000 lb. (900 kg)

Average tire contact pressure, minimum

55 psi (380 kPa)

For pneumatic tire rollers, use self-propelled, reversible units with vertical oscillation on all wheels on at least one axle.  Determine the tire inflation pressure necessary to meet the specified minimum contact area and contact pressure requirements.  Furnish the tire manufacturer’s charts or tabulations to the Engineer for verification of the required inflation pressure.  Check tire inflation pressure as the Engineer directs and maintain it within 5 pounds per square inch (35 kPa) of the required pressure.

Provide rolls and wheels with the necessary accessories to prevent adhesion of the mixture, and keep them properly moistened with water, water containing a detergent, or water containing an approved additive.  Do not use excess liquid.

401.14  Conditioning Existing Surface.  Clean the surface on which the asphalt concrete is to be placed, and keep it free of accumulations of materials that would, in the judgment of the Engineer, contaminate the mixture, prevent bonding, or interfere with spreading operations.  Where approved subgrade or pavement courses previously constructed under the Contract become loosened, rutted, or otherwise defective, correct the deficiency according to the contract item or items involved before the spreading of a subsequent pavement course.

If a quantity of asphalt concrete is specified for use in spot leveling or patching an existing pavement surface, spread and compact the material needed to effect the corrections as directed by the Engineer.

Paint contact surfaces of curbing, gutters, manholes, and other structures with a thin, uniform coating of asphalt material before placing the asphalt concrete against them.

If placing asphalt concrete against the vertical face of an existing pavement structure, clean the vertical face of foreign material and apply asphalt material that results in a coating of approximately 0.25 gallon per square yard (1 L/m²).

Before placing a surface course onto an intermediate course, apply a tack coat to the intermediate course according to 407.06.

In areas where the surface is required to be feathered to meet an adjoining surface, coat the existing surface uniformly with a thin coat of asphalt binder.

401.15  Spreading, Finishing and Night Work

Spreading and Finishing. Spread the mixture at a rate calculated using the specified thickness and the compacted width of the pavement course being placed, and the weight-to-volume conversion factors established in 401.21.  Maintain the actual rate of spreading the mixture equal to the required calculated rate within the tolerance specified in 401.19.  For pavement courses specified for leveling an existing pavement surface, the actual rate of spreading the mixture may vary from the required calculated rate as approved by the Engineer to accomplish the intended purpose.

For intermediate courses, make the maximum compacted depth of any one layer 3 inches (75 mm).

Spread and finish the mixture using approved equipment or methods such that compaction can follow immediately.  Preheat screeds and extensions before placing any asphalt concrete.  Use side plates sufficient to contain the mixture laterally during spreading.  Use only screed extensions, rigid or extendable, having the same features as the main screed including, but not limited to, vibration, heating, pre-strikeoffs, and tamping bars.  When using front-mounted hydraulically extendable screeds at a fixed paving width use full width auger extensions and full tunnel extensions.  When using fixed screed extensions use full width auger extensions and full tunnel extensions.  Do not allow a buildup of excess material in front of any extended screed.  Where excessive buildup of material is not controlled in front of the extended screed, the Engineer will require paver changes to correct the problem. 

Ensure the paver operation, screed, screed extension, and, or, mix design provide a mat, prior to compaction, that is free of texture inconsistencies, shadowing, streaking, tearing, pulling, or other deficiencies.  Take immediate action to correct the paver operation, screed, screed extensions, or, mix design.  The Engineer may stop placement until corrections are completed.

Use strike-off plates/strike-off extensions only on irregular areas such as mailbox turnouts, driveway turnouts, and other irregular non-travelled roadway areas.  The Engineer may approve the use of strike-off plates/extensions on variable width shoulders if the use of a standard extendable screed extension with the same features as the main screed is not practicable.  Perform supplemental hand forming and tamping where irregularities develop and where placing the mixture by hand methods.

Take prompt corrective action if placed mixture is not free of any defect (ex. segregation, tenderness, lack of mixture and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control and as determined by the Engineer.  Remove and replace, or otherwise correct, any portion of the pavement course found to be defective in surface texture or composition before or after compaction in a manner satisfactory to the Engineer.  Coordinate the spreading operation with the rate of production and delivery of the mixture to attain uniform, continuous progress.  Avoid erratic spreader operation due to irregular contact with the hauling vehicle, surging in the feed and distribution of the mixture, or other cause.  Maintain sufficient control of the spreading equipment with regard to line and grade references so that the pavement course, when compacted as specified, is in reasonable conformance with the Contract Documents.

Do not displace or damage bridge deck waterproofing membranes during spreading operations on the membranes.

Do not allow traffic on the compacted mixture until it has cooled sufficiently to prevent glazing as determined by the Engineer.

After completion of the surface course, seal gutters with asphalt binder as directed by the Engineer.  Apply the material at a uniform width of approximately 4 inches (100 mm) and at a rate just sufficient to fill surface voids.

Night Work.  Do not start night work or carry on day work into night work without operating an adequate and approved lighting system.  Night work is defined as work performed from 30 minutes before sunset to 30 minutes after sunrise.

Operation of adequate lighting system consists of furnishing, installing, operating, maintaining, moving, and removing night time lighting to illuminate construction work areas for night work.  Obtain the Engineer’s approval of the lighting at the beginning of the project and before starting the paving operation by measuring the luminance.

Provide an illuminated zone around all operating machinery.  Provide an illuminated zone of at least 5 Foot-candles (55 lux) of lighting luminance in the immediate vicinity of pavers, rollers, grinding equipment, material transfer vehicles, etc., and at least 1 Foot-candle (10 lux) at 25 feet (7.6 m) from this equipment.  Provide an illuminated zone of at least 5 Foot-candles (55 lux) of lighting luminance in the immediate vicinity of coring equipment and at least 1 Foot-candle (10 lux) at 10 feet (3m).  Position the light sources so they don’t interfere with or impede traffic in any direction and do not cause glare for motorists or point onto adjacent properties.  Provide a photometer capable of measuring the level of luminance on each night project. Take luminance measurements at a height of 20 inches (500 millimeters) above the roadway.

Obtain the luminance level any time requested by the Engineer. Test the illumination levels on the site each time a change in lighting configuration is made.  Replace non-functioning lamps immediately.  Check the luminaires aiming daily.  Clean the luminaires regularly.  Correct any deficient lighting within one hour or the Engineer will terminate construction activities.

When the total project includes more than one continuous lane mile (including bridges) of surface course paving in combination with night paving, provide a Material Transfer Vehicle (MTV) with paver hopper insert; a Material Transfer Device (MTD) with paver hopper insert; or a remixing paver specifically manufactured to eliminate segregation.

Provide equipment that:

A.     Includes a mixer/agitator mechanism that consists of either segmented, anti-segregation, re-mixing augers or two full-length longitudinal paddle mixers specifically designed for the specific purpose of re-mixing.  The longitudinal paddle mixers shall be located in the paver hopper insert.

B.     Eliminates segregation, and provides a uniform temperature throughout the mixture;

C.     Limits temperature differentials to less than 25 °F (14 °C);

Use the equipment on all mainline lanes of the traveled way including express lanes, collector-distributor lanes, continuous center turn lanes, acceleration/ deceleration lanes, and ramp lanes.

Use paver hopper inserts with a minimum capacity of 14 tons.  Remixing may be done by the MTV or MTD, in the paver hopper insert, or by the remixing paver. 

Demonstrate to the Engineer that the selected equipment eliminates physical segregation and limits the temperature differential of the mat surface measured transversely to 25 °F (14 °C).  Provide a method before the start of paving that ensures non-segregation and thermal differential requirements are met, continuously during placement operations.

Remove equipment that does not consistently eliminate physical segregation and, or, does not meet the temperature differential requirement.

401.16  Compaction.  Immediately after spreading the asphalt concrete and adjusting any surface irregularities, compact the mixture uniformly using rollers conforming to 401.13.  Do not use a spreading rate that exceeds the total of the specified capacities of the rollers in use.  However, if compacting a mixture spread as an intermediate or pre-leveling course less than 1-inch (25 mm) thick do not use a spreading rate that exceeds twice the total capacity of the rollers in use.

Coordinate the spreading of the mixture with the required roller coverage, considering the rate of cooling of the mixture as affected by lift thickness and environmental conditions.  Complete the required roller coverage during the period of time in which the temperature of the mixture is sufficient for the roller coverage to be effective in compacting the mixture.

Compact base mixtures using a combination of both steel and Type I pneumatic tire rollers; however, in small areas, compact these mixtures as approved by the Engineer using any of the rollers specified in 401.13.

Compact intermediate and surface mixtures using a three-wheel roller in the breakdown position (roller immediately behind the paver) of the roller train; however, in small areas, compact these mixtures as approved by the Engineer using any of the roller types specified in 401.13.

Compact variable depth courses using a combination of both steel and pneumatic tire rollers; however, in small areas, compact these mixtures as the Engineer approves using any of the roller types specified in 401.13.

For surface courses using a polymer modified asphalt binder give a copy of the JMF approval letter containing the design compaction temperature to the Engineer before any mix is placed.  Unless otherwise specified ensure that the mix temperature immediately before rolling is not less than 290 °F (145 °C) if placing hot mix asphalt, and not less than 250 °F (121 °C) if placing warm mix asphalt according to 402.04.  Do not compact polymer asphalt concrete surface courses with pneumatic tire rollers.

When using pneumatic tire rollers, ensure for any mix, that surface deviations and deformations caused by the tires are removed with steel wheel rollers.  Do not use pneumatic tire rollers if any resultant surface deformations cannot be removed.

Do not use vibratory rollers on courses with a thickness under 1 1/2 inches (38 mm).

If using vibratory rollers, supplement them with three-wheel or pneumatic tire rollers.

Unless otherwise directed, begin rolling at the sides and proceed longitudinally parallel to the centerline at a slow, uniform speed.  After each coverage or complete round trip, move the roller towards the crown of the road to begin its next pass, overlapping the previous pass by at least one-half the width of the previous pass.  On superelevated curves, begin rolling at the low side and progress toward the high side.  Where a longitudinal joint is being made, roll the joint then follow the applicable rolling procedure.

Continue rolling until full coverage of the course is complete and all roller marks are eliminated.  Take care to prevent displacement of the edge line and grade.  Where displacement occurs, correct the area immediately in a manner satisfactory to the Engineer.

Along curbs, headers, walls, and in other areas not accessible to rollers, thoroughly compact the mixture with hot, hand tampers or with mechanical tampers.  On depressed areas, the Contractor may use trench rollers or rollers fitted with compression strips.

Replace mixture that becomes loose, broken, contaminated, or otherwise defective with fresh, hot mixture.  Compact it to match with the surrounding area.

401.17  Joints.  Place the asphalt concrete mixture as continuous as possible.  Set up joints at the proper height above the adjacent construction to receive maximum compaction.  Where the edge of the new surface has been significantly rounded by the action of traffic, trim it to a vertical face before placing the adjacent pavement.  On projects where traffic is allowed to cross the edge of the new pavement lane, complete the longitudinal joint of the adjacent lane or berm within 24 hours.  Construct longitudinal joints using string line or other controls as a point of reference to provide a straight longitudinal joint. Prior to placing adjacent pavement, trim any locations along the longitudinal joint that deviate horizontally from the point of reference.  Maintain a consistent overlap of 1 inch to 1 ½ inches on adjacent pavement when closing longitudinal joints.

Form hot longitudinal joints using pavers operating in contiguous lanes, one just ahead of the other.  Maintain the distance between pavers in adjacent lanes such that it does not exceed the distance that a normal size load of mixture will cover.  Alternate loads of mixture between the pavers.  Do not allow rollers performing the initial rolling operation in one lane closer than 12 inches (0.3 m) to the longitudinal joint until the adjacent lane is placed.

Instead of hot joint construction using multiple pavers, the Contractor may use full width construction with a single unit paver.

Compact all cold longitudinal joints on intermediate and surface courses using a three-wheel roller.

For surface courses, form or cut all transverse construction joints to a vertical.

Seal all cold longitudinal construction joints by coating the entire face of the cold joint with a certified 702.01 PG binder or 702.13 SBR Asphalt Emulsion to provide 100 percent coverage of the joint.  Overlap the joint edges by at least 1/2 inch (13 mm). Seal all cold transverse construction joints with a certified 702.01 PG binder or 702.13 SBR Asphalt Emulsion to provide 100 percent coverage of the joint or with a certified 702.04 asphalt material applied at a rate of 0.25 gallon per square yard (1 L/m²).

401.18  Asphalt Binder Compatibility.  If excess fat spots, regular random areas of flushing, or excess drain down occur on a project that are not attributable to over rolling, plant operation, or mix quality compared to the JMF, the Department will consider the asphalt binder incompatible.  The Department will reject any on-hand asphalt binder because of incompatibility.  The Department may use its discretion in determining if problem areas can be corrected, but if an unsafe condition exists, remove and replace the area in question.  Demonstrate to the Laboratory through reporting actual testing analysis the compatibility of another asphalt binder and that proper equipment is in place in order to be allowed to resume.

401.19  Spreading and Surface Tolerances.  If a uniform course is specified, make checks and adjustments to maintain the rate of spreading within a tolerance of ±5 percent of the required calculated weight per unit of area.

If a variable depth course is specified, place the mixture as shown on the plans.

If a longitudinal profile is specified by elevations on the plans, do not allow the completed pavement surface to deviate more than 1/2 inch (13 mm) at any point from parallel with the specified profile.  Before placing the surface course, check the profile of the preceding course at 50-foot (15 m) intervals along the outside edge of each traffic lane and along any additional line described in superelevation tables, and submit a tabulation of all results that includes documentation of all deviations from the above tolerance to the Engineer.  Perform corrective work necessary for compliance with the profile tolerance before placing the surface course.  The requirements of this paragraph do not apply to small incidental areas of pavement less than 500 feet (150 m) in length.

Do not vary the transverse slope of the surface of the completed course from the specified slope by more than 3/8 inch in 10 feet (10 mm in 3 m).

Do not vary the surface of each completed intermediate or surface course from the testing edge of a 10-foot (3 m) rolling straightedge by more than 1/4 inch (6 mm).  Furnish straightedges, straightedges equipped with levels, or other devices such as approved profilers conforming to S1058 and using ProVAL software.  Equipment will be satisfactory to the Engineer. 

Check the surface course for variations in slope or surface at locations where bumps are suspected when directed by the Engineer.

Correct variations in excess of slope or surface tolerance by removing mixture to neat lines and replacing, or by surface grinding in a manner satisfactory to the Engineer.

401.20  Asphalt Binder Price Adjustment.   A contract item is eligible for a price adjustment when the contract’s proposal specifically includes an Asphalt Binder Price Adjustment note and the contract item meets the quantity limitations of the proposal note. 

401.21  Method of Measurement.  The Contractor is responsible for recording the net weight of each truckload of mixture to the nearest 100 pounds (50 kg) in triplicate on plant ticket forms approved by the Department.  If the pay quantities are established by platform scales, provide a tare weight for each truck at the beginning of each day’s operation and a minimum of every 4 hours of operation each day.  The Engineer may require additional tare weight measurements at any time.  The Engineer will have the right to monitor all weighing operations and may require reweighing trucks at any time or location. Correct any discrepancies immediately.  Continued non-compliance will result in the Department taking necessary and appropriate action, such as, but not limited to, assigning a Department ticket writer to the plant.  Send one copy of the plant ticket with each load delivered to the paver and present it to the Engineer.

The Engineer will convert the total of the weights recorded on the plant tickets representing mixture finished according to contract requirements to cubic yards (cubic meters) using a conversion factor established by the Laboratory.  The Laboratory will establish this conversion factor from the approved JMF.  However, if a mix design is not available, the Laboratory will use the conversion factors in Table 401.21.  If a uniform course is specified, the Department will not pay for a number of cubic yards (cubic meters) that exceeds the quantity calculated from plan lines and dimensions.

Table 401.21

Aggregate

lb/yd³

(kg/m³)

Gravel and stone

4000

(2370)

Slag less than 90 lb/yd³ (less than 1450 kg/m³) [1]

3600

(2135)

Slag 90 to 100 lb/yd³ (1450 to 1600 kg/m³) [1]

4000

(2370)

Slag more than 100 lb/yd³ (more than 1600 kg/m³) [1]

4300

(2550)

[1]  Based on average dry rodded weight at the Laboratory.

401.22  Basis of Payment.  The Department will pay for all work performed and measured as specified above according to the appropriate contract items for each type.

The cost of sealing the joints is included in the unit price bid for the asphalt concrete.

The Department will assess all costs against the Contractor that it incurs as a result of taking necessary and appropriate action due to the Contractor’s continued non-compliance.

If an unsafe condition exists, the Department will not pay for removing and replacing incompatible asphalt binder areas.

ITEM 402  ASPHALT CONCRETE MIXING PLANTS

402.01  Description

402.02  Calibration

402.03  Polymer Binders

402.04  Water Injection System for Warm Mix Asphalt

402.01  Description. This specification consists of the minimum requirements for an asphalt concrete mixing plant to produce asphalt concrete mixes according to Department specifications.

Ensure asphalt concrete mixing plants conform to the requirements of Supplement 1101 in addition to the following.

402.02  Calibration. Ensure the plant is calibrated according to Supplement 1101 when producing any asphalt concrete for the Department. Ensure that the calibration is accurate within 1.0 percent. When performing a complete calibration for ODOT projects notify the ODOT district 24 hours in advance of the calibration.

402.03  Polymer Binders. If an asphalt binder is modified by SBR at an asphalt concrete mixing plant, equip the plant with an automated SBR flow control and monitoring system. Obtain the Department’s approval of the system before operating and demonstrate the system calibration to the District. If the District waives the demonstration, provide a letter documenting calibration data for the flow system to the DET for each project. Obtain written approval from the Laboratory for the use of SBR and ensure the QCP contains methods for properly controlling SBR.

For drum mix plants, introduce the SBR directly into the asphalt binder line through means of an in-line motionless blender or other device approved by the Laboratory which is able to provide a homogeneous blend. Locate a sampling valve between the in-line blender and the plant drum.

For batch plants, add the SBR after the aggregate has been completely coated with asphalt binder. Continue mixing for a minimum of 20 seconds after SBR is added and long enough to provide a uniform mixture.

Ensure the SBR pumping and metering system is capable of adding the SBR within the limits of 702.01. For drum plants ensure the SBR pump is automatically controlled by an independent computer and interfaced with the asphalt binder flow to automatically maintain the SBR flow within specification limits. Produce asphalt mixtures for placement in automatic SBR control mode only.

Ensure the SBR meter is accurate to ± 2.0 percent over a flow range typical of that used at the asphalt plant (typically 0.8 to 12 gpm at drum plants and 10 to 25 gpm at batch plants). Ensure the SBR meter is a magnetic flow meter consisting of a metering flow tube which utilizes Faraday’s Law of Induction to measure the flow and includes a transmitter to transmit the flow signal to a totalizer located in the control room of the asphalt plant. Locate the SBR meter downstream of any recirculation lines. Provide a means for removing the SBR line at the in-line blender to be able to obtain a sample of the SBR for calibration purposes.

Obtain Laboratory approval for use of any other type of SBR meter. Ensure the totalizer displays total volume measured and flow rate in standard engineering units. Ensure the totalizer is interfaced with a data logger which produces printouts of the logged data every five minutes for a drum plant or every batch for a batch plant. Ensure the logged data includes time, date, flow rate, and flow total except flow rate is not necessary for batch plant production.

Balling or wadding of SBR or uncoated aggregate indicates improper mixing; cease production immediately and until corrected to District satisfaction.

402.04  Water Injection System for Warm Mix Asphalt.

When allowed by specification use a water injection system approved by the Department for the purpose of foaming the asphalt binder and lowering the mixture temperature. Only use equipment that has been proven stable and effective through project use on non-ODOT projects. Ensure equipment for water injection meets the following requirements:

1.       Injection equipment computer controls are in the plant control room and are tied to the plant computer metering.

2.       Injection equipment has variable water injection control controlled by the plant operation rate and the water injection can never exceed 1.8 percent by weight of asphalt binder.

3.       Water injection rate cannot be manually overridden by the plant operator once in the computer.

4.       Injection equipment stops water flow when a control or equipment failure in the injection system occurs.

5.       The water injects into the asphalt binder flow before the asphalt binder spray hits aggregate. Do not allow water to touch aggregate before the binder spray.

6.       Injection equipment includes water storage and pump control tied to the injection computer controls.

7.       Water storage low water alarm installed in the control room.

8.       Provide a PG binder sampling valve between the last piping tee on the tank side of the line and the injection equipment to sample PG binder before water is injected.

Item 403  ASPHALT CONCRETE QUALITY CONTROL AND ACCEPTANCE

403.01  Description

403.02  General

403.03  Quality Control Program (QCP)

403.04  Plant Calibration

403.05  Quality Control Tests

403.06  Verification Acceptance (VA)

403.07  Unconditional Acceptance

403.08  Acceptance Tables for 448 Mixes

403.01  Description.  This specification outlines the Contractor requirements for controlling asphalt concrete, asphalt concrete base, or other asphalt mixtures as specified.

403.02  General.  The Department will verify quality control by Department Verification Acceptance (VA) tests and monitoring reviews as specified.  If the Contractor fails to operate according to its Quality Control Program (QCP), the Department will accept asphalt mixtures by Unconditional Acceptance.

Restoration of VA procedures will be by the Department’s Quality Control Qualification Committee (QCQC) based on District recommendation and review of the Contractor problems, resolutions and QCP.

Acceptance does not relieve the Contractor of responsibility for supplying and installing a finished product conforming to all requirements of the Contract.

403.03  Quality Control Program (QCP).  Create and implement a Quality Control Program (QCP) for each paving season.  The QCP will cover processes conducted to provide an asphalt mixture at the paving site that is uniform in composition, conforms to the specification requirements and that when placed is free of any defect (ex. segregation, lack of mixture and texture uniformity,  raveling, rutting, holes, debris etc.) within the Contractor’s control at project completion.  A minimum of 3 weeks before mix production, but no later than February 28, submit a hard copy of the proposed QCP to the Laboratory for review and approval.

Send a hard copy and a digital copy (if available) of the approval letter and approved QCP to the DET in every District in which work is performed.  Keep copies of the approval letter and the approved QCP in each Contractor plant laboratory and plant operation control room.  Digital copies of the approved QCP and approval letter in pdf format are allowed in each Contractor plant laboratory and plant operation control room with the following requirements:  The file icon must be appropriately labeled and be on the computer desktop of a computer in each area, the QCP must contain a Table Of Contents inside the front cover locating all sections by page number and the QCP must be page numbered, and out of date QCPs must be removed from the computer desktop.

Failure to comply with the approved QCP may result in removal of personnel in accordance with Supplement 1041, removal from VA, and adversely affect the Contractor’s Prequalification rating.

The QCP is a reflection of a Contractor’s sincerity and ability in producing a quality product.  Development of this program beyond the minimum requirements specified below is encouraged and is taken into consideration by the QCQC when reviewing Contractor plant operation for qualification for VA.

Include in the program:

A. The assignment of quality control responsibilities. Quality control includes all efforts required to achieve a product meeting specifications.  The QCP will list individuals as required below and note their designated responsibilities to meet QCP requirements.  Provide a Quality Control Manager holding a Supplement 1041 Level 3 approval and who is a company employee.  Assign Level 2 technicians for all Level 2 QC testing duties, and provide a list designating their responsibilities and expected actions.   Ensure only approved personnel handle and test samples at all times.   If Level 2 consultant technicians are used provide a document in the QCP and to them listing designated responsibilities and expected actions (if different from employee expectations).  Define in the QCP who is responsible at plants and specific methods for assuring haul vehicles meet all requirements and proper bed release products are used.  Provide a Field Quality Control Supervisor (FQCS), holding Supplement 1041 Field Quality Control Supervisor approval and who is a company employee, who is routinely and usually at the paving site during placement of any non-temporary asphalt concrete pavement.  Ensure personnel obtaining and handling cores at the project site are approved Level 2 technicians, FQCS or personnel approved by the Laboratory. 

B. Provisions to meet the Department mix specifications.

C. Procedures for extra testing (e.g., job start, responses to poor test results or field mix problems, aggregate stock testing, reclaimed asphalt concrete pavement checks, moistures) and any other testing necessary to control materials not already defined in these Specifications.

D. Methods to maintain all worksheets, including all handwritten records, and other test and sample records from the plant or project for the duration of the contract or 5 years, whichever is longer.  Define the test record process.  Define company records retention requirements.  Provide copies of all test reports and forms used in the quality control process.

E.           Procedures for equipment calibration and documentation for Level 2 lab equipment.  Provide documentation that all Level 2 lab equipment has been calibrated at the time of the Level 2 lab approval inspection.  Procedures for calibration record storage.

F.  Method of Quick Calibration and documentation for each plant type.

G. Procedure for random sampling to be used at the plant and documentation method.  Procedures for sample taking, tracking, handling and documentation method for all samples taken at the project paving site including taking of all cores used for density determination or density gauge correlation.

H. All procedures to meet the processing, testing and documentation requirements for RAP and RAS in 401.04 including test forms, record keeping, technician responsibilities, etc.

I.  Procedure for ensuring that every Contractor employee involved in the testing of asphalt mix and operation of the asphalt plant facility has read the QCP and has on site access to all applicable Department specifications, proposals, policies, and the current approved JMF.

J.  Means to meet the handling and storage requirements of 402.03 and asphalt binder suppliers for all asphalt binders.

K. Means to meet delivered mixture uniformity/coating and hauling/trucking requirements.

L. Define the roles and responsibilities of the Field Quality Control Supervisors.  List approved Field Quality Control Supervisors.

M.          Signature of the Quality Assurance Manager and, if different, the person in authority to enforce all operations covered by the QCP as outlined in this subsection.

N.      Specify in the QCP warning bands to be used by technicians for all tests and give specific instruction how they will be used for tests in concert with Table 441.10-1 specification requirements.

403.04  Plant Calibration.  Conform to the requirements of Item 402.

Before manufacturing asphalt concrete, demonstrate to the Monitoring Team that the Contractor’s facility adequately meets the specification requirements.  Calibrate the plant using procedures approved by the Department.  Perform initial calibrations in the presence of the Monitoring Team.  The Monitoring Team may request a letter of certification and certified data documenting the calibration results, instead of having the Monitoring Team present.

Verify the calibrations biweekly using a Quick Calibration.  However, the Department may request additional Quick Calibrations if there are mix production problems or plant operation concerns.  The Quick Calibration is a quality control procedure developed by the Contractor that verifies the accuracy of a facility to proportion materials to meet the current JMF.  Include the Quick Calibration procedure and data forms in the QCP.  If the difference between current calibration and the Quick Calibration is within ±2 percent, then the current calibration is acceptable.  If the 2 percent variation is exceeded, perform a recalibration of the facility.  Document the Quick Calibration procedure as specified in the QCP and post the procedure and results in plain view in the plant control room and plant laboratory for reference by the Monitoring Team.  Document all data from calibrations in a format approved by the Laboratory, and retain the data for review by the Monitoring Team.

If asphalt concrete is being produced from a batch type facility, verify the accuracy of the aggregate and asphalt binder weighing devices on a biweekly basis.  Include the verification procedure in the QCP.  Document the verification procedure as specified in the QCP and post the procedure and results in plain view in the plant control room and plant laboratory for reference by the Monitoring Team.  Do not allow the deviation between the plant recorded weights and actual weights to exceed 1 percent.  Record all data from verification of weighing devices in a format approved by the Laboratory, and retain the data for review by the Monitoring Team.

403.05  Quality Control Tests.  Perform quality control tests to control the asphalt concrete mix within the appropriate specifications.

Perform all Item 448 mix testing and quality control according to 441.09.  The Contractor may test a 448 Sublot sample instead of the required quality control test provided the sample is tested in the half day in which the Sublot sample mix was produced and is tested for all required quality control properties.

For mixes that do not use Item 448 acceptance (e.g. Items 301, 302, and Supplemental Specification 803), test the mix according to 441.09 for asphalt binder content and gradation (Basic).  Other requirements of 441.09 and 441.10 do not apply.  Control the Basic mixes as follows:

A.      If a single asphalt binder content is more than ±0.5 percent beyond the JMF, immediately take and test an additional sample.

B.      If two consecutive asphalt binder content tests are more than ± 0.5 percent beyond the JMF, notify the Monitoring Team and cease production until the problem is corrected.

C.      If the Range difference in any three consecutive asphalt binder content tests is greater than 0.7 percent (for 302 mix) or 0.6 percent (Basic mix, other than 302) immediately notify the Monitoring Team.

D.      If the Range difference in any three consecutive gradation tests for the No. 4 (4.75 mm) sieve is greater than 10.0 percent, immediately notify the Monitoring Team.

E.      If Range deviations as specified continue, cease production.

Range is defined as the difference between the largest and the smallest test result.

403.06  Verification Acceptance (VA).  The Department will perform VA.  If the random Department sampling and testing verifies the accompanying Contractor tests, the average of the Contractor’s quality control tests for each day or night (for Basic mix) ,the average of the Contractor’s tests for each Lot (for 448 mix) or daily average MSG (446 mix) will be used to determine acceptance.

A. Sampling.  The Department will perform the VA by testing independent and split samples taken and tested by the Department.

For plant sampling for Basic mixes or 441 quality control testing, the Contractor’s technician will randomly select the truck in which to take a sample by using a random number procedure as outlined in the QCP.  The Contractor’s technician will give no indication to anyone of the time that the sample is to be taken.  For other than job start, previous mix production problems, low production tonnage, or as requested by the Monitoring Team, exclude the first three trucks from sampling.  Include the random number and sample tonnage location and time of taking on the daily Quality Control Report (Department Form TE-199) with each test.  Tests, other than the required random sample tests, are at the Contractor’s discretion according to the QCP.

Provide a clean area of sufficient size and a hard surface to perform sample splitting.  Split samples by quartering and recombining only as described in AASHTO T 248, Method B for hard surfaces for the Department and Contractor’s sample.  The Department split sample size required is generally 22 to 27 pounds (10,000 to 12,000 g).  A mechanical quartering device approved by the Laboratory may be used in lieu of the above but only split according to the procedure outlined in the Contractor QCP.  Ensure that every quality control or Item 448 Sublot sample taken by the technician has a labeled split for the Department.  Wrap and label the Department split samples as to Lot or Sublot, time, location (tonnage), and accompanying Contractor test identification.  The Monitoring Team will pick up all Department split samples within 4 workdays.  Sample mishandling (careless identification, changing sample size, consistency, or pre-testing) will result in a change to Unconditional Acceptance.

For Item 448 mixes, conform to the procedures of Supplements 1035, 1038, 1039, and 1043 except take samples from a truck at the plant.  If workmanship problems continue on the project (segregation, etc.) or if quality control problems persist, the Monitoring Team may require sampling on the road according to Supplement 1035.  Lots will be 3000 tons (3000 metric tons), and Sublots will be 750 tons (750 metric tons).  However, when production is limited to less than 3000 tons (3000 metric tons), consider the quantity produced as a partial Lot.  For partial Lots of 1500 tons or less sample and test at least two sublot samples regardless of the tons produced. Split and test all Sublot sample locations, as selected by the Monitoring Team or project and taken by the Contractor.  The Contractor may test a QC sample at the required Sublot sample location  as both a QC and Sublot test provided the sample is tested for all required quality control properties. Test results will apply for both QC and sublot requirements.  A change in the location of the Sublot sample must be approved by the District and be reasonably close to the original location.  This allowance does not apply to any other samples including Department VA sample locations selected by the Monitor. Label Department split samples as Sublot or quality control samples.

For Item 446 mixes MSG VA testing will be performed by the District on a minimum of one in every four required District sampled Daily samples.

B.      Reporting.  Report all testing performed and sample identification on a Quality Control Report (Department Form TE-199).  Record on the TE-199 if the mixture produced was ran at the asphalt plant as a hot mix asphalt (HMA) or as a warm mix asphalt (WMA) produced according to 402.04 or another approved method. Deliver (fax, e-mail, hand) completed Quality Control Reports by the end of each day in which testing is conducted.  If desired by the Monitoring Team and always for unsigned E-mail versions, mail the originals.  After startup adjustments, report any plant operation changes on the Quality Control Report.  Ensure that each Quality Control Report contains technician comments as to production quality, input materials received, and condition and includes any other quality control activities as specified in the QCP.  Ongoing problems with inadequate, incomplete, or illegible reporting will result in a change to Unconditional Acceptance.  The Contractor’s technician must sign each Quality Control Report.

Report test results to the accuracy of the following decimal places.  When the figures to be dropped in rounding off are exactly one-half of unity in the decimal place to be retained, round the value up to the nearest number in the decimal place to be retained.

Single Test

Average

Asphalt Binder Content

0.1

0.01

No. 200 (75 µm) sieve

0.1

0.01

Other sieves

Whole number

0.1

BSG

0.001

0.001

For Item 448 mixes, track the Item 448 Sublot and Lot tonnages through the project and identify on the Quality Control Report each random Sublot test as to Lot number and Sublot tonnage location.  In addition to the Quality Control Report submit the TE-448 Department form with lot identification and actual sieve weights for each Sublot sample from the technician’s gradation worksheets.  Attach computerized plant printouts representing samples tested to that day’s report, if desired by the Monitoring Team, or otherwise keep it with the quality control records.  Ensure that the technician notes on the accompanying printout in which tonnage the quality control sample was taken with accompanying test results for AC content and percent passing the No. 4 (4.75 mm) sieve.  Keep remaining printouts in the plant laboratory for the duration of the project.  Keep a copy of all quality control reports for a project in the Contractor’s plant laboratory.

C.      Department Verification Testing and Monitoring.  For Basic and 448 mixes the Monitor/ District will randomly choose one Department sample in a maximum of every four production days for VA testing to confirm Contractor testing and mix control.  More frequent VA samples can be taken when desired.  The Department VA sample location will be chosen randomly by the Monitor, including where in the truck to take the sample, if applicable.    The Contractor technician will take the sample from the truck with the Monitor witnessing. The Monitor will keep the sample in the Department’s possession until delivered to the District lab or testing is complete.  The Monitor will have enough sample taken to split with the Contractor.  The Monitor will split the sample in the contractor lab.  The Monitor will have the sample tested in the District lab or as noted below. The Contractor will test his split of the VA sample with the Monitor witnessing.  The Department will use its VA test result; the Contractor result of the split: as well as the most recent previous contractor quality control and/or sublot test in the comparison for the  Department VA testing.  

The Monitor may opt to test the Department VA sample in the plant laboratory with the Contractor’s permission, according to the Contractor’s safety practices, and with the restriction of only the Contractor’s technician physically placing a sample pan in the AC Gauge.  However, if the Department tests VA samples on contractor equipment, test a VA sample on District lab equipment a minimum of one time in 15 production days from a given plant regardless of the number of projects or JMFs tested in the Level 2 lab.  Record the results and testing location in the District project record.  One day may be added to the above Department sample testing frequency for each day production is less than 500 tons (450 metric tons).

For Item 446 mixes MSG VA testing will be performed by the District on a minimum of one in every four required District-sampled Daily samples.  This result will be compared to that days Contractor average of MSG QC test results.

For all mixes, the District may increase the number of VA testing samples if desired.

All Department VA test results will be given to the Contractor by a reasonable arrangement acceptable to both.  Department VA sample testing not completed in a timely manner is of no value in verifying quality control testing quality for Contractor test acceptance and/or investigating problem causes.  As such, if not completed in a timely manner, Contractor tests will automatically stand and the District will note the problem in the District’s VA record.

Table 403.06-1  DEPARTMENT VERIFICATION ACCEPTANCE AND QUALITY CONTROL TEST COMPARISON

Percent Asphalt Binder

Percent

Passing No. 4 (4.75mm)

MSG Comparison

VA [1]

QC/lot test [2]

VA [1]

QC/lot test [2]

VA [3]

Basic

±0.3

±0.4

±4.0

±5.0

448

±0.3

±0.3

±4.0

±4.0

446

0.025

[1]  District VA mix test deviation from Contractor split.

[2]  District VA mix test deviation from QC and/or lot test.

[3]  Deviation of District Daily sample MSG compared to QC MSG daily average.

If the Department VA tests confirm Contractor testing is within the verification tolerances, but a pattern of high or low results exist that suggests mix control is not at the JMF, then investigate with the Monitoring Team’s assistance to correct the problem to the Monitoring Team’s satisfaction.  Direct any questions regarding interpretation of circumstances to the Laboratory.

D.      Contractor Tests are Verified.  Production is acceptable if:

1.      The Monitoring Team verifies the Contractor’s QCP is being fully followed; and

2.      The Department VA tests are within the limits specified in 403.06.C; and

3.      For Basic mixes, the remaining sieves do not exceed the limits of the applicable specification.

Failure on the Contractor’s part to respond and resolve Monitoring Team concerns may result in a change to Unconditional Acceptance.

Acceptance is based on Table 403.06-2.

Table 403.06-2  Mix Acceptance

Mix Type

Acceptance Tolerances or Method

Deviation

from JMF

[1]

Range

Basic Mixes
(no acceptance limits stated in appropriate specification)

Asphalt Binder Content

±0.5%

1.0

No. 4 (4.75 mm) sieve

±6%

12

Basic Mixes
(acceptance limits stated in appropriate specification)

Use acceptance limits in appropriate specification

448 Mixes

Calculate pay factor according to 403.08

446 Mixes

Calculate pay factor according to 446.05

[1] Based on the average of the day or night QC Tests

E.      Contractor Tests not Verified.  If the Department VA test does not verify the accompanying Contractor tests within the verification tolerances, then the Monitoring Team will investigate.

If the deviation between the District and Contractor test is greater than the limits in Table 403.06-3 immediately cease production until resolved.  If the deviation is less than the limits in Table 403.06-3 and discrepancies continue, perform additional tests to aid in problem solving.

Table 403.06-3  Deviation Limits

Property

Mix

Limits

Asphalt Binder Content

All

±0.5 %

No. 4 (4.75 mm) sieve

All, except 302

±6.0%

302

±7.0%

Additional tests may include any testing necessary to resolve the problem.  If the additional testing does not resolve the problem by one-half production day or 1000 tons (1000 metric tons), whichever occurs first, to the Monitoring Team’s satisfaction, stop production, if not already, until problems are resolved.  Contact the Laboratory for assistance in resolving problems.  If the District testing program is confirmed by the additional tests and Monitoring Team investigation and no reason to question the original test exists, then the original District VA tests will stand.

After the above investigation, one of the three following actions will occur:

1.      Mix Production Compares Well to the JMF.  If the District test and investigation shows mix is actually controlled well compared to the JMF in spite of the Contractor test, the District does not have to test additional samples if the Contractor testing problem is corrected.

2.      Mix Production Does Not Compare Well to the JMF.  If the District tests and investigation shows lack of Contractor mix control compared to the JMF the District will test the remaining Department split or Daily samples for the days or Lots represented by the original tests.  The District will use the test results to calculate the acceptance.  While working with the District, immediately take steps to correct the problem according to the QCP.  Failure to achieve a quick resolution will result in a change to Unconditional Acceptance.

3.      District Testing Problem.  If the District testing program has a problem as confirmed by the additional testing and District review, the District will correct the problem, throw out the original District test results and take new samples from the samples representing the days or Lots in question for the VA tests.

F.      Contractor Removal, Restoration.  If repeated problems with poor comparison of tests are not the District’s fault; or poor comparison of Contractor tests to the JMF; or with plant operation, input materials, or any of the other requirements of Department specifications occur in a single project or successive projects, the District will request an opinion from the QCQC before notifying the Contractor of removal from Department VA.  The District will immediately notify the Contractor of the removal with a follow up letter from the District Engineer of Tests.  Once notified, acceptance of asphalt mixtures is by Unconditional Acceptance.  Restoration of the VA procedures may occur on a future project with a District recommendation to the QCQC based on consistent improved plant operation and mix control, a review of the Contractor problems and resolutions, and a review of the QCP by the QCQC.

403.07  Unconditional Acceptance.  If the Contractor is removed from Department VA, the following will occur.

The Contractor must bring its QCP and operation to a level acceptable to the District and QCQC before production continues.  The DET will ensure that the project C-95 (Contractor’s Prequalification Rating survey) will reflect the change to Unconditional Acceptance in all of the appropriate C-95 categories.  The Department will accept all material for Department projects from the facility under Unconditional Acceptance.  While the facility is under Unconditional Acceptance, acceptance of small quantities under the small quantities policy will not apply.

Quality control testing requirements specified in 403.05 are modified as follows:

A.      The required number of test series is a minimum of four each per production day or night.  If a production day is less than 6 hours, the Department may reduce the frequency but not less than one test series per every 3 production hours.

B.      For Basic mixes, if the variation from the JMF for one test is ±8 percent passing the No. 4 (4.75 mm) sieve or ±0.3 percent asphalt binder content, investigate and correct the problem, then resample and test.  Maintain the moving average of three tests within ±4 percent passing the No. 4 (4.75 mm) sieve and ±0.2 percent asphalt binder content.  In addition to the Quality Control Report, maintain control charts according to 441.10 for asphalt binder content and the No. 4 (4.75 mm) sieve.  If the Range difference in any three consecutive tests is greater than 0.6 percent for asphalt binder content or 10.0 percent passing the No. 4 (4.75 mm) sieve, notify the Monitoring Team.  If Range deviations as specified continue, cease production.

C.      Report each day’s testing on a Quality Control Report, according to 446.04.  Report all testing performed by the Contractor’s technician on the Quality Control Report.  After startup adjustments, report any plant operation changes on the Quality Control Report.  Ensure that each Quality Control Report contains technician comments as to production quality, input materials received, and condition and includes any other quality control activities required in the QCP.  The Contractor’s technician must sign each Quality Control Report.  Attach each day’s computerized plant printouts to that day’s report.  The technician must note on the accompanying printout in which tonnage the quality control sample was taken with accompanying test results for asphalt binder content and percent passing the No. 4 (4.75 mm) sieve.  Keep a copy of all Quality Control Reports for a project in the Contractor’s plant laboratory.

The District will monitor according to 441.06, except notification for ceasing production does not have to be in writing.  Additional samples may be obtained for Department test at any time.

For Basic mixes, if the average of the Lot or partial Lot acceptance tests for any sieve other than the No. 4 (4.75 mm) sieve exceeds the specification limits, the pay factor is determined as follows:

Table 403.07-1  Basic Mix Pay Factors

Number of Tests

1

2

3

4

Pay Factor

0.98

0.97

0.96

0.95

For Item 448 mixes, the Department will perform acceptance sampling and testing according to 403.06 and 403.08, except the Lot size will be 5000 tons (5000 metric tons) with 1250 ton (1250 metric tons).  Sublots and acceptance samples may be taken from the roadway or plant at the Districts discretion.  Department testing under Unconditional Acceptance will receive a lower testing priority than other VA projects.

403.08  Acceptance Tables for 448 Mixes.  A Lot is considered acceptable for gradation and asphalt binder content if the deviation of the average from the JMF and the Range is no more than the tolerances shown in Table 403.08-1.

Table 403.08-1  Deviation from the JMF
and Range Tolerances [1]

Mix Property

Deviation from JMF

(Percent)

Range

(Percent)

Asphalt Binder Content

0.3

1.0

1/2 inch (12.5 mm) sieve

6

15

No. 4 (4.75 mm) sieve

5

15

No. 8 (2.36 mm) sieve

4

15

[1]  Based on average of four Lot Acceptance tests.

If the average of the Lot acceptance tests for a particular sieve or sieves, or for asphalt binder content deviates from the JMF by more than the tolerances shown in Table 403.08-1, but falls within the tolerances shown in Table 403.08-2, then the Lot is considered reasonably acceptable and may remain in place with payment at a reduced pay factor as show in Table 403.08-2.

If the Range of the Lot acceptance tests for asphalt binder content or for any particular sieve, or sieves, exceeds the tolerance shown in Table 403.08-1, the Department will apply a pay factor of 0.95.

Table 403.08-2  448 Acceptance Schedule [1]

Mix

Property

Pay

Factor

2

Tests

3

Tests

4

Tests

Asphalt

Binder

Content

1.00

0 to 0.47

0 to 0.36

0 to 0.30

0.98

0.48 to 0.54

0.37 to 0.42

0.31 to 0.35

0.90

0.55 to 0.61

0.43 to 0.48

0.36 to 0.40

0.80

0.62 to 0.68

0.49 to 0.54

0.41 to 0.45

0.60

0.69 to 0.75

0.55 to 0.59

0.46 to 0.50

[2]

> 0.75

> 0.59

> 0.50

1/2 inch

(12.5 mm)

sieve

1.00

0 to 8.5

0 to 6.9

0 to 6.0

0.99

8.6 to 9.9

7.0 to 8.1

6.1 to 7.0

0.97

10.0 to 11.3

8.2 to 9.2

7.1 to 8.0

0.94

11.4 to 12.7

9.3 to 10.4

8.1 to 9.0

0.90

12.8 to 14.1

10.5 to 11.5

9.1 to 10.0

[3]

> 14.1

> 11.5

> 10.0

No. 4

(4.75 mm)

sieve

1.00

0 to 7.1

0 to 5.8

0 to 5.0

0.99

7.2 to 8.5

5.9 to 6.9

5.1 to 6.0

0.97

8.6 to 9.9

7.0 to 8.1

6.1 to 7.0

0.94

10.0 to 11.3

8.2 to 9.2

7.1 to 8.0

0.90

11.4 to 12.7

9.3 to 10.4

8.1 to 9.0

[3]

> 12.7

> 10.4

> 9.0

No. 8

(2.36 mm)

sieve

1.00

0 to 5.7

0 to 4.6

0 to 4.0

0.99

5.8 to 7.1

4.7 to 5.8

4.1 to 5.0

0.97

7.2 to 8.5

5.9 to 6.9

5.1 to 6.0

0.94

8.6 to 9.9

7.0 to 8.1

6.1 to 7.0

0.90

10.0 to 11.3

8.2 to 9.2

7.1 to 8.0

[3]

> 11.3

> 9.2

> 8.0

[1]  Based on average of Lot Acceptance tests from the JMF.

[2]  Remove and replace material

[3]  Engineer will determine if the material may remain in place.  Pay factor for material allowed to remain in place is 0.70.

The Department will determine payment for the Lot by multiplying the contract unit price by the pay factor.  When two or more pay factors for a specific Lot are less than 1.00, use lowest pay factor to calculate the payment.

The Department will base acceptance of partial Lots on the average and the Range of the results of tests on the number of samples obtained.

ITEM 407  TACK COAT

407.01  Description

407.02  Materials

407.03  Equipment

407.04  Weather Limitations

407.05  Preparation of Surface

407.06  Application of Asphalt Material

407.07  Method of Measurement

407.08  Basis of Payment

407.01  Description.  This work consists of preparing and treating a paved surface with asphalt material, and cover aggregate if required.

407.02  Materials.  Conform to the applicable requirements of 702 for the asphalt material and use one of the following types: 702.04 RS-1, SS-1, SS-1h, CRS-1, CSS-1, or CSS-1h; or 702.13.

Conform to 703.06 for cover aggregate.

407.03  Equipment.  Provide adequate cleaning equipment, spreader boxes, and distributors.

Use distributors designed, equipped, maintained, and operated to apply asphalt material at the specified rate per square yard (square meter) with uniform pressure over the required width of application.  Ensure that the distributor includes a tachometer, pressure gauges, accurate volume measuring devices, or a calibrated tank.  Mount an accurate thermometer with a range covering the specified application temperature for asphalt material at approximately center height of the tank with the stem extending into the asphalt material.  Ensure that the distributor has a full-circulating system with a spray bar that is adjustable laterally and vertically.  Ensure that the spray bar will maintain a constant height above the pavement under variable load conditions.  Supply each distributor with suitable charts showing truck and pump speeds and other pertinent application data necessary to obtain the required results.

Do not use equipment that cannot obtain the correct tack application.

407.04  Weather Limitations.  Do not apply the asphalt material if the surface temperature is below the minimum placement temperature for the pavement course to be placed, as specified in 401.06.

407.05  Preparation of Surface.  Ensure that the surface is thoroughly clean and dry when the asphalt material is applied.  Remove material cleaned from the surface and dispose of it as the Engineer directs.

407.06  Application of Asphalt Material.  Uniformly apply the asphalt material with a distributor having clean nozzles functioning properly.  Obtain the Engineer’s approval for dilution with water, if desired to achieve a more uniform application.  The Department will not pay for diluted tack used without approval.  Ensure any diluted asphalt material used for tack has a minimum viscosity of 20 seconds Saybolt Furol (702.04).

For irregular areas such as driveways and intersections, apply the asphalt material using a method the Engineer approves.

If paving asphalt concrete directly onto Portland cement concrete or brick pavement, tack the pavement with SBR asphalt emulsion conforming to 702.13.

Before placing a surface course onto an intermediate course, apply a tack coat on the intermediate course.

Apply the tack coat in a manner that offers the least inconvenience to traffic.  Only apply the tack coat to areas that will be covered by a pavement course during the same day. Ensure the tack breaks before releasing to traffic unless the paver is equipped with a spray bar system to apply tack just prior to mat placement.

Obtain the Engineer's approval for the quantity, rate of application, temperature, and areas to be treated before application of the tack coat.  The Engineer will determine the actual application in gallons per square yard (liters per square meter) by a check on the project. 

The application is considered satisfactory when the actual rate is within ±10 percent of the required rate and the material is applied uniformly with no visible evidence of streaking, ridging or pickup by construction traffic.  The Engineer will require proper correction when ridging, streaking, pickup or other non-uniform coverage is observed.  Correct non-uniform tack only in areas of non-uniform coverage.  Do not reapply tack in areas where the tack meetings uniformity and application requirements.

If the coverage is not uniform and not corrected the total square yardage of non-uniform application will be considered non specification material.  The Engineer will determine the number of gallons (liters) for non-payment by using the approved rate of application times the total square yards (square meters) of non-uniform application.

407.07  Method of Measurement.  The Department will measure Tack Coat and Tack Coat for Intermediate Course by the number of gallons (liters) of undiluted asphalt material applied for each according to Item 109.

407.08  Basis of Payment.  The cost of cover aggregate and water to dilute an emulsion is incidental to Tack Coat.

The Department will not pay for non-uniformly applied materials as defined in 407.06.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

407             Gallon (Liter)                  Tack Coat

407             Gallon (Liter)                  Tack Coat for Intermediate Course

ITEM 408  PRIME COAT

408.01  Description

408.02  Asphalt Material

408.03  Cover Aggregate

408.04  Weather Limitations

408.05  Equipment

408.06  Preparation of Surface

408.07  Application of Asphalt Material

408.08  Application of Cover Aggregate

408.09  Method of Measurement

408.10  Basis of Payment

408.01  Description.  This work consists of preparing and treating an existing surface with asphalt material, and cover aggregate if required.

408.02  Asphalt Material.  Conform to the applicable requirements of 702 for asphalt material and use one of the following types:  702.02 MC-30, MC-70, or MC-250; or 702.03 Primer 20.

408.03  Cover Aggregate.  Use cover aggregate conforming to No. 9 size or gradation requirements of 703.05 or 703.06.

408.04  Weather Limitations.  Do not apply asphalt material on a wet surface.  Do not apply prime coats for asphalt concrete or surface treatment work when the atmospheric temperature is below 50 °F (10 °C) or when the air temperature within the preceding 24 hours has been 40 °F (5 °C) or lower.  Do not apply prime coats on stabilized or granular base courses when the atmospheric temperature is below 40 °F (5 °C).

408.05  Equipment.  Use equipment conforming to 407.03.

408.06  Preparation of Surface.  Shape the surface to be primed to the required grade and section.  Ensure the surface is free from all ruts, corrugations, segregated material or other irregularities and is smooth and uniformly compacted at the time of application of the asphalt material.  Clean the surface in a manner that will thoroughly remove all mud, earth, and other foreign material.  Take care to clean the edges of road to be primed to ensure uniform application of the asphalt material directly onto the existing base or pavement surface.  Remove material cleaned from the surface and dispose of it as the Engineer directs.

408.07  Application of Asphalt Material.  Apply asphalt material in a uniform manner spread to the width of the section to be primed by means of a distributor conforming to 407.03.  When traffic is maintained, do not treat more than one-half of the width of the section in one application.  Take care that the application of asphalt material at the junction of spreads is not in excess of the specified amount.  Squeegee excess asphalt material from the surface.  Correct skipped areas or deficiencies.

When traffic is maintained, allow one-way traffic on the untreated portion of the road bed.  As soon as the asphalt material has been absorbed by the surface and will not be picked up, transfer traffic to the treated portion and prime the remaining width of the section.  Obtain the Engineer's approval for the quantity, rate of application, temperatures and areas to be treated before application of the prime coat.

408.08  Application of Cover Aggregate.  If, after applying the prime coat, the asphalt material fails to penetrate and traffic must use the roadway, spread cover aggregate in the amount required to absorb any excess asphalt material.

408.09  Method of Measurement.  The Department will measure Prime Coat by the number of gallons (liters) according to 109.

408.10  Basis of Payment.  The cost of cover aggregate is incidental to Prime Coat.

The Department will pay for accepted quantities, complete in place, at the contract price as follows:

Item           Unit                                Description

408             Gallon (Liter)                  Prime Coat

ITEM 409  SAWING AND SEALING ASPHALT CONCRETE PAVEMENT JOINTS

409.01  Description

409.02  Materials

409.03  Construction Details

409.04  Method of Measurement

409.05  Basis of Payment

409.01  Description.  This work consists of saw cutting and sealing the finished surface of the asphalt concrete pavement and shoulders directly over and in line with transverse joints in the underlying Portland cement concrete pavement.

409.02  Materials.  Use joint sealant conforming to 705.04 and approved by the Laboratory before shipment to the project.  Use a 1/2 inch (13mm) diameter closed cell foam backer rod that will form and maintain a reservoir of sealant as specified in 409.03.

409.03  Construction Details.  Saw cut, clean, and seal transverse joints as a continuous operation.  If the surface course is not placed within 5 days after the intermediate course is placed, make a 1/8-inch (3 mm) wide saw cut that is one-fourth the depth of the intermediate course over contraction joints and a 1/2-inch (13 mm) wide cut that is one-fourth the depth of the intermediate course expansion joints.

Saw joints in the surface course as soon as the saw can be operated without damaging the asphalt concrete, but no later than 48 hours after the asphalt concrete is placed.

Locate the sawed joints directly over each existing transverse pavement joint, including joints at full-depth pavement repairs.  Accurately locate joints with pins or stakes before paving.  Pre-mark the saw cut on the new asphalt surface with a chalk line or other acceptable method.  Obtain the Engineer's approval of the method for locating and accurately marking the proposed saw cuts before starting any resurfacing operations.

Saw all transverse joints and create a joint sealant reservoir according to the following table:

Measurement

Inch (mm)

Saw cut depth

2 (50)

Backer rod diameter

1/2 (13)

Joint sealant reservoir

   Width

3/8 (10)

   Depth

3/4 (19)

   Recess below surface course

1/8 (3)

The Contractor may make one pass to achieve the full width and depth of the saw cut.  Use either dry or wet cutting.

Clean dry sawed joints with compressed air to remove dirt, dust, or deleterious matter.  Use an air compressor with a minimum rated capacity of 100 pounds per square inch (689 kPa) and sufficient hose for continuous cleaning operations.

Clean wet sawed joints with a water blast to remove sawing slurry, dirt, or deleterious matter.  Dry wet sawed joints with a propane torch or lance unit capable of producing a blast of hot air at 2000 °F (1093 °C) and with a gas velocity of 2000 feet per second (610 m/s).

Extend the transverse saw cut joints the full width of the asphalt over the concrete pavement and paved shoulders.

Do not allow traffic to knead together or damage the sawed joints before sealing.

Heat joint sealant material in a kettle or melter constructed as a double boiler, with the space between the inner and outer shells filled with oil or other heat transfer medium.  Provide positive temperature control and mechanical agitation.

Heat the material according to the manufacturer’s recommendation.  Consider the first gallon (4 L) of material that flows out of the applicator wand at the start of the day spoil, and discard it into a container so designated.

After cleaning, place the backer rod in the sawed joints, then immediately seal the joints with hot-poured sealant applied through a nozzle projected into the sawed joint, filling from the bottom up.  Ensure that the seal completely fills the joint such that after cooling, the level of the seal is not greater than 1/8 inch (3 mm) below the pavement surface.  Fill any depression in the seal greater than 3/16 inch (5 mm) to the specified limit by adding additional hot poured sealant.  Do not overfill the joints.  Take care in the sealing of the joints so that the final appearance will present a neat line.

409.04  Method of Measurement.  The Department will measure Sawing and Sealing Asphalt Concrete Pavement Joints by the number of feet (meters) of joints sawed and sealed.

409.05  Basis of Payment.  The Department will not pay for saw cuts in the intermediate course.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

409             Foot (Meter)                    Sawing and Sealing Asphalt
                                                               Concrete Pavement Joints

ITEM 410  TRAFFIC COMPACTED SURFACE

410.01  Description

410.02  Materials

410.03  Conditioning of the Subgrade

410.04  Spreading and Shaping

410.05  Maintaining

410.06  Method of Measurement

410.07  Basis of Payment

410.01  Description.  This work consists of furnishing and placing an aggregate wearing course on the completed and accepted subgrade or temporary road.

410.02  Materials.  Furnish materials conforming to 703.18 for the type of material specified (Type A, Type B, or Type C). 

410.03  Conditioning of the Subgrade.  Eliminate wavy and irregular surfaces and maintain the subgrade in this condition until the application of material under this item.  If the subgrade is soft due to rain, frost, or snow, place material only as permitted.

410.04  Spreading and Shaping.  Uniformly spread the material using an approved spreader box or by other methods.  Spread the amount of material shown on the plans or as directed by the Engineer.  After spreading, blade and shape the materials to the specified cross-sections.  Haul the material to its place on the road over the previously spread material.  Conduct the hauling to obtain uniform compaction over the entire width of the surface material without rolling.

410.05  Maintaining.  After shaping the material, blade it as directed by the Engineer.  Open the road to traffic immediately after all the material has been spread and shaped.

Correct all holes, ruts, defects, or soft places that occur in the subgrade or surface by adding material and dragging.  Maintain the surface, slopes, shoulders, ditches, and drainage structures until the work on this item has been completed and accepted.

410.06  Method of Measurement.  The Department will measure Traffic Compacted Surface, Type ___ by the number of cubic yards (cubic meters) or tons (metric tons) of accepted material placed, shaped, and maintained as specified.

The Department will measure the cubic yards (cubic meters) of aggregate used loose in the vehicle at the point of delivery or calculate it by converting from weight using the following conversion factors:

TABLE 410.06-1

Material

Conversion Factor

Gravel, bank run or crusher run

2700 lb/yd³

1600 kg/m³

Limestone, crusher run

2500 lb/yd³

1485 kg/m³

Gravel, Size No. 4 and 57

2500 lb/yd³

1485 kg/m³

Limestone, Size No. 4 and 57

2400 lb/yd³

1425 kg/m³

Crushed slag [1]

   less than 80 lb/ft³ (1300 kg/m³)

2000 lb/yd³

1185 kg/m³

   80 to 90 lb/ft³ (1300 to 1450 kg/m³)

2100 lb/yd³

1250 kg/m³

   90.1 to 100 lb/ft³ (1451 to 1600 kg/m³)

2300 lb/yd³

1365 kg/m³

   100.1 to 125 lb/ft³ (1601 to 2000 kg/m³)

2700 lb/yd³

1600 kg/m³

   more than 125 lb/ft³ (2000 kg/m³)

3000 lb/yd³

1780 kg/m³

Recycled Portland Cement Concrete

2250 lb/yd³

1335 kg/m³

Recycled Asphalt Concrete Pavement

2650 lb/yd³

1570 kg/m³

[1]  Based on average dry rodded weight determined by the Laboratory.  The conversion factors listed are the long gradation weights.  These numbers are based on the dry rodded weights of Nos. 67, 57, or 8 gradation.  The Department will determine slag weights based on weights obtained from the original source.

The Department will classify salvaged or mixed materials according to the material that makes up the majority of the mixture. 

Ensure that the moistures of the delivered material are less than 2 percent above saturated surface dry condition; if not, the Department will base payment on the dry densities and dry weights.

Furnish freight bills, and weight and volume evidence according to 109.

410.07  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

410             Cubic Yard or Ton          Traffic Compacted Surface, Type A or B
                       (Cubic Meter                  
                       or Metric Ton)

410             Cubic Yard or Ton          Traffic Compacted Surface, Type C
                       (Cubic Meter                  
                       or Metric Ton)

ITEM 411  STABILIZED CRUSHED AGGREGATE

411.01  Description

411.02  Materials

411.03  Construction Methods

411.04  Method of Measurement

411.05  Basis of Payment

411.01  Description.  This work consists of placing a compacted course or courses of crushed aggregate.

411.02  Materials.  Furnish materials conforming to 703.18.

411.03  Construction Methods.  Construct the subgrade according to Item 204.  Use the spreading and compaction requirements of Item 304, except as modified by the following:

A.      Use a maximum compacted lift thickness of 6 inches (150 mm).

B.      Perform the initial compaction of the material by using crawler type tractors, tamping rollers, trench rollers, suitable pneumatic tire equipment, or other suitable equipment.

C.      Perform final compaction of the surface of the stabilized crushed aggregate by using approved pneumatic tire equipment.

411.04  Method of Measurement.  The Department will measure Stabilized Crushed Aggregate by the number of cubic yards (cubic meters), computed from the profile grade, cross-sections and typical sections, compacted in place.

When the plans provide for the use of material in variable width or depth of course and the quantity cannot be readily calculated from the profile grade, typical sections and cross-sections, the Department will measure the cubic yards (cubic meters) by converting from weight using the following conversion factors:

Table 411.04-1

Material

Conversion Factor

Crushed stone

3800 lb/yd³

2250 kg/m³

Crushed gravel

3900 lb/yd³

2310 kg/m³

Crushed slag [1]

   less than 90 lb/ft³ (1450 kg/m³)

3600 lb/yd³

2140 kg/m³

   90 to 100 lb/ft³ (1450 to 1600 kg/m³)

4000 lb/yd³

2375 kg/m³

   more than 100 lb/ft³ (1600 kg/m³)

4500 lb/yd³

2670 kg/m³

Granulated slag

2800 lb/yd³

1660 kg/m³

Recycled Portland Cement Concrete

3400 lb/yd³

2020 kg/m³

Recycled Asphalt Concrete Pavement

4000 lb/yd³

2375 kg/m³

[1]  Based on average dry rodded weight of standard size of slag aggregates on record at the Laboratory.  The conversion factors listed are the long gradation weights.  These numbers are based on the dry rodded weights of Nos. 67, 57, or 8 gradation.  The Department will determine slag weights based on weights obtained from the original source.

The Department will classify salvaged or mixed materials according to the material that makes up the majority of the mixture.

Ensure that the moistures of the delivered material are less than 2 percent above saturated surface dry condition; if not, the Department will base payment on the dry densities and dry weights.

Furnish freight bills or certified weight bills according to 109.

411.05  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

411             Cubic Yard                      Stabilized Crushed Aggregate
                       (Cubic Meter)             

ITEM 421  MICROSURFACING

421.01  Description

421.02  Materials

421.03  Proportioning

421.04  Weather Limitations

421.05  Mixing Equipment

421.06  Equipment Calibration

421.07  Spreading Equipment

421.08  Surface Preparation

421.09  Test Strip

421.10  Application

421.11  Acceptance

421.12  Method of Measurement

421.13  Basis of Payment

421.01  Description.  This work consists of constructing a cold laid polymer modified emulsified asphalt pavement course to fill ruts or provide a leveling and/or surface course for existing pavements.  The paving mixture is composed of a polymer modified emulsified asphalt binder, crushed aggregate, mineral filler, water, and other additives.

421.02  Materials. Use a polymer modified emulsified asphalt binder (Binder) consisting of the following materials milled together:

A.      Natural SBR latex modifier or synthetic SBR latex modifier conforming to 702.14. Use only one type of latex.

B.      CSS-1h or CSS-1m (as required below) emulsified asphalt conforming to 702.04, except the cement-mixing test is waived. Use only emulsion certified according to Supplement 1032.

C.      Other emulsifiers.

Use CSS-1mL (as defined below) if the project ADTT is less than 2000, otherwise use CSS-1hL (as defined below). Do not use port addition of the polymer to the emulsified asphalt. Provide to the Engineer certified test data and a statement from the Binder manufacturer with each load of Binder that the Binder is the same formulation as used in the mix design. Ensure the Binder meets one of the following:

CSS-1hL: Combine CSS-1h and SBR latex modified (L) to yield 3 percent SBR solids based on the weight of the asphalt binder content of the Binder. Ensure that the SBR latex modified residue conforms to the following requirements:

Test

Description

Specification

AASHTO T 59

Residue by Evaporation

62 %

AASHTO T 53

Softening Point

60 °C minimum

AASHTO T 202

Absolute Viscosity @ 60 °C

8000 poise minimum

CSS-1mL: Combine CSS-1m and SBR latex modifier (L) to meet the following properties.

Tests on emulsion, ASTM D 244, unless otherwise designated:

Viscosity, Saybolt Furol, ASTM D 88, at 25 °C (sec)

20 to 100

Storage Stability Tests, 24-hr (% difference)

1 maximum

Particle Charge Tests

Positive

Sieve Tests (%) (Distilled Water)

0.10 maximum

Distillation to 260 °C, % by Weight, Residue, min[1]

62

Tests on distillation residue:

Penetration, 25 °C, 100 g, 5 sec (dmm) ASTM D 5

70 to 90

Ductility, 4 °C, 5 cm/min, ASTM D 113

40 minimum

Elastic Recovery, 4 °C, 10 cm (%)[2]

65 minimum

Softening Point, Ring & Ball (°C) ASTM D 36

60 minimum

[1]  ASTM D 244, with modifications to include a 400 °F ± 10 °F (204 °C ± 6 °C) maximum temperature to be held for 15 minutes.

[2]  Straight molds. Hold at test temperature for 90 minutes. Place in ductilometer and elongate 10 cm at 5 cm/min. Hold for 5 minutes and cut. After 1 hour retract the broken ends to touch and measure the elongation (X) in centimeters. Use the following formula to calculate the elastic recovery:

Conform to 703.01 and 703.05 for aggregate, except as follows:

Percent by weight of fractured pieces

100

Sand Equivalence (ASTM D 2419)

45 minimum

Conform to Gradation A for the aggregate for leveling and surface courses and to Gradation B for the aggregate for rut fill courses according to the following:

Sieve Size

Total Percent Passing

A

B

3/8 inch

(9.50 mm)

100

100

No. 4

(4.75 mm)

85 to 100

70 to 90

No. 8

(2.36 mm)

50 to 80

45 to 70

No. 16

(1.18 mm)

40 to 65

28 to 50

No. 30

(600 µm)

25 to 45

19 to 34

No. 50

(300 µm)

13 to 25

12 to 25

No. 100

(150 µm)

–

7 to 18

No. 200

(75 µm)

5 to 15

5 to 18

Screen the aggregate for oversize material prior to use. For mineral filler, use Portland cement conforming to ASTM C 150, Type I. Use water conforming to 499.02. Use mix set additives as required.

421.03  Proportioning.  Submit to the Laboratory a sample of the Binder to be used and a complete mix design prepared by an approved laboratory. Verify the compatibility of the aggregate, Binder, mineral filler, and other additives.  Make the mix design with the same materials that will be used on the project.

Ensure that the mix design:

A.      Has aggregate meeting the gradation specified.

B.      Has residual asphalt by dry weight of aggregate of 7.0 to 8.5 percent for leveling and surface courses or 6.5 to 8.0 percent for rut fill courses.

C.      Has a mineral filler content of 0.25 to 3.5 percent by dry weight of aggregate.

D.      Meets the specified properties of the following International Slurry Seal Association (ISSA) tests:

ISSA Test No.

Description

Specification

TB-139  (1-90)

Wet Cohesion

30 minutes min. (set time)

12 kg-cm min.

60 minutes min. (traffic)

20 kg-cm min or near spin

TB-114  (1-90)

Wet Stripping

90 percent min.

TB-100  (90)

Wet Track Abrasion Loss

1-hour soak

6 day soak

450 g/m² max.

650 g/m² max.

TB-144  (2-89)

Saturated Abrasion

Compatibility

3 g loss max.

TB-113  (1-90)

Mix Time @ 25 °C

Controllable to 120 seconds

Mix Time @ 40 °C

Controllable to 35 seconds

Check the ISSA TB-139 (set time) and ISSA TB-113 (mix time) tests at the highest temperature expected during construction.  For the ISSA TB-113 test at 104 °F (40 °C), preheat all ingredients and containers.

Ensure that the final mix design states the following (all percentages are based on the dry weight of the aggregate):

A.      Source of each individual material.

B.      Aggregate gradation.

C.      Percentage of aggregate.

D.      Sand equivalence of the aggregate.

E.      Percentage of mineral filler (minimum and maximum).

F.      Percentage of water (minimum and maximum).

G.      Percentage of mix set additives (if required).

H.     Percentage of Binder and type.

I.       Quantitative effects of moisture content on the unit weight of the aggregate.

421.04  Weather Limitations.  Apply the mixture only when it is not raining and the existing pavement surface temperature is a minimum of 40 °F (5 °C) and there is no forecast of an atmospheric temperature below 32 °F (0 °C) within 24 hours from the time the mixture is applied.  Between September 30 and May 1, do not apply the mixture if the existing pavement surface temperature is less than 50 °F (10 °C).

421.05  Mixing Equipment.  Produce the mixture in a self-propelled, front feed, continuous loading mixing machine equipped with a conveyer belt aggregate delivery system and an interconnected positive displacement, water jacketed gear pump to accurately proportion aggregate and asphalt emulsion.  Locate the mineral filler feed so the proper amount of mineral filler is dropped on the aggregate before discharge into the pugmill.  Provide a spray bar to completely prewet the aggregate dropping down to the pugmill with additive and water before introduction of asphalt emulsion.  The twin-shaft, multi-blade pugmill will be a continuous flow type and minimum of 49 inches (1.25 m) long.  Ensure that the blade size and side clearances meet the equipment manufacturer’s recommendations.  Introduce the emulsion within the first one-third of the mixer length to ensure proper mixing of all materials before exit from the pugmill.

Equip the machine with opposite side driving stations to allow full control of the machine from either side.  Equip the mixer with a remote forward speed control at the back mixing platform so the back operator can control forward speed and level of mixture in the paving or rut box.  Provide material control devices that are readily accessible and positioned so the amount of each material used can be determined at any time.

Equip the mixing machine with a water pressure system and nozzle type spray bar to provide a water spray ahead of and outside the spreader box when required.  Apply water at a rate that will dampen the surface, but will not create free flowing water ahead of the spreader box.

The Contractor may use truck-mounted machines with a conveyer belt aggregate delivery system and without the front feed, continuous loading feature on project segments of less than 15,500 square yards (13,000 m²) or on spot repairs.

421.06  Equipment Calibration.  Before mix production, calibrate the mixing equipment in the presence of the Engineer.  Generate documentation for the Engineer, including individual calibrations of each material at various settings.  Perform a new calibration if there is any change in the mix design.  Supply all of the equipment, materials, and scales necessary to perform the calibration.  Following calibration and adjustments for changes in the mix design do not make any further calibration adjustments to the mixing equipment without the Engineer’s approval.

421.07  Spreading Equipment.  If a leveling or surface course is specified, apply the mixture uniformly by means of a conventional spreader box.

If a rut fill course is specified, apply the mixture with a V-shaped rut filling spreader box.  Equip the rut filling spreader box with a steel strike-off.

Attach either type of spreader box to the mixer and equip it with paddles mounted on an adjustable shaft to continually agitate and distribute the materials throughout the box.  Ensure that the equipment provides sufficient turbulence to prevent the mix from setting in the box or causing excessive side build-up or lumps.  To prevent loss of the mixture from the box, attach flexible seals, front and rear, in contact with the road.  Operate the spreading equipment in such a manner as to prevent the loss of the mixture on superelevated curves.

For surface courses, attach a secondary strike-off to the spreader.

The Contractor may use burlap drags or other drags, if necessary, to obtain the desired finish.  Replace drags having excessive build-up.

421.08  Surface Preparation.  Before applying the mixture, thoroughly clean the surface.

Remove raised pavement markers according to 621.08, when specified.  The Contractor may fill the depression caused by the removal of the casting with material meeting this specification.

Remove any existing pavement markings, except 740.02 (traffic paint), using an abrasion method conforming to 614.11,G. 

Apply a tack coat conforming to Item 407, consisting of one part asphalt emulsion and three parts water.  Apply the tack coat at a rate of 0.06 to 0.12 gallon per square yard (0.25 to 0.45 L/m²).

Protect drainage structures, monument boxes, water valve, etc. during material application.

421.09  Test Strip.  Construct a test strip for the Engineer to evaluate.  Construct this test strip 1000 feet (300 m) long, and include all of the application courses specified.  Construct the test strip at the same time of day or night the full production will be applied.  The Contractor may construct the test strip in 2 days or nights if multiple course applications are specified.

The Engineer will evaluate the completed test strip after 24 hours of traffic to determine if the mix design is acceptable.  The Contractor may begin full production after the Engineer accepts the test strip.

If the microsurfacing is not being applied between September 30 and May 1, the Department will waive the test strip if the Contractor has constructed a Department approved test strip this construction season with the same materials and mix design.

421.10  Application.  Apply the paving mixture in a manner to fill cracks, shallow potholes, and minor surface irregularities and achieve a uniform surface without causing skips, lumps, or tears.  Carry a sufficient amount of material at all times in all parts of the spreader box to ensure complete coverage.  Avoid overloading of the spreader box.  Do not allow lumping, balling, or unmixed aggregate in the spreader box.

If a rut fill course is specified, apply enough material to fill the wheel paths without excess crowning (overfilling).  An excess crown is defined as 1/8 inch (3 mm) after 24 hours of traffic compaction.  Apply rut fill courses in widths from 5 to 6 feet (1.5 to 1.8 m) for each wheel path.  Provide a smooth, neat seam where two rut fill passes meet.  Take care to restore the designed profile of the pavement cross-section.  Feather the edges of the rut fill course to minimize the use of excess material.

If a leveling course is specified, apply the paving mixture at 14 ± 2 pounds per square yard (7.6 ±1.1 kg/m²).

If a surface course is specified and it is placed on another microsurfacing course, apply the paving mixture at 16 ±1 pounds per square yard (8.7 ±0.6 kg/m²).  If a surface course is specified and it is not placed on another microsurfacing course, apply the paving mixture at a minimum of 18 pounds per square yard (9.8 kg/m²).

For leveling and surface courses, provide a smooth, neat seam of 1 to 3 inches (25 to 75 mm) where two passes meet.  Immediately remove excess material from the ends of each run.

Construct surface courses wide enough to cover the outside edges of rut fill and leveling courses.  Maintain straight edge lines along curbs and shoulders.  Do not allow runoff of these areas.  Ensure that lines at intersections are straight.

Use squeegees and lutes to spread the mixture in areas inaccessible to the spreader box and areas requiring hand spreading.  The Contractor may adjust the mix set additive to provide a slower setting time if hand spreading is needed.  Do not adjust the water content to adjust the setting time.  If hand spreading, pour the mixture in a small windrow along one edge of the surface to be covered and spread it uniformly by a hand squeegee or lute.

Ensure that the microsurfacing cures at a rate that will permit traffic on the pavement within 1 hour after application without damaging the pavement surface.  However, should the contractor have concerns about adequate cure, work out an arrangement agreeable to the project before releasing traffic on the pavement.

If there is an excessive streaking problem created by high amounts of oversize material in the mix, stop applying the mixture and take steps to correct the streaking problem.  Do not resume work until the Engineer is satisfied the problem has been corrected.

If a section of pavement is not going to be exposed to traffic within 48 hours, compact it with a pneumatic tire roller after curing.  Conform the pneumatic tire roller to 401.13, and inflate the tire pressure to 40 to 60 pounds per square inch (275 to 400 kPa).

421.11  Acceptance.  Maintain continuous control of the binder to dry aggregate proportioning to conform to the approved mix design within a tolerance of ±2 gallons per ton (±8.5 L/metric ton).  Control the spread rate to not less than the specified quantity of aggregate per square yard (square meter) on a dry weight basis.

The Engineer will base acceptance of the Binder to dry aggregate proportion and spread rate on the Engineer’s summary of quantities used each day.  The Engineer will approve and accept a day’s application of microsurfacing provided:

A.      The Engineer’s summary indicates conformance with the above control requirements for proportioning and spread rate and

B.      The pavement is free from excessive scratch marks, tears, rippling and other surface irregularities, longitudinal joints and lane edges coincide with any lane lines and edge lines and transverse joints are uniform, neat and provide a smooth transition.

The spread rate requirement does not apply to rut fill courses if the Contractor filled the wheel paths according to this specification.

421.12  Method of Measurement.  The Department will measure Microsurfacing, Surface Course and Microsurfacing, Leveling Course by the number of square yards (square meters), complete and accepted in place.  The Department will base the width of the pavement course on the width shown on the plans, specified in this specification, or directed by the Engineer.  The Department will measure the length along the centerline of each roadway or ramp.

The Department will measure the number of raised pavement markers removed.

The Department will measure Microsurfacing, Rut Fill Course by the number of tons (metric tons) of dry aggregate used, complete and accepted in place.  The Department will base the weight of the dry aggregate used on the ticket net weight of individual loads from an approved scale.

421.13  Basis of Payment.  The cost of tack coat is incidental to Microsurfacing.

The cost of any removal of any existing longitudinal pavement markings according to 421.08 is incidental to Microsurfacing.

The Department will pay for removal of existing raised pavement markers according to Item 621 Raised Pavement Markers Removed.

The Department will pay for the construction of accepted test strips at the individual bid prices for the courses constructed.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

421           Square Yard                 Microsurfacing, Surface Course
                     (Square Meter)

421           Square Yard                 Microsurfacing, Leveling Course
                     (Square Meter)

421             Ton                                  Microsurfacing, Rut Fill Course

                       (Metric Ton)

Item 422  CHIP SEAL

422.01  Description

422.02  Materials

422.03  Equipment

422.04  Weather Limitations

422.05  Test Strip

422.06  Surface Preparation

422.07  Binder Application

422.08  Cover Aggregate Application

422.09  Construction Operation

422.10  Quality Control

422.11  Acceptance

422.12  Method of Measurement

422.13  Basis of Payment

422.01  Description.  This work consists of preparing and applying a single or double chip seal.

422.02  Materials.  Use polymer emulsified binder conforming to 702.16 Type A.

Provide cover aggregate for the chip seal Job Mix Formula (JMF) of washed limestone or dolomite conforming to 703.05.  Do not use an aggregate source designated with “SR” on the Aggregate Source Group list in accordance with 703.01.F.  Additionally the following requirements apply:

Stockpile the material to be used for the chip seal at the aggregate source. 

Obtain five (5) samples from the stockpile and perform gradation testing on each sample and determine the percent passing for each sieve size listed in Table 422.02-1

A.      Calculate the total range for the No. 8 (2.36 mm) sieve for all five samples.  The range will not exceed 6%.

B.      Calculate the percent passing the No. 200 (75 µm) sieve for each sample.  No single sample value will exceed 2.0 percent.

C       Calculate the average of each sieve for all five samples.  Assure the average value for each sieve is within the requirements of Table 422.02-1.

Submit a letter to the Engineer and DET containing the Job Mix Formula (JMF) gradations and the calculations to show the cover aggregate meets requirements.

If a staging location will be used for the chip seal aggregate first move the initially tested aggregates from the aggregate source stockpile to the staging location and construct a staging stockpile.  Then obtain five (5) aggregate samples from the staging location stockpile and perform gradation testing on each sample to determine the percent passing for each sieve size listed in Table 422.02-1.

Evaluate the staging location aggregate samples the same as the aggregate source samples except allow an average for the No. 200 (75 µm) sieve not greater than 1.7 percent.

Submit the Job Mix Formula (JMF) gradations from the staged stockpile and the calculations to show the cover aggregate meets requirements in letter form to the Engineer and DET.

If the chip seal aggregates fail to meet requirements, either at the aggregate source or the staging location, re-wash and/or rework the aggregate materials and retest the new stockpiles.

TABLE 422.02-1

Sieve Size

Total Percent Passing

1/2 inch

(12.5 mm)

100

3/8 inch

(9.5 mm)

85 to 100

No. 4

(4.75 mm)

5 to 25

No. 8

(2.36 mm)

0 to 10

No. 16

(1.18 mm)

0 to 5

No. 200

(75 µm)

0 to 1.5 [1]

[1]  Washed gradation value

The District may obtain and test validation samples of the JMF aggregates at any time. If a single validation sample is either outside the values in TABLE 422.02-1 with the exception that  the No. 200 (75 µm) value is not greater than 2.0 percent, the district will obtain five (5) samples and retest to determine if the aggregate JMF falls within the limits of TABLE 422.02-1.  If the JMF verification test doesn’t meet the source or staging location limits the stockpile is not acceptable.

422.03  Equipment.  Provide equipment conforming to the requirements of this section.  Obtain approval of equipment before starting the job.

Use equipment for binder distribution conforming to 407.03, except ensure that it has a computerized rate control that automatically adjusts the binder pump to the unit ground speed and has a gauge or meter in plain view for reading gallons (liters).  Use appropriate spray nozzles for the material and rate specified.

Use Type II pneumatic tire rollers conforming to 401.13, except the maximum capacity shall not apply.

Use self-propelled aggregate spreaders with a variable width aggregate hopper capable of placing from 8 to 16 feet (2.4 to 4.8 m) in any increment and a computerized rate control that automatically adjusts the aggregate output to the unit ground speed.  Equip spreaders with pneumatic tires, a screen to remove oversized material, revolving cylinders, and adjustments necessary to produce a uniform distribution of particles at the specified rate.

Use power sweepers or rotary brooms in initial surface preparation and for removing loose particles.  Use pickup type sweepers in areas where the aggregate shoulder does not exist.  Do not sweep loose aggregate onto lawns, curbed areas, or intersections.

Furnish accurate thermometers for determining any of the applicable temperature requirements of this specification.

422.04  Weather Limitations.  Place the chip seal when the pavement temperature is between 60 °F (16 °C) and 140 °F (60 °C).  Do not schedule the performance of this work for the time period before May 1 or after September 1.  Do not place chip seal if any of the following conditions exist:

A. The atmospheric temperature is below 70 °F (21 °C).

B. Impending weather conditions do not allow for proper curing.

C. If temperatures are forecasted below 50 °F (10 °C) within 24 hours from the time of work.

422.05  Test Strip.  Construct a continuous 1000-foot (300 m) long by lane width test strip. Do not waive test strips regardless if the same materials have been used on another project.

Determine the initial binder application rates and aggregate application rates for the test strip.

For a single chip seal, an initial target rate of 0.37 ±0.03 gallon per square yard (1.68 L/m²) is recommended for the test strip.  For double chip seal, a target rate of 0.36 ±0.03 gallon per square yard (1.54 L/m²) for the first course and 0.33 ±0.05 gallon per square yard (1.68 L/m²) for the second course is recommended for the test strip.  Notify the Engineer of the initial target rates.

Calibrate the aggregate spreader and verify the application rates with a one square yard (one square meter) piece of cardboard or other material to collect and weigh the aggregate. Do not over apply cover aggregate relying on vacuum and broom sweeping to pick up all excess. Amounts of loose aggregate that create a nuisance to the public will result in work stoppage. If work is stopped by the Engineer recalibrate the aggregate spreader determining a new application rate and apply cover aggregate at the new rate.  Verify the aggregate gradation during the test strip and give results to the Engineer.

The Engineer and Contractor will review the test strip the next workday for streaking, ridging, bleeding, aggregate loss or other problems. If the review shows the test strip meets the requirements of 422.11 and the application rate and quality control tests show all is in control compared to the JMF, then progress with the work. Should problems be noted, the Engineer may require another test strip.

422.06  Surface Preparation.  Clean the pavement according to 407.05.  If necessary, clean areas of the pavement with a hand broom. 

Remove all existing pavement markings, except 740.02 (traffic paint), using an abrasion method conforming to 614.11,G.   

For a single chip seal either remove and replace any existing raised pavement markers or protect the existing raised pavement markers from the single chip application process.

For a double chip seal application remove the raised pavement markers according to 621.08.

Do not place material until the Engineer approves the surface.

422.07  Binder Application.  Before applying binder, ensure that sufficient cover aggregate is available for immediate application.  Apply the binder at the target rate(s) established during the test strip. 

Maintain the binder temperature from 150 to 185 °F (65 to 85 °C) during construction, including the start of each day.  Reheat the binder at a rate of no more than 25 °F (14 °C) per hour, when the binder is allowed to cool below 150 °F (65 °C).

If the target application rates are not the optimum application rates to achieve proper stone embedment during the actual application, immediately notify the Engineer. Proper stone embedment is typically 1/2 to 2/3 of the stone chip height and can be checked by pulling out several chips by hand. Adjust and document the new application rate by stationing.   Recheck stone embedment after adjustment and obtain the Engineer’s approval of the new rate.

Do not allow the binder to streak on the road surface.  If the Engineer determines that streaking is occurring, cease operations until the Engineer is satisfied that streaking has been eliminated.

At the beginning and at the end of a contract section, start and stop the application on a removable protective cover (paper, metal sheets, or other suitable material) sufficiently wide enough to allow full application on the surface being treated.  Make transverse and longitudinal laps in such manner to ensure that the texture of the finished surface is uniform and continuous.  To prevent lapping at transverse junctions, promptly shut off the binder spray at the end of the application.  Before continuing the application, place a removable protective cover a sufficient distance back from the joint on the cover aggregate so the sprayers are operating at full force when the distributor has attained the predetermined speed upon reaching the uncovered surface.  Upon completion, remove all removable protective covers.

422.08  Cover Aggregate Application.  Verify the application rate with a one square yard (one square meter) piece of cardboard or other material to collect and weigh the aggregate before placing binder.  Adjust if necessary and re-verify.  Record final results and inform the Engineer. Immediately after applying the binder, apply cover aggregate uniformly without ridges or laps at the specified rate adjusted as directed by the Engineer to produce a minimum of excess loose particles.  Spread the material in such manner that the tires of the truck or aggregate spreader at no time contact the uncovered and newly applied binder.  Before rolling, correct deficiencies in the application of cover aggregate in a manner satisfactory to the Engineer.

After rolling, protect the surface from traffic damage during the period required for the binder to cure sufficiently and prevent dislodging of the aggregate particles by normal traffic.  During this period and as directed by the Engineer, correct deficiencies in cover aggregate by spreading additional aggregate or by light brooming.

Apply cover aggregate at a rate necessary to provide full coverage of the binder and to avoid tracking. Do not over apply cover aggregate relying on vacuum and broom sweeping to pick up all excess.  Nuisance to the public amounts of aggregate will result in work stoppage.  If work is stopped by the Engineer recalibrate the aggregate spreader determining a new application rate and apply cover aggregate at the new rate. If the target rate needs adjustment due to the gradation of the aggregate or due to existing surface conditions of the pavement, immediately notify the Engineer and document the new rate by stationing.

422.09  Construction Operation.  Establish stations at 1000-foot (300 m) intervals on the entire project before placing materials.  Clearly identify and maintain the stations until project completion.

Keep the binder distributor, aggregate spreader, and rollers as close to each other as possible.  Do not allow the binder distributor to be more than 150 feet (45 m) ahead of the aggregate spreader.

Perform rolling immediately after placing the aggregate, but before the binder sets up.  Do not leave aggregate unrolled for more than 5 minutes.  Perform a minimum of two complete roller passes over the aggregate.  A single complete pass is forward and backward over the same path.  For each new pass, overlap the previous pass by about one-half the width of the roller.  Use a minimum of three rollers, and roll in a longitudinal direction at a speed not greater than 5 miles per hour (8 km/h).  Do not operate rollers at speeds that cause pick-up or dislodging of aggregate particles.

After the binder sets, and before placing a second course for double chip seals, and within 4 hours, sweep the pavement using a power broom or pickup sweeper as needed to remove all loose aggregate. If the pavement cannot be swept within the 4-hour period due to problems associated with the stone moisture, binder, breaking, humidity, or other unknown, the Engineer may suspend the operation until the problem is resolved or more suitable conditions are obtained to maintain the 4-hour time frame for sweeping. Extend sweeping 1 foot (0.3 m) beyond the edge of the pavement to help prevent migration of loose aggregate back onto the pavement.  Do not re-use aggregate from a chip seal that is swept from the pavement or that is already loose off the pavement edge. 

The Contractor is responsible for claims of damage to vehicles until the pavement and shoulders receive a final sweeping immediately before application of permanent pavement markings or a fog seal, if a fog seal is required.

Wait at least 24 hours before placing the second course of a double chip seal.  Ensure that the first course meets requirements of this specification and is cured, swept and capable of withstanding construction traffic without damage. 

Correct damage to the underlying chip seal before placing the final chip seal.

Place the longitudinal construction joint on a lane line or as directed by the Engineer.  For double chip seal, place the longitudinal construction joint for the first course 6 inches (150 mm) off the centerline and place the second course so the longitudinal joint is at the centerline.

Before opening to traffic, post the roadway with “Loose Stone” signs and a “35 mph” speed plaque mounted below the sign.  Ensure that signs conform to Item 614.  Place these signs at a maximum of 0.5-mile (0.8 km) intervals.  Remove the signs as directed by the Engineer.

On two-lane roads or pavements where traffic is maintained on a chip seal constructed that workday, provide a traffic control pilot vehicle operated at no more than 25 miles per hour (40 km/h) in the immediate work area.

Protect all utility castings, monument boxes, and other similar items using tarpaper or other approved material.  Remove protection before sweeping and opening to traffic.

422.10  Quality Control

A.      General.  Use the methods described in this section to measure compliance.  If test results exceed any of the identified quality control tolerances, stop placement and immediately notify the Engineer and DET.  Identify the cause of exceeding any of the identified quality control tolerances and document in detail the corrective action necessary to bring the deficiency into compliance.  Obtain the Engineer’s approval before resuming work.  Upon resuming work, take another sample and immediately provide the test results to the Engineer.  If the tolerances are exceeded, stop the work.  Do not resume work until approved by the Engineer and DET.  The Department can obtain samples of materials at any time. Aggregate samples can be taken from sources, on-hand stockpiles or the aggregate spreader box.  Work can be stopped and materials can be rejected on the basis of poor Department test results.

B.      Binder.  Within one hour of start of production obtain and label a binder sample from the distributor truck and give the sample to the Engineer the same day.  Provide and sample the binder in one quart plastic containers with plastic screw tops.  Take more samples when requested by the Engineer. 

For the binder application rate, as determined by a yield check, do not exceed a tolerance of ±0.02 gallon per square yard (0.09 L/m²) from the established application rate.

C.      Coarse Aggregate.  At a minimum test one sample taken from the aggregate spreader box at production start and sample and test one sample from the aggregate spreader box randomly during the day.  An aggregate spreader box sample may be taken by laying a piece of suitable material under the spreader as it moves forward.  Include additional testing when directed to sample and test by the Engineer.  Sample and test aggregate according to AASHTO T 2, AASHTO T 248, and Supplement 1004 (AASHTO T 11 where required).  Use washed gradations for determining the No. 200 (75 µm) sieve.  The Contractor may use additional tests.  These may include dry gradations for control purposes but acceptance of on-hand aggregate will be based on washed gradations only.  Reject and do not use aggregate creating dusting nuisance to the public on the project.

Reject truckloads of aggregate if water is seen coming from the truck bed.

Reject aggregate that does not meet the following requirements:

No. 4 (4.75 mm) sieve from JMF

±5.0%

No. 8 (2.36 mm) sieve from JMF

±3.0%

No. 200 (75 µm) sieve from JMF

±1.0%, 2.05% upper limit

Aggregate moisture content
(by dry weight)

4.0% max. for aggregates with an Absorption > 2.0%,

3.0% max. for aggregates with an Absorption ≤ 2.0%

D.      Documentation.  Provide the Engineer a daily report with the following:

1.      Control section, project number, county, route, and Engineer.

2.      Date, air temperature, pavement temperature, and humidity.

3.      Binder temperature.

4.      Beginning and ending stations.

5.      Yield checks on binder (three per day, minimum).

6.      Yield checks on aggregate (three per day, minimum).

7.      Gradation, moisture content, and station (One sample from spreader box at production start, one random sample during the day and any other samples when directed by the Engineer).

8.      Length, width, and total area.

9.      Condition of “Loose Stone” signs with “35 mph” speed plaques.

10.    Contractor representative’s signature.

Provide a bill of lading for binder and aggregate as requested or at project completion.

422.11  Acceptance.  During the application of the chip seal, inspect the chip seal for deficiencies resulting from poor workmanship, flushing, tracking from equipment, surface patterns, loss of stone, and sweeping.  Inspect workmanship for untreated areas, minimum overlap on longitudinal joints, and minimum overlap on construction joints.

Verify the following for daily acceptance:

A.      Finished surface has no more than four tears or untreated areas greater than 1 inch (25 mm) wide and 4 inches (100 mm) long in any 120-square yard (100 m2) area.

B.      Joints appear neat and uniform without buildup, uncovered areas, or unsightly appearance.

C.      Longitudinal joints have less than a 2-inch (50 mm) overlap on the adjacent passes.

D.      Transverse joints have no more than 1/4-inch (6 mm) difference in elevation across the joint as measured with a 6-foot (2 m) straightedge.

E.      Chip seal edge is neat and uniform along the roadway lane, shoulder, and curb lines.

F.      Chip seal edge has no more than 2-inch (50 mm) variance in any 100 feet (30 m), along the roadway edge or shoulder.

G.      Typical stone chip embedment is 1/2 to 2/3 of typical stone chip height.

For project acceptance, the Contractor and Engineer will review the completed work 25 to 35 days after placement.  The finished work must meet the following requirements:

Defect [1]

Severity

Surface patterns

Alternate lean and heavy lines
(Ridges or streaking over the surface)

Bleeding/flushing

Distinctive appearance
(Excess binder on surface)

Loss of cover aggregate

Patches or lines of aggregate lost from surface

[1]  No more than 20% of any 120 square yard area can contain any defect.  The measurement of the 120 square yard area begins at the start of the defect.

Perform all corrective work to the satisfaction the Engineer.

422.12  Method of Measurement.  The Department will measure Single Chip Seal Course or Double Chip Seal Course by the number of square yards (square meters), completed and accepted in place.  The Department will determine the width by measuring the actual width of the chip seal.  The Department will determine the length along the centerline of each roadway or ramp.

The Department will measure the number of raised pavement markers removed if a Double Chip Seal is specified.

422.13  Basis of Payment.  The Department will not pay for materials, equipment, or labor to make corrections.

The cost of removal of all existing pavement markings according to 422.06 is incidental to this item.

The cost of any removal or protection of existing raised pavement markers on a single chip seal according to 422.06 is incidental to this item.

The Department will pay for removal of existing raised pavement markers on a Double Chip Seal application according to Item 621 Raised Pavement Markers Removed

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

422            Square Yard                 Single Chip Seal
                       (Square Meter)         

422            Square Yard                 Double Chip Seal
                       (Square Meter)         

item 423  CRACK SEALING, HOT APPLIED

423.01  Description

423.02  Materials

423.03  Equipment

423.04  Weather Limitations

423.05  Preparation

423.06  Mixing Type II and III

423.07  Application of Sealant

423.08  Opening to Traffic

423.09  Method of Measurement

423.10  Basis of Payment

423.01  Description.  This work consists of preparing and sealing pavement cracks with a hot applied crack sealant.

423.02  Materials.  Furnish hot applied crack sealant, of the type specified, conforming to:

Type I...................................................................... 705.04

Type II................................................................ 702.17.B

Type III................................................................ 702.17.C

Type IV............................................................... 702.17.D

Obtain the Laboratory’s approval of Type I crack sealant before shipping to the project.  Obtain approval of other crack sealants according to 702.17.

423.03  Equipment.  Equipment used in the performance of this work is subject to the Engineer’s approval and to the requirements of 108.05.

For Type I crack sealant, heat the sealant in a kettle or melter constructed as a double boiler, with the space between the inner and outer shells filled with oil or other heat-transfer fluid.  Use a kettle or melter with positive temperature control of the oil bath, and provide a mixing vat, mechanical agitation, and recirculating pumps.  Do not apply direct heat to the sealant.

For Types II, III, and IV crack sealants, heat the sealant in a kettle or melter constructed as a double boiler, with the space between the inner and outer shells filled with oil or other heat-transfer fluid.  Use a kettle or melter with separate thermometers for the oil bath and mixing vat.  Equip the kettle with a full sweep type agitator.  Also, equip the kettle with a 2-inch (50 mm) minimum recirculating pump to provide circulation of the materials when not applying the crack sealant.  Do not apply direct heat to the sealant.

For Types I and IV crack sealants, use a mechanical applicator wand capable of continuously feeding the sealant through nozzles shaped to penetrate the cracks.  A positive sealant flow shutoff mechanism is required.  Ensure that the wand produces a band according to the tolerances of 423.07.

For Types II and III crack sealants, use a mechanical applicator wand head capable of placing the crack sealant according to the tolerances of 423.07 while filling the cracks.  A positive sealant flow shutoff mechanism is required.

Use portable air compressors capable of furnishing at least 100 pounds per square inch (690 kPa) of air pressure at the nozzle.  Use compressors equipped with traps that maintain the compressed air free of oil and water.

Use water cleaning equipment capable of delivering water at 2000 pounds per square inch (14 MPa) of pressure from a nozzle to the crack being cleaned.

Use a propane lance unit capable of producing a blast of hot air that operates at 1000 °F (538 °C) and a gas velocity of 2000 feet per second (600 m/s).

Use mechanical and power driven routing and sawing equipment capable of following close to the path of cracks and of widening the cracks to the required dimension without causing excessive spalling or damage to the adjacent pavement.  For sawing equipment, use diamond saw blades with a diameter of 8 inches (200 mm) or less.

423.04  Weather Limitations.  Do not seal cracks if the surface is visibly damp or the temperature is below 45 °F (7 °C).

423.05  Preparation.   The contractor shall fill all visible cracks per 423.07 or as directed by the Engineer.

If routing is specified, rout cracks with an opening less than 3/4 inch (19 mm) to provide a sealant reservoir with a nominal size of 3/4 inch (19 mm) wide by 1 inch (25 mm) deep.

If sawing is specified, saw all cracks to 3/4 to 7/8 inch (19 to 22 mm) wide and 7/8 to 1 inch (22 to 25 mm) deep.  Use hand tools or a lightweight chipping hammer to remove all slivers of asphalt concrete less than 1 inch (25 mm) wide remaining along the crack after sawing.  Immediately before sealing, sandblast both faces of the sawed crack to remove all contamination and to texture the faces.  If the crack below the sealant reservoir is greater than 3/8 inch (10 mm) wide, insert a backer rod into the crack to form the bottom of the reservoir at the proper depth.

Before applying the hot sealant, clean cracks by an approved method or methods to remove dust, dirt, moisture, vegetation, and other foreign material.  Keep the cracks clean and dry until all sealing operations are completed.

423.06  Mixing Type II and III.  Use weigh tickets in determining the specified proportion of fiber to blend into the binder.  Add fibers to the binder, and mix thoroughly in the kettle.  Do not allow the temperature of the sealant in the field application to exceed the safe heating temperature recommended by the manufacturer.  Do not heat Type III crack sealant greater than 295 °F (146 °C).

423.07  Application of Sealant.  Perform the crack sealing operation within 250 feet (76 m) of the cleaning operation.

Seal only cracks that are wide enough to permit entry of sealant.  Seal tightly closed cracks (less than 1/4-inch (6 mm) wide) only if they show signs of raveling or spalling.  Do not seal cracks greater than 1-inch (25 mm) wide, and do not seal spalls or cavities greater than 4 inches (100 mm) wide, unless otherwise directed.

For Types I and IV crack sealants, fill the entire crack reservoir with the sealant from the bottom up to approximately 1/16 inch (2 mm) above the pavement surface.  Immediately scrape the filled cracks with a V-shaped or U-shaped squeegee, or similar hand tool, to smooth the overfill.  This may require more than one application of sealant.  The Engineer will not accept the work if the band of sealant on the pavement surface is greater than 2 inches (50 mm) wide.

For Types II and III crack sealants, place the sealant such that it fills the cracks with a band of sealant within 2 to 4 inches (50 to 100 mm) wide.  The Engineer will not accept the work if the thickness on the pavement is greater than 3/16 inches (5 mm).

423.08  Opening to Traffic.  Do not allow traffic on the sealant until it has cured and the possibility of tracking no longer exists.  However, if the Engineer determines it is necessary to allow traffic to pass over the sealant before adequate curing, dust Portland cement or other approved material over sealed cracks to eliminate pickup or tracking.

423.09  Method of Measurement.  The Department will measure Crack Sealing, of the type specified, by the number of pounds (kilograms) of hot applied sealant in place, completed, and accepted.

The Department will measure Crack Sealing, of the type specified, by the square yards of sealing completed and accepted.

423.10  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

423             Pound (Kilogram)           Crack Sealing, Type I
                       or Square Yard
                       (Square Meter)

423             Pound (Kilogram)           Crack Sealing with Routing, Type I
                       or Square Yard
                       (Square Meter)

423             Pound (Kilogram)           Crack Sealing with Sawing, Type I
                       or Square Yard
                       (Square Meter)

423             Pound (Kilogram)           Crack Sealing, Type II
                       or Square Yard
                       (Square Meter)

423             Pound (Kilogram)           Crack Sealing, Type III
                       or Square Yard
                       (Square Meter)

423             Pound (Kilogram)           Crack Sealing, Type II or III
                       or Square Yard
                       (Square Meter)

423             Pound (Kilogram)           Crack Sealing, Type IV
                       or Square Yard
                       (Square Meter)

ITEM 424  FINE GRADED POLYMER ASPHALT CONCRETE

424.01  Description

424.02  Composition

424.03  Materials

424.04  Mixing

424.05  Weather Limitations

424.06  Spreading, Compacting and Finishing

424.07  Surface Tolerances

424.08  Acceptance

424.09  Method of Measurement

424.10  Basis of Payment

424.01  Description. This work consists of constructing a surface course of aggregate and polymer modified asphalt binder mixed in a central plant and spread and compacted on a prepared surface. The requirements of 401 apply, except as modified by this specification.

424.02  Composition. For Type A mixes use 8.5 percent modified asphalt binder by total mix weight.

For Type B mixes, submit a proposed JMF according to 441.02 to the Laboratory that meets the requirements of a Type 1 surface course, except as follows:

A.     Minimum VMA, 15.0 percent

B.     Minimum total binder content, 6.4 percent

C.     Design air voids, 4.0 percent

424.03  Materials. Furnish clean, uncoated aggregate conforming to the applicable requirements of Table 424.03-1 and quality requirements of 703.05.

Use a PG 76-22M asphalt binder; or a PG 64-22 asphalt binder modified by adding 5.0 ±0.3 percent by weight Styrene Butadiene Rubber (SBR) solids and meeting the requirements of PG 76-22.  Provide SBR conforming to 702.14.  Provide mineral filler conforming to 703.07.  Provide binders conforming to 702.01.

Ten percent reclaimed asphalt concrete pavement may be used in a Type B mix if all requirements of footnote [3] are met by the reclaimed asphalt concrete.  Do not use reclaimed asphalt concrete pavement in a Type A mix.

TABLE 424.03-1 - MIX GRADATION

Total Percent Passing

Sieve Size

Type A [1][2]

Type B [1][3][4]

1/2 inch

(12.5 mm)

100

3/8 inch

(9.5 mm)

100

95 to 100

No. 4

(4.75 mm)

95 to 100

85 to 95

No. 8

(2.36 mm)

90 to 100

53 to 63

No. 16

(1.18 mm)

80 to 100

37 to 47

No. 30

(600 µm)

60 to 90

25 to 35

No. 50

(300 µm)

30 to 65

9 to 19

No. 100

(150 µm)

10 to 30

--

No. 200

(75 µm)

3 to 10

3 to 8

[1]  Gradation includes any mineral filler and is specified in percent passing.

[2]  Use natural sand with at least 50 percent silicon dioxide by weight according to ASTM C 146.  Include with a JMF submittal certified test data from an AASHTO accredited laboratory showing conformance to the 50 percent silicon dioxide requirement.  Ensure data is no more than one year old at time of submittal.

[3]  Fine Aggregate - Use natural sand with at least 50 percent silicon dioxide by weight according to ASTM C 146.  Include with a JMF submittal certified test data from an AASHTO accredited laboratory showing conformance to the 50 percent silicon dioxide requirement.  Ensure data is no more than one year old at time of submittal.  For medium mixes, use no more than 20 percent limestone sand by weight of total aggregate. For heavy mixes, use 20 percent limestone sand or air cooled slag sand by weight of total aggregate.  If 10 percent RAP is used the silicon dioxide content of the total natural sand blend must be at least 50 percent.  Contact the Office of Materials Management, Asphalt Materials section for guidance on submitting RAP aggregate silicon dioxide data.

[4]  Coarse Aggregate - For medium mixes, for the final blend of all coarse aggregate use a minimum 10 percent two or more fractured faces aggregate. For heavy mixes, use 100 percent two or more fractured faces aggregate. Meet the two or more fractured faces aggregate criteria of ASTM D5821-01 (Reapproved 2006).

424.04  Mixing. Ensure the mixing plant conforms to 402. Discharge the mix from the plant at temperatures between 335 °F to 370 °F (168 °C to 188 °C) for hot mix asphalt or 300 °F to 340 °F (149 °C to 171 °C) for warm mix asphalt.

424.05  Weather Limitations.  Do not place the asphalt concrete when the surface of the existing pavement is less than 60 °F or the air temperature is less than 60 °F.

424.06  Spreading Compacting and Finishing.  Compact Type A or B mixes conforming to 401.13 and 401.16.  If compacting a mixture 1 inch (25 mm) thick or less do not use a spreading rate that exceeds twice the total capacity of the rollers in use.  Use a minimum of two rollers.  Do not allow traffic on the compacted mixture until it has cooled sufficiently to prevent damage.

424.07  Surface Tolerances. Ensure the completed surface course conforms to 401.19.

Remove raised pavement markers according to 621.08.  The Contractor may fill the depression caused by the removal of the casting with material meeting this specification.

424.08  Acceptance. For Type A mixes comply with acceptance requirements of 301.  For Type B mixes comply with all requirements of 448.

424.09  Method of Measurement.  For Type A mixes use a unit weight conversion of 1.75 tons/cubic yard (2.08 metric tons/cubic meter).

The Department will measure the number of raised pavement markers removed.

424.10  Basis of Payment. The Department will pay for removal of existing raised pavement markers according to Item 621 Raised Pavement Markers Removed.

The Department will make payment for accepted quantities, completed in place, at the contract price as follows:

Item           Unit                                Description

424             Cubic Yard                      Fine Graded Polymer
                       (Cubic Meter)                  Asphalt Concrete, Type A

424             Cubic Yard                      Fine Graded Polymer
                       (Cubic Meter)                  Asphalt Concrete, Type B

ITEM 441  CONTRACTOR MIX DESIGN AND QUALITY CONTROL—GENERAL

441.01  Description

441.02  Composition

441.04  Antistrip Additive

441.05  JMF Field Adjustment

441.06  Monitoring

441.07  Quality Control Program

441.08  Testing Facilities

441.09  Quality Control Tests

441.10  Control Charts

441.11  Quality Control Reports

441.12  Mixture Deficiencies

441.01  Description.  This specification includes general requirements applicable to all types of asphalt concrete pavements where the Contractor is responsible for performing the mix design and quality control.  Deviations from these general requirements will be covered in the specific requirements for each type.  The requirements of Item 401 apply, except as follows.

Control all production processes to assure the Engineer that the mixture delivered to the paving site is uniform in composition, conforms to the specification requirements and that the placed mixture is free of any defect (e.g. segregation, tenderness, lack of mixture and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control at project completion.

441.02  Composition.  Compose the asphalt concrete of approved aggregates, asphalt binder and, if required, other modifiers.  Develop a JMF to comply with the mix design criteria and submit it to the Laboratory on approved forms at least two weeks prior to the start of production for preliminary approval.  The Laboratory may perform additional tests on lab or plant produced mixtures to ensure adequate mix performance.  Based on the results of these tests, the Laboratory may require the Contractor to design a new JMF.  Allow time for this additional testing.

Perform the mix design and supply all required data in a manner taught in Level 2 Asphalt Technician School, Level 3 Asphalt Mix Design School and in the Asphalt Institute Manual Series No. 2.  Use a 2-hour cure for all mix samples.  Ensure the cure temperature and specimen compaction temperature are the same.   Select the JMF asphalt binder content using the Design Air Voids and ensure the JMF meets the other requirements of Table 441.02-1.  Determine Air Voids from specimens prepared and tested per Supplement 1036.  Provide a mix design with at least four asphalt binder content points, including a minimum of two points above and two points below the JMF asphalt binder content. Submit no more than two JMFs for each asphalt concrete pay item per project.  Additional submittals are at the discretion of the Laboratory.  Submit a 5-pound (2500 g) minimum uncompacted sample (all mixes) representing the JMF.  Submit additional samples as requested by the Laboratory.

Do not start mix production without a preliminary JMF approval and 48 hour notification of the District.  Final approval of a JMF will be based upon field verification.  According to 441.12 the JMF can be rejected for failure to verify in the plant or at the project.

Do not apply the gradation requirements of 703.05 for fine aggregate. 

If the F/A ratio using total asphalt binder content is greater than 1.0 recalculate it using the effective asphalt binder content.  Calculate the effective asphalt binder content according to Chapter 4 of the Asphalt Institute Manual Series No. 2.  The value (calculated to the nearest percentage point) of the Fifty to Thirty (F-T) value, is the percent of total aggregate retained between the No. 50 (300 mm) and No. 30 (600  mm) sieves, minus the percent of total aggregate retained between the No. 30 (600 mm) and No. 16 (1.18 mm) sieves.

For Type 1H mixes ensure that a minimum of 50 percent of the virgin fine aggregate is sand manufactured from stone, gravel or air-cooled slag.  If the sand is manufactured from gravel, ensure that it is crushed from gravel material retained on the 3/8 inch (9.5 mm) sieve.

Use a PG 70-22M asphalt binder for Type 1H mix.  Use a PG 64-28 asphalt binder for Type 2 mix for heavy traffic volume regardless of the amount of reclaimed asphalt concrete pavement.  Use a PG 64-22 asphalt binder and Type 1 medium gradation for asphalt concrete for driveways and under guardrails.

Identify the PG Binder supplier, as well as the polymer type if applicable, on the JMF submittal.  A change in polymer asphalt binder or polymer source will require a redesign.  Provide on one page neatly summarized, dated test results for the requirements of Table 702.01-1.  Ensure data is no more than two months old.  If SBR polymer is added at the asphalt concrete mixing plant, provide in the JMF data from the SBR polymer supplier for total solids (percent) and ash (percent) according to the 702.14.  As well, provide the target amount of SBR polymer greater than or equal to 3.5 percent to achieve the properties specified. Include a letter of certification from the polymer supplier verifying percent butadiene in the SBS or SBR polymer.  Report in the JMF submittal results of temperature-viscosity testing for mixing and compaction temperatures.  For polymer asphalt binders supplier recommended temperatures may be used in lieu of the temperature-viscosity results, but the temperature-viscosity results must still be reported.

Table 441.02-1

Course

Type 1 Surface

Traffic

Heavy

Medium

Light

1 1/2 inch (37.5 mm)[1]

1 inch (25.0 mm)[1]

3/4 inch (19.0 mm)[1]

100

1/2 inch (12.5 mm)[1]

95 to 100

100

100

3/8 inch (9.5 mm)[1]

70 to 85

90 to 100

90 to 100

No. 4 (4.75 mm)[1]

38 to 50

45 to 57

45 to 57

No. 8 (2.36 mm)[1]

20 to 37

30 to 45

30 to 45

No. 16 (1.18 mm)[1]

14 to 30

17 to 35

17 to 35

No. 30 (600 mm)[1]

10 to 22

12 to 25

12 to 25

No. 50 (300 mm)[1]

6 to 15

5 to 18

5 to 18

No. 100 (150 mm)[1]

4 to 10

2 to 10

2 to 10

No. 200 (75 mm)[1]

2 to 6

Asphalt Binder[2]

5.6 to 10.0

5.8 to 10.0

6.0 to 10.0

Virgin Asphalt Binder (min.)

5.0

5.2

F/A Ratio, max.[3]

1.2

1.2

1.2

F-T Value[4]

+2

+2

Blows[5]

75

50

35

Stability, min., pounds[5]

1800

1200

750

   (N)

(8006)

(5338)

(3336)

Flow, 0.25 mm[5]

8 to 14

8 to 16

8 to 18

Design Air Voids[6]

3.5

3.5

3.5

VMA, min.[7]

14

16

16

Special Designation

1H

Coarse Agg Mech Crush[8]

65

[1]  Sieve, percent passing

[2]  Percent of total mix

[3]  Using effective asphalt binder content

[4]  Percentage points maximum

[5]  T 245

[6]  Percent, Supplement 1036

[7]  Percent, Supplement 1037

[8]  Percent, two or more fractured faces ASTM D5821

Table 441.02-1 (continued)

Course

Type 1 Intermediate

Traffic

Heavy

Medium

Light

1 1/2 inch (37.5 mm)[1]

1 inch (25.0 mm)[1]

3/4 inch (19.0 mm)[1]

1/2 inch (12.5 mm)[1]

100

100

100

3/8 inch (9.5 mm)[1]

90 to 100

90 to 100

90 to 100

No. 4 (4.75 mm)[1]

50 to 72

50 to 72

50 to 72

No. 8 (2.36 mm)[1]

30 to 55

30 to 55

30 to 55

No. 16 (1.18 mm)[1]

17 to 40

17 to 40

17 to 40

No. 30 (600 mm)[1]

12 to 30

12 to 30

12 to 30

No. 50 (300 mm)[1]

5 to 20

5 to 20

5 to 20

No. 100 (150 mm)[1]

2 to 12

2 to 12

2 to 12

No. 200 (75 mm)[1]

Asphalt Binder[2]

5.0 to 10.0

5.0 to 10.0

5.0 to 10.0

F/A Ratio, max.[3]

1.2

1.2

1.2

F-T Value[4]

+2

+2

Blows[5]

75

50

35

Stability, min., pounds[5]

1800

1200

750

   (N)

(8006)

(5338)

(3336)

Flow, 0.25 mm[5]

8 to 14

8 to 16

8 to 18

Design Air Voids[6]

4.0

3.5

3.5

VMA, min.[7]

16

16

16

Special Designation

[1]  Sieve, percent passing

[2]  Percent of total mix

[3]  Using effective asphalt binder content

[4]  Percentage points maximum

[5]  T 245

[6]  Percent, Supplement 1036

[7]  Percent, Supplement 1037

Table 441.02-1 (continued)

Course

Type 2 Surface

Traffic

Heavy

Medium

Light

1 1/2 inch (37.5 mm)[1]

100

100

100

1 inch (25.0 mm)[1]

95 to 100

95 to 100

95 to 100

3/4 inch (19.0 mm)[1]

85 to 100

85 to 100

85 to 100

1/2 inch (12.5 mm)[1]

65 to 85

65 to 85

65 to 85

3/8 inch (9.5 mm)[1]

No. 4 (4.75 mm)[1]

35 to 60

35 to 60

35 to 60

No. 8 (2.36 mm)[1]

25 to 48

25 to 48

25 to 48

No. 16 (1.18 mm)[1]

16 to 36

16 to 36

16 to 36

No. 30 (600 mm)[1]

12 to 30

12 to 30

12 to 30

No. 50 (300 mm)[1]

5 to 18

5 to 18

5 to 18

No. 100 (150 mm)[1]

2 to 10

2 to 10

2 to 10

No. 200 (75 mm)[1]

Asphalt Binder[2]

4.0 to 9.0

4.0 to 9.0

4.0 to 9.0

F/A Ratio, max.[3]

1.2

1.2

1.2

F-T Value[4]

+2

Blows[5]

75

50

35

Stability, min., pounds[5]

1800

1200

750

   (N)

(8006)

(5338)

(3336)

Flow, 0.25 mm[5]

8 to 14

8 to 16

8 to 18

Design Air Voids[6]

4.0

4.0

4.0

VMA, min.[7]

13

13

13

Special Designation

[1]  Sieve, percent passing

[2]  Percent of total mix

[3]  Using effective asphalt binder content

[4]  Percentage points maximum

[5]  T 245

[6]  Percent, Supplement 1036

[7]  Percent, Supplement 1037

Table 441.02-1 (continued)

Course

Type 2 Intermediate

Traffic

Heavy

Medium

Light

1 1/2 inch (37.5 mm)[1]

100

100

100

1 inch (25.0 mm)[1]

95 to 100

95 to 100

95 to 100

3/4 inch (19.0 mm)[1]

85 to 100

85 to 100

85 to 100

1/2 inch (12.5 mm)[1]

65 to 85

65 to 85

65 to 85

3/8 inch (9.5 mm)[1]

No. 4 (4.75 mm)[1]

35 to 60

35 to 60

35 to 60

No. 8 (2.36 mm)[1]

25 to 48

25 to 48

25 to 48

No. 16 (1.18 mm)[1]

16 to 36

16 to 36

16 to 36

No. 30 (600 mm)[1]

12 to 30

12 to 30

12 to 30

No. 50 (300 mm)[1]

5 to 18

5 to 18

5 to 18

No. 100 (150 mm)[1]

2 to 10

2 to 10

2 to 10

No. 200 (75 mm)[1]

Asphalt Binder[2]

4.0 to 9.0

4.0 to 9.0

4.0 to 9.0

F/A Ratio, max.[3]

1.2

1.2

1.2

F-T Value[4]

+2

Blows[5]

75

50

35

Stability, min., pounds[5]

1800

1200

750

   (N)

(8006)

(5338)

(3336)

Flow, 0.25 mm[5]

8 to 14

8 to 16

8 to 18

Design Air Voids[6]

4.0

4.0

4.0

VMA, min.[7]

13

13

13

Special Designation

[1]  Sieve, percent passing

[2]  Percent of total mix

[3]  Using effective asphalt binder content

[4]  Percentage points maximum

[5]  T 245

[6]  Percent, Supplement 1036

[7]  Percent, Supplement 1037

441.03  Use of Reclaimed Pavement.  Comply with the requirements of 401.04.

441.04  Antistrip Additive.  If the proposed JMF contains any gravel coarse aggregate, or contains more than 25 percent natural sand, or contains more than 20 percent reclaimed asphalt concrete pavement containing gravel coarse aggregate, or is designed according to Item 442 conduct the following tests:

A.      Moisture damage potential test according to Supplement 1051.

B.      Washed gradation according to AASHTO T 11 as modified by Supplement 1004.

C.      Adherent fines test for each component according to ASTM D 5711.

Modify the mix with one of the following antistrip additives if the results of the moisture damage potential test show the Tensile Strength Ratio (TSR) of the asphalt concrete mix to be less than 0.80 for 442 mixes or 0.70 for all other mix types:

A.      Liquid Antistrip Material.  Include liquid antistrip material at a rate of 0.5 to 1.0 percent by weight of the asphalt binder.  However, if 442 is specified, include liquid antistrip material at a rate of 0.50 to 1.25 percent by weight of the asphalt binder. Ensure the TSR of the asphalt concrete mix is greater than or equal to 0.80 after the addition of the liquid antistrip material.

B.      Hydrated Lime.  Include hydrated lime in the dry form at a rate of 1.0 percent by the dry weight of aggregate for asphalt concrete.  Conform to AASHTO M 303, Type 1 for hydrated lime.  Ensure the TSR of the asphalt concrete mix is greater than or equal to 0.80 after the addition of the hydrated lime.  Provide the Engineer the following information for each shipment of hydrated lime: Letter of certification, Production date, Shipment date, Shipment destination, Batch or lot number and Net weight.  The Laboratory may obtain samples of the hydrated lime at any time to verify quality.  If the quality of the hydrated lime is in question, the Laboratory may require independent laboratory testing.

Include the antistrip additive in the mix design.  Submit the following to the Laboratory with the proposed JMF:

A.      All TSR data (before and after the addition of the antistrip additive).

B.      Rate of addition of the liquid antistrip material, if used.

C.      If using liquid antistrip material submit product information, information on use by other State DOTs using the liquid antistrip material, and a letter of certification.  If using hydrated lime submit certified test data showing the hydrated lime conforms to AASHTO M 303, Type 1.  

D.      Results of the washed gradation test of the individual components of the mix used in determining the combined gradation.

E.      Results of the adherent fines testing for each component.

The Laboratory may perform additional tests on lab or plant produced mix according to Supplements 1004, 1051, and 1052.  If a change in the aggregate production is suspected, the Department may require the Contractor to perform washed gradations on components and calculate adherent fines to determine the need for additional TSR review.  Store and introduce antistrip additives into the plant according to Supplement 1053.  Obtain Laboratory approval of the antistrip additive storage and feed systems prior to the start of production. 

Provide delivery tickets to the Engineer at the end of the project and at the end of each construction year on a multiple year project.  The Engineer will verify the number of pounds of antistrip additive used is within 10 percent of the calculated amount of antistrip additive required for the total weight of asphalt binder, based on the JMF, used in the asphalt concrete.

441.05  JMF Field Adjustments.  During production the Contractor may adjust the JMF gradation within the below limits without a redesign of the mixture.  Limit adjustments of the JMF to conform to actual production, without a redesign of the mixture, to ±3 percent passing the 1/2 inch (12.5 mm), No. 4 (4.75 mm), and No. 8 (2.36 mm) sieves and ±1 percent passing the No. 200 (75mm) sieve. Do not exceed the limits in Table 441.02-1 in the adjusted JMF.  The adjustment on the 1/2 inch (12.5 mm) sieve applies only to Type 1H and Type 2 mixes.  Determine the need for any JMF gradation adjustments in the time specified.  Should no adjustments be made, the Department will base acceptance on conformance to the original JMF.  After the time period specified, the Department will allow no further adjustment of the JMF.

Should a redesign of the mixture become necessary, submit a new JMF according to the requirements for the initial JMF.  A new acceptance lot will begin when a new JMF established by a redesign of the mixture becomes effective.  Make any adjustment of this new JMF as provided for the original JMF.  Record both the design JMF and the adjusted JMF in effect during production of an acceptance lot on the Quality Control Report for that lot.  In the event that a new design JMF is proposed and approved, also make a notation on the ticket for the first load produced under the new design JMF.

441.06  Monitoring.  The Department will establish District Monitoring Teams for the purpose of verifying all Contractor mixture production processes.  Verification may be accomplished by obtaining split samples or independent samples from the plant or roadway.  If the mixture quality verifies then production may continue.  If mixture quality does not verify then the Monitoring Team and Contractor will cooperatively investigate and resolve the problem.  Whenever results are disputed the Laboratory will investigate and conduct additional testing to resolve.  Based on their review, the Monitoring Team may at any time disallow production to continue. 

441.07  Quality Control Program.  Submit a Quality Control Program (QCP) according to 403.03.  Include an example control chart according to 441.10 with the QCP.  Use quality control technicians working in the plant lab during all mixture production and that are approved by the Department.  Technician approval will be according to Supplement 1041. 

441.08  Testing Facilities.  Provide testing facilities at the plant site conforming to Supplement 1041.

441.09  Quality Control Tests.  Perform quality control tests to control the asphalt concrete mix within the specifications.  Ensure that these quality control tests measure the asphalt binder content, gradation, air voids, and Maximum Specific Gravity (MSG) according to the Contractor’s approved QCP.  Perform each quality control test a minimum of one time each half of a production day or night (two tests per production day or night), or one each 1400 tons (1300 metric tons), whichever is less.  

Perform more sampling and testing than the minimum specified at the start of production.  Additionally perform more sampling and testing than the minimum during production when the quality control tests show the asphalt concrete being produced is outside the warning bands as shown in the Contractor’s approved QCP.  Immediately resolve problems indicated by any out of warning band test and immediately retest to validate corrections have returned the materials to within the warning band limits.  The Contractor may determine the method of testing of the asphalt concrete beyond the minimum specified, and will detail the methods technicians will follow in the Contractor’s approved QCP. 

Should additional testing as required above not be performed the DET, after consultation with the Laboratory, will require the testing frequency be increased to all tests each two hours of production for the remainder of the project.  If this occurs, the DET will request an opinion from the QCQC for action(s) against the technician and/or Contractor including but not limited to warning, removal and/or a change of the facility to Unconditional Acceptance.

Record the results of every test performed.

Perform the required quality control tests as follows:

A.      Asphalt Binder Content.  Determine the asphalt binder content of a sample of asphalt concrete by performing an Asphalt Content (AC) Gauge test according to Supplement 1043.  Make all printouts available for review by the Monitoring Team at any time.  Offset the AC Gauge for each JMF on each project at the project’s start.  Perform the offset using solvent extraction methods for every QC sample according to Supplement 1038 and the AC Gauge Verification and Offset Record.  Use solvent extraction according to Supplement 1038 when an AC Gauge problem exists and for testing cooled samples that cannot adequately be tested in an AC Gauge test.

Total, for each day’s production, the flow meter printouts for SBR polymer added at the asphalt concrete mixing plant.  Calculate the percent of polymer versus neat asphalt binder in the mix each day and record on the TE-199.  Hold calculation worksheets and printouts in the plant laboratory for review by the Monitoring Team.  A +/- 0.2 percent tolerance from the target amount of SBR polymer will be used as a guide for an acceptable amount of SBR polymer, but will not be consistently low.  Only take SBR PG-Modified Binder samples using a five gallon bucket, stirring its contents and transferring to the required sample containers.

Determine the moisture content of the asphalt concrete for each AC Gauge test.  Maintain the moisture content at 0.8 percent or less.

B.      Gradation.  Perform at least one gradation test each production day on aggregate remaining after removing the asphalt binder with a solvent from an asphalt concrete sample used in an AC Gauge test (solvent sample) or on aggregate remaining after removing the asphalt binder with a preapproved asphalt ignition oven according to Supplement 1054 and from an asphalt concrete sample used in an AC Gauge test (ignition oven sample).  Use only an asphalt ignition oven to obtain an aggregate sample from an asphalt concrete sample having a polymer modified PG Binder.  The DET may make an exception for this for SBS polymer as long as no issues arise.  Correct each solvent sample for ash.  Perform all other gradations on solvent samples, ignition oven samples, or on samples obtained according to the Contractor’s approved QCP. 

The gradation results of all the sieves must be representative of the JMF.  If the Contractor fails to control the entire gradation, the Laboratory may require a redesign according to 441.02.

When the F-T value is specified for a mix in 441.02 calculate it for each gradation analysis.  Maintain the F-T value at +4 percentage points or less for these mixes.

Calculate the F/A ratio for every solvent sample or ignition oven sample analysis.  Maintain the F/A ratio so no F/A ratio is greater than 1.2 for all mixes.  Use the asphalt binder content determined by the AC Gauge for calculating the F/A ratio.  If the F/A ratio is greater than 1.0, recalculate the F/A ratio using the effective asphalt binder content.  Calculate the effective asphalt binder content on the calculation sheet using the asphalt binder content determined by the AC Gauge and attach it to the Quality Control Report.  Use bulk and effective aggregate specific gravities and remaining values needed in the calculation from the approved JMF.  Do not deviate from these values without the Laboratory’s approval.  If the F/A ratio is greater than 1.0 for ignition oven samples, calculate the F/A ratio using the percent passing the No. 200 (75 mm) sieve from a washed gradation of the ignition oven sample according to AASHTO T 30.

C.      Air Voids and MSG.  Determine the air voids of the asphalt concrete by analyzing a set of compacted specimens and a corresponding MSG determination according to Supplement 1036.    Ensure that the cure temperature and specimen compaction temperature are the same.  Use a 1-hour cure for all mix samples used in voids analysis.  The Contractor may use a 2-hour cure time if voids are consistently near the low void warning band.  In this case, use the 2-hour cure for all voids testing through the remainder of the project.  For hot mix asphalt use the JMF lab compaction temperature.  For warm mix asphalt according to 402.04 use a lab compaction temperature 30.0 ºF (16.7 ºC) less than the JMF lab compaction temperature for hot mix asphalt.  Use a compaction temperature tolerance of +/- 5.0 ºF (3.0 ºC).  Record on the TE-199 if the mixture produced was ran at the asphalt plant as a hot mix asphalt (HMA) or as a warm mix asphalt (WMA) produced according to 402.04 or another approved method.

Calculate the Voids in Mineral Aggregate (VMA) value for every set of compacted specimens according to Supplement 1037.

Calculate the average of all the MSG determinations performed each production day and report this average on the Quality Control Report.  When the range of three consecutive daily average MSG determinations is equal to or less than 0.020 average these three average MSG determinations to determine the Maximum Theoretical Density (MTD).  After the MTD is established, compare all individual MSG determinations to the MTD

Whenever compacted specimens are to be made and an MSG determination is to be run, take a sample of sufficient size to run a corresponding AC Gauge test.  When the air void and MSG test results are recorded reference them to the AC Gauge test of the sample.

D.      Other Requirements.  Supply proper containers and take two 1 quart (1 liter) asphalt binder samples from the first transport truck load of each different asphalt binder grade of the project before incorporation into the storage tank.  Label the samples with binder grade, supplier, project number and date and retain them in the plant laboratory for future reference by the Department.  Discard the samples at project finaling if not taken by the Monitoring Team.

Retain a split sample for each AC Gauge test and MSG test and all compacted specimens for monitoring by the Department.  Maintain MSG samples in the state described in ASTM D 2041, Section 9.2.  The Contractor may dispose of the AC Gauge test samples after two days and all other split samples after seven days if the Department does not process the split samples.

Measure the temperature of the mixture and record.  Validate the results on the load tickets at least once during each hour of production.

The Contractor may conduct additional testing of any type.  Record such additional testing along with all other quality control records and have these records readily available for the Monitoring Team’s review.  The Laboratory may observe, review, and approve the procedures at any time. 

441.10  Control Charts.  Maintain up to date control charts showing each individual test result and also the moving accumulative range as follows:

A.      Plot tests showing the percent passing for the 1/2 inch (12.5 mm), No. 4 (4.75 mm), No. 8 (2.36 mm), and No. 200 (75 µm) sieves the percent asphalt binder content, the MSG and the percent air voids.  Round all percentages to the nearest whole percent; except, round asphalt binder content, the No. 200 (75 µm) sieve, and air voids to the nearest 0.1 percent.

B.      Show the out of specification limits specified in Table 441.10-1 and QCP Warning Band Limits on the control charts. 

C.      Label each control chart to identify the project, mix type and producer. 

D.      Record the moving accumulative range for three tests under each test point on the chart for air voids and asphalt binder content.  Accumulative range is defined as the positive total of the individual ranges of two consecutive tests in three consecutive tests regardless of the up or down direction tests take.  If more than the minimum required testing (i.e. two tests per production day or night, 441.09 first paragraph) is performed do not include the result in accumulative range calculations.

          Stop production and immediately notify the Monitoring Team when either A or B occurs:

A.      Any two tests in a row or any two tests in two days are outside of the specification limits of Table 441.10-1.

B.      Any four consecutive moving accumulative ranges greater than specification limits of 2.50 percent for air voids or 0.60 percent for asphalt binder content occur. 

Any mixture sent to the paving site without stopping production and notifying the Monitoring Team, when required by this specification, will be considered non-specification material.

Do not restart production until an adequate correction to remedy problems is in place and the Monitoring Team is satisfied.  Following a shutdown restart production in a manner acceptable to the DET.  When production problems cannot be solved within one day after a plant shut down a Contractor’s representative holding Level 3 Asphalt Department approval is required to be at the asphalt plant until a full production day is achieved with results satisfactory to the Monitoring Team. 

TABLE 441.10-1

Mix Characteristic

Out of Specification Limits

Asphalt Binder Content[1]

-0.3% to 0.3%

1/2 inch (12.5 mm) sieve[1]

-6.0% to 6.0%

No. 4 (4.75 mm) sieve[1]

-5.0% to 5.0%

No. 8 (2.36 mm) sieve[1]

-4.0% to 4.0%

No. 200 (75 mm) sieve[1]

-2.0% to 2.0%

Air Voids[2]

2.5% to 4.5%

Air Voids[3]

3.0% to 5.0%

MSG[4]

-0.012 to 0.012

[1]  deviation from the JMF

[2]  for Design Air Voids of 3.5%

[3]  for Design Air Voids of 4.0%

[4]  deviation from the MTD

441.11  Quality Control Reports.  Use Department Form TE-199 for the Quality Control Report.  Record all test results on the Quality Control Report.  Document all decisions regarding responses to test results on the Quality Control Report (referring to the particular test), including reasons why a particular problem may exist what action was taken to correct the problem (plant operation or testing), and what communication with Department personnel took place.  Submit one Quality Control Report to the DET no later than specified.  Retain copies of all records documenting the quality control inspections and tests throughout the life of the Contract and furnish them to the DET on request.

441.12 Mixture Deficiencies.   Control all production processes to assure the Engineer that the mixture delivered to the paving site is uniform in composition; within the specification requirements and limits; conforms to the JMF: and that the placed mixture is free of any defect (ex. segregation, tenderness, lack of mixture and texture uniformity, raveling, flushing, rutting, holes, debris etc.) within the Contractor’s control.  Correct obvious pavement problems according to 401.15.  If the Department has any suspicion that other mixture composition or pavement problems exist, the Monitoring Team will conduct an initial investigation through review of data and/or sampling of the asphalt pavement.  Should a Department investigation determine that the Contractor’s QCP is not controlling the mixture in a manner to achieve mixture quality as described above, the Contractor quality control data may be rejected.  In that case the Department will conduct a thorough test investigation based on samples from the roadway and use those test results in determining disposition of the non-specification material.

A mixture is not uniform in composition if multiple random non-specification individual tests or any four consecutive non-specification moving accumulative ranges exist. The mixture can be rejected, production can be stopped and/or a redesign can be called for by the Department.  The Laboratory will not approve any redesign it determines is unsatisfactory to provide acceptable mix performance.  Submit this new design for approval according to 441.02 and at no additional cost to the Department. 

When any out of specification material, based on quality control tests not within the limits of Table 441.01-1, is sent to the paving site the Engineer will determine disposition of the material according to the Department non specification material policy. 

Item 442  Superpave Asphalt Concrete

442.01  Description

442.02  Type A Mix Design

442.03  Type B Mix Design

442.04  Asphalt Binder

442.05  Quality Control

442.06  Compaction

442.07  Acceptance

442.08  Basis of Payment

442.01  Description.  This work consists of gyratory mix design, material, and quality control requirements for constructing a Superpave asphalt concrete pavement surface or intermediate course.  The asphalt concrete pavement course consists of aggregate, and asphalt binder mixed in a central plant and spread and compacted on a prepared surface.

The requirements of Item 441 apply, except as modified by this specification.

442.02  Type A Mix Design.  Design the mixture composition for a Type A mix according to 441.02 and the most recent Asphalt Institute Superpave Mix Design Manual (SP-2) for design procedures and material properties except as modified by this subsection.  Include in the JMF submittal the standard Department cover and summary page; all printouts from the gyratory compactor (all gyratory points not necessary); and analysis covering the required mix properties.  Submit one compacted gyratory sample and loose mix for compaction of another sample, in addition to a 5-pound (2000 g) loose sample, for each JMF.

The Contractor may use the Marshall flow test in design as an indicator of potential for excess tenderness.

Supply aggregate according to the lane current average daily truck traffic (Lane ADTT) as follows unless otherwise shown on the plans:

Lane ADTT = Current ADT × T₂₄ × 0.45

Where:

     Current ADT =  current average daily traffic count from the plans

                  T₂₄ =  percent trucks per day from the plans

Table 442.02-1  Gyration Level and Material Requirements

Lane

ADTT

Nini

Ndes

Nmax

Coarse

Aggregate

Angularity

Fine

Aggregate

Angularity

Flat and

Elongated

Particles

Sand

Equivalent

<4000

7

65

105

95 [1] /90 [2]

44

10

45

>4000

7

65

105

100 [1] /100 [2]

44

10

50

[1]  Percent fractured (one or more faces) according to ASTM D5821

[2]  Percent fractured (two or more faces) according to ASTM D5821

Submit aggregate to be used to the Laboratory for approval a minimum of 3 weeks before submitting a JMF for approval.

If fine aggregate is from crushed carbonate stone or air-cooled blast furnace slag, the Department will not require the fine aggregate angularity (FAA) test.  The Department will allow a blend of a material not meeting the FAA with a material that meets the FAA, but calculate the FAA result based on the individual Department FAA results and actual blend percentages.  Obtain Department approval of  any blends.

The restricted zone does not apply.  Use control points according to SP-2, except as specified in Table 442.02-2.

Table 442.02-2  Aggregate Gradation Requirements

Sieve Size

9.5 mm mix

12.5 mm mix

19 mm mix

Total Percent Passing

1 1/2 inch

(3.75 mm)

–

–

100

3/4 inch

(19 mm)

–

100

85 to 100

1/2 inch

(12.5 mm)

100

95 to 100

90 max

3/8 inch

(9.5 mm)

90 to 100

96 max

–

No. 4

(4.75 mm)

70 max

52 min

–

No. 8

(2.36 mm)

34 to 52

34 to 45

28 to 45

No. 200

(75 µm)

2 to 8

2 to 8

2 to 6

Ensure that the F/A ratio is a maximum of 1.2.  Use a 2-hour cure for the mix design .

If more than 15 percent fine aggregate not meeting FAA is used, perform a loaded wheel test (LWT) according to Supplement 1057.  To estimate a LWT sample mix volume, use the bulk density from gyratory specimens at Ndes.  Results less than 0.20 inch (5.0 mm) at 120 °F (49 °C) are considered passing.

The Contractor may use reclaimed asphalt concrete pavement according to 401.04.  Test design volumetric properties at Ndes.  Test Nmax for the required criteria.  Ensure that the VMA is not less than the minimum values of Table 442.02-3.

Table 442.02-3  VMA Criteria

Mix

VMA (percent minimum)

9.5 mm

15

12.5 mm

14

19.0 mm

13

442.03  Type B Mix Design.  Apply the mix design specified in 442.02 for a Type A mix except as modified by this subsection:

Modify the Coarse Aggregate Angularity of Table 442.02-1 according to Table 442.03-1.

Table 442.03-1

Lane ADTT

Coarse Aggregate Angularity

<4000

65 [1] /65 [2]

>4000

75 [1] /70 [2]

[1]  Percent fractured (one or more faces) according to ASTM D5821

[2]  Percent fractured (two or more faces) according to ASTM D5821

Ensure that at least 50 percent by weight of virgin fine aggregate is aggregate meeting FAA or is crushed carbonate stone or air-cooled blast furnace slag.  Modify the No. 8 (2.36 mm) sieve requirement for a 12.5 mm mix in Table 442.02-2 to 34 to 40 percent.  Apply an F-T value of +2 according to 441.02 and 441.09.

442.04  Asphalt Binder.  Use a PG 70-22M asphalt binder for surface courses and a PG 64-28 asphalt binder for intermediate courses.

The minimum total asphalt binder content for a surface course is 5.7 percent.

442.05  Quality Control.  Conform to 441.09, except as specified in this subsection.  Ensure that plant operation and quality control testing conform to the Contractor’s Quality Control Program (QCP).

Use a gyratory compactor conforming to the requirements of Superpave.  If the gyratory compactor was moved to the plant before production, calibrate it and present the results to the DET. 

Determine bulk gravity for air voids determination on specimens compacted to Ndes.  Once each day for the first 3 production days compact one set of specimens to Nmax.  Ensure that density at Nmax is less than 98.0 percent of MSG.  The Department will not allow production to continue if Nmax is greater than or equal to 98.0 percent of MSG unless acceptable corrections and retest are made.

If the design gradation requires an LWT test, take a sample sufficient to run a LWT test  once each day for the first 3 days and test it according to Supplement 1057.  The Contractor may perform the LWT test in the Contractor’s Level 2 laboratory, but must compact the sample the same day the sample was taken, cure it overnight, and test it the following day.  Give the test result and sample density to the DET the day of the LWT test.  Report the LWT data on the Quality Control Report.

442.06  Compaction.  Cease production if compaction causes bumps in the mix or the mix is excessively tender.

442.07  Acceptance.  The Department will base acceptance of the asphalt concrete mix on the item specified in the Contract (i.e., Item 446, Item 448).

442.08  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

442             Cubic Yard                      Asphalt Concrete Surface
                       (Cubic Meter)                  Course, 12.5 mm, Type A (446)

442             Cubic Yard                      Asphalt Concrete Surface
                       (Cubic Meter)                  Course, 12.5 mm, Type B (446)

442             Cubic Yard                      Asphalt Concrete Surface
                       (Cubic Meter)                  Course, 9.5 mm, Type A (446)

442             Cubic Yard                      Asphalt Concrete Surface
                       (Cubic Meter)                  Course, 9.5 mm, Type B (446)

442             Cubic Yard                      Asphalt Concrete Intermediate
                       (Cubic Meter)                  Course, 19 mm, Type A (446)

442             Cubic Yard                      Asphalt Concrete Intermediate
                       (Cubic Meter)                  Course, 19 mm, Type B (446)

442             Cubic Yard                      Asphalt Concrete Intermediate
                       (Cubic Meter)                  Course, 9.5 mm, Type A (448)

442             Cubic Yard                      Asphalt Concrete Intermediate
                       (Cubic Meter)                  Course, 9.5 mm, Type B (448)

442             Cubic Yard                      Asphalt Concrete Surface
                       (Cubic Meter)                  Course, 12.5 mm, Type A (448)

442             Cubic Yard                      Asphalt Concrete Surface
                       (Cubic Meter)                  Course, 12.5 mm, Type B (448)

442             Cubic Yard                      Asphalt Concrete Surface
                       (Cubic Meter)                  Course, 9.5 mm, Type A (448)

442             Cubic Yard                      Asphalt Concrete Surface
                       (Cubic Meter)                  Course, 9.5 mm, Type B (448)

442             Cubic Yard                      Asphalt Concrete Intermediate
                       (Cubic Meter)                  Course 19 mm, Type A (448)

442             Cubic Yard                      Asphalt Concrete Intermediate
                       (Cubic Meter)                  Course, 19 mm, Type B (448)

ITEM 443  STONE MATRIX ASPHALT CONCRETE

443.01  Description

443.02  Quality Control Program

443.03  Composition

443.04  Mixing

443.05  Storage

443.06  Quality Control

443.07  Construction

443.08  Acceptance

443.09  Basis of Payment

443.01  Description.  This work consists of constructing a stone matrix asphalt concrete (SMA) course consisting of aggregate, asphalt binder, and additives.

The requirements of 442 and 446 apply except as follows. Do not use the warm mix asphalt method (402.04) for this item.

443.02  Quality Control Program.  Update the Quality Control Program meeting 403.03 to include a section for how the quality control, production and placement of SMA will meet this specification.  Submit the revised program to the Laboratory with the SMA mix design to be approved.

443.03  Composition.  Discuss the mix design approach with the Laboratory during the mix design and prior to submittal.

A       Design Limits.  Submit a JMF to the Laboratory which meets the requirements of Table 443.03.1 and Table 443.03-2.

TABLE 443.03-1  MIX GRADATION

Sieve size

Total Percent Passing

3/4 inch

(19.0 mm)

100

1/2 inch

(12.5 mm)

85 to 100

3/8 inch

(9.5 mm)

50 to 75

No. 4

(4.75 mm)

20 to 28

No. 8

(2.36 mm)

15 to 24

No. 50

(300 µm)

10 to 20

No. 200

(75 µm)

8 to 12

TABLE 443.03-2  MIX PROPERTIES

Property Description

Specification

Binder, % [1]

5.8 to 7.5

VMA, % [2]

16.0 to 19.0

Draindown Test, % [3]

0.3

Design Air Voids, %

3.5

Design Gyrations [4]

65

VCA MIX / VCA DRC [5]

< 1.0

TSR [6]

0.80

F/A

NA

[1]  By total mix

[2]  Based on bulk gravity

[3]  AASHTO T305 conducted at mix production temperature (not compaction temperature)

[4]  Nini and Nmax do not apply

[5]  VCA = Volume of Coarse Aggregate (Calculated for mix and dry rodded conditions according to AASHTO PP41- 02 or newer version.)

[6]  Unconditioned specimens will have a minimum 65 psi (450 kPa) retained strength.

Compact specimens at 300 °F (149 °C) for PG 70-22M and 310 °F (154 °C) for PG 76-22M.

B.      Asphalt Binder.  Provide asphalt binder conforming to 702.01.

C.      Coarse Aggregate.  Use approved coarse aggregates.  Ensure coarse aggregates meet 703.05 and Table 443.03-3.

TABLE 443.03-3  AGGREGATE REQUIREMENTS

Tests

Description

Specification

ASTM D 4791

% Flat and Elongated Ratio at

3:1, (max. to min.)

5:1, (max. to min.)

20 max

5 max

ASTM D 5821

% Crushed, one / two faces

100 / 90 min

AASHTO T 96

LA Abrasion (stone or gravel)

35 max

D.      Mineral Filler.  Conform to 703.07.  Use mineral filler in the JMF with a plasticity index (AASHTO T 90) not greater than 4 (does not apply to hydrated lime).  Reclaimed asphalt concrete pavement passing the 5/8 inch (16 mm) sieve may be used as filler only.  Do not account for reclaimed asphalt concrete pavement binder content.  Do not use quicklime (CaO).  Do not premix filler with another aggregate.  Cover mineral filler piles to protect from rain.

Blend the mineral filler, asphalt binder and fiber stabilizer into a homogenous mixture and test the mortar for the following properties of Table 443.03-4.

TABLE 443.03-4  Mortar TEST REQUIREMENTS

Tests

Description

Specification

AASHTO T315

Unaged DSR, G*/ sin d (kPa)

5 minimum

AASHTO T315 & T240

RTFO Aged DSR, G*/ sin d (kPa)

11 minimum

AASHTO R28 & T313

PAV Aged BBR, Stiffness (MPa)

1500 maximum

E.      Reclaimed Asphalt Concrete Pavement.  Do not use reclaimed asphalt concrete pavement except as described in D above.

F.      Fiber Stabilizer.  Choose and meet the requirements of one of the following fiber stabilizers.  Submit with the JMF submittal the fiber manufacturer’s most recent actual test data and a certification of compliance for the fiber type to be used.  Protect the fiber stabilizer from moisture or other contamination.

Cellulose Fibers.  Add the fiber at a dosage rate of 0.3 to 0.4 percent by weight of the total mix as directed by the Engineer to control draindown in production.

1.      Fiber Length (max)                       0.25 inches (6.35 mm)

2.      Sieve Analysis – Alpine Sieve Method

Sieve size

Total Percent Passing

No. 100

(150 µm)

60 to 80

         Sieve Analysis – Ro-Tap Sieve Method

Sieve size

Total Percent Passing

No. 20

(850 µm)

80 to 95

No. 40

(425 µm)

45 to 85

No. 100

(150 µm)

5 to 40

3.      Ash Content                                   18% non-volatiles (±5%)

4.      pH                                                    7.5 (±1.0)

5.      Oil Absorption (times fiber weight) 5.0 (±1.0)

6.      Moisture Content (max)              5.0%

Cellulose Pellets.  Cellulose pellets consist of cellulose fiber and may be blended with 0 to 20 percent asphalt binder.  Meet the cellulose fiber requirements above.  If no asphalt binder is used, add the pellet at a dosage rate of 0.3 to 0.4 percent by weight of the total mix as directed by the Engineer to control draindown in production.  Adjust the fiber dosage to maintain the desired fiber amount when fiber is pre-blended with binder.

1.      Pellet size            1/4 cubic inch (maximum)

2.      Binder                 25 to 80 pen.

Mineral Fiber.  Use mineral fibers made from virgin basalt, diabase, or slag treated with a cationic sizing agent to enhance disbursement of the fiber as well as increase adhesion of the binder to the fiber surface.  Add the fiber at a dosage rate of 0.3 to 0.4 percent by weight of the total mix as directed by the Engineer to control draindown in production.

1.      Average Fiber length (max)                  0.25 inches (6.35 mm)

Average Fiber thickness (max)   0.0002 inch (0.005 mm)

2.      Shot content (ASTM C612)

Passing No. 60 (250 µm) sieve   90 to 100 percent

Passing No. 230 (63 µm) sieve   65 to 100 percent

3.      Degradation (max)*                     30 percent

* (GeorgiaDOT-124/McNett) - copy available from the Office of Materials Management, Asphalt section.

443.04  Mixing.  Conform to the following additional requirements.

A.      Fiber Stabilizer.  Furnish feeder equipment specifically manufactured to uniformly feed fiber into the plant and that is automated through connection with plant controls.  Include a low level and no-flow indicator and print out the feed rate of the feeder supply system and include a transparent pipe section for observing flow consistency.  The Engineer will approve the fiber feed system by a trial load of SMA and inspection of the bag house collected material prior to the start of production.  Conduct and document a weekly quick check of the fiber feed calibration according to the Quality Control Plan.  Conduct a daily check of fiber usage by calculating and documenting on the TE 199 that fiber usage is within 10 percent of the intended usage.

In drum plants, add the fibers in loose form, by an automated calibrated feed system, such that the fibers are coated by asphalt binder before being caught in the drum air flow.

In batch plants, distribute the fiber uniformly before injecting asphalt binder and increase mixing time a minimum of 5 seconds.

B.      Mineral Filler.  Filler may be fed through a hopper if consistency of flow is achieved.  If a problem in feeding consistency occurs a pneumatic system will be required.  Feed filler into the weigh hopper or pug mill of a batch plant, or at a point away from the flame on a drum plant.

443.05  Storage.  Do not store the SMA at the plant for more than 2 hours.  Do not exceed a mix temperature of 350 °F (180 °C).  Provide SMA at a minimum of 300 °F (148 °C) when it arrives at the paver, unless otherwise approved by the Laboratory.  If draindown occurs shorten the storage time and increase the fiber dosage.

443.06  Quality Control.  Ensure an employee of the Contractor with a Level 3 rating is at the plant or construction site during production of the SMA for any test strips and through at least one full production day satisfactory to the District.

Perform quality control tests every 3 hours of production.  The increased frequency of quality control testing may require additional quality control personnel at the plant.  Determine the asphalt binder content, gradation, moisture content, air voids, VMA, and MSG of the SMA.  For each test series calculate the VCAMIX / VCADRC.  If the limit of 1.0 is exceeded stop production until resolved.  Perform a draindown test once each day of production and raise fiber dosage 0.1 percent if the test limit is exceeded.  Do not exceed the No. 200 (75 µm) sieve design bands by the moving average of three tests.  Compact specimens at 300 °F (149 °C) for PG 70-22M and 310 °F (154 °C) for PG 76-22M.  Due to sample variability with SMA, a larger than usual sample size from which material is obtained for the various tests is required.

443.07  Construction.  At least 24 hours prior to beginning a test strip meet with the Engineer and DET and provide a written summary of steps taken to assure mix quality and construction practices account for the special needs of SMA production and placement.  Send a copy of the written summary to the Laboratory.

A.      Test Strips and JMF Adjustment.  Do not begin full production of the SMA until receiving authorization from the District.  This authorization will be based on the successful construction of one or more test strips.  Test strips consist of 50 to 100 tons of SMA produced and placed in accordance with these specifications.  Cease SMA production that day unless another test strip is needed.  Place test strips in one continuous mat.  The test strip will be included in the first lot for determining density for payment.  Test strips are incidental to the pay item.

During the construction of a test strip, perform 1 set of quality control tests as described above and obtain and test 3 random cores of the compacted pavement.  Within 1 working day after a test strip is completed, the District, the Laboratory and the Contractor's Level 3 employee will determine if any changes in the SMA JMF, production, or placement procedures are needed.  A redesign of the JMF or another test strip may be required.  The Laboratory will notify the District of any JMF adjustments.  Do not start production until notified by the District.

B.      Compaction.  Start compaction immediately after the SMA has been placed by the paver.  Use only steel wheel rollers.  Vibratory rollers in vibratory mode, set at a high frequency and low amplitude, can be used as the breakdown roller only.  Always operate the breakdown roller immediately behind the paver.  If isolated, small fat spots develop, apply sand immediately during compaction.  If continuous and/or large fat spots develop, cease production until resolved.  Do not compact SMA that is below 230 °F (110 °C).

C.      Hauling.  Do not allow trucks to dump any mix on the project mat after delivering mix to the paver.  Provide a suitable place for bed cleaning off of the mat.

443.08  Acceptance.  After accepting the test strips, the Department will accept SMA according to 446.05.

443.09  Basis of Payment.  The Department will pay for accepted quantities of Stone Matrix Asphalt Concrete, complete in place, including test strip, at the contract price as modified by 446.05, as follows:

Item           Unit                                Description

443             Cubic Yard                      Stone matrix asphalt concrete,
                       (Cubic Meter)                  12.5mm, PG70-22M, (446)

443             Cubic Yard                      Stone matrix asphalt concrete,
                       (Cubic Meter)               12.5mm, PG76-22M, (446)

ITEM 446  ASPHALT CONCRETE

446.01  Description

446.02  JMF Field Adjustments

446.03  Monitoring

446.04  Reports

446.05  Density Acceptance

446.06  Joints

446.07  Basis of Payment

446.01  Description.  This work consists of constructing a surface course or an intermediate course of aggregate and asphalt binder mixed in a central plant and spread and compacted on a prepared surface. The Department will base acceptance of the compacted mixture in place on the level of density attained as sampled by the Contractor and analyzed by the Department.

The requirements of Item 441 apply, except as modified by this specification.

446.02  JMF Field Adjustments.  Determine the need for any JMF gradation adjustments, provided for in 441.05, in the first 3 days or first 3000 tons (3000 metric tons) of production, whichever comes last.  Give the DET written notice of JMF adjustments no later than the end of the following day’s production.

For projects smaller than the above JMF field adjustment period give the DET written notice of any JMF gradation adjustments within 1 workday following the last day of production.

446.03  Monitoring.  If there is poor comparison between the Department’s comparison samples and the Contractor’s quality control tests, the Monitoring Team may at any time disallow production to continue under Item 446.  In this case, conform to Items 448 and 446.  The Department will notify the Contractor in writing to stop production.

446.04  Reports.  Submit the Quality Control Report according to 441.11 on the workday following the production day of the material represented by the report.

446.05  Density Acceptance.  The requirements of 401.13 do not apply.  However, rollers must fully and satisfactorily provide the required compaction, be mechanically sound, and meet Hot Mix Asphalt industry standards.  The Department retains the right to reject the use of rollers which are not in good repair, or are not designed to do the work required.  A three-wheel roller according to 401.17 is not required.

Obtain ten, 4-inch cores for the Department to test to determine the in-place density of the compacted mixture as a percentage of the average QC Maximum Specific Gravity (MSG) for the production day the material was placed.  If Department MSG VA tests show poor comparison to the average QC MSG according to 403.06 use Department determined MSG results in the density calculation for each production day.  Compact shoulders using the same equipment and procedures as used on the mainline pavement.  The requirements of 401.16, except for the last four paragraphs, are waived.

Payment for compaction of the completed mainline pavement and ramps is by Lot, based upon the degree to which density is attained.  Payment for shoulders depends on the degree to which the density is obtained on the adjacent mainline pavement lane or ramp.  However, when a cold longitudinal joint is made between a mainline pavement lane and an adjoining shoulder, payment for the shoulder will be based on the degree to which the density is obtained on the shoulder.

A Lot consists of an area of pavement placed during a production day, including the shoulders.  If less than 400 tons (400 metric tons) is produced in a production day, then that production day is combined with the next production day into a single Lot.  If greater than 250 tons (250 metric tons) and less than 400 tons (400 metric tons) are produced on the last day of production for the project, then the day’s production is a separate Lot.  If less than 250 tons (250 metric tons) is produced on the last production day for the project, it is part of the previous Lot for acceptance, provided the previous Lot was placed within 3 days; otherwise, it is a separate Lot.

Within 48 hours after the pavement is placed, obtain ten cores for each Lot at random locations the Engineer determines.  The Engineer will divide a Lot into five equal sublots and calculate two random core locations in each sublot as described below using an acceptable random number selection method.  Both mainline pavement and ramps will be included in Lot determinations.  The Engineer will not give the Contractor random core locations early in the Lot placement.  The Engineer will tell the Contractor the method used to determine random locations as noted below before project start and will use the same method for all Lots.

For each Lot three cores will be taken as follows from cold longitudinal joints and seven cores will be taken from the mat not including the joints.  If locations not according to this specification are given, immediately inform the Engineer.  Do not take cores from ramp joints.  Take joint cores from the first, last and randomly from one of the three middle sublots.  Determine the longitudinal location of the joint core within the sublot randomly and also randomly determine whether or not the cold longitudinal joint core is to be taken from a confined or unconfined joint if both exist in the mat to be cored.  Do not take cores on the sloped face of a wedge before the adjoining lane is placed.  Take joint cores such that the core's closest edge is six inches (150 mm) from the edge of the joint upper notch of a wedge joint or 4 inches (100 mm) from the edge of a vertical face joint.  If a nine inch or wider wedge joint is used take the core three inches from the upper wedge joint notch.  Take the seven random mat cores that are not for the joint coring such that the core's closest edge is at least twelve inches from the cold longitudinal joint wedge joint upper notch or vertical face edge.  If taken, locate cores for the Contractor’s quality control (QC sister core) longitudinally from and within four inches (100 mm) of the random core.  In addition to the QC sister cores, three extra cores may be taken from the first lot of a JMF for testing to correlate density gauges. Do not take additional cores beyond what is noted above unless clearly identified in the approved Contractor’s QCP. Clearly label all cores with mat locations so that they may be readily identified. Any unlabeled cores may be destroyed by the Department. Notify the Laboratory if any questions arise.  Do not store additional cores anywhere (project, in vehicles or at the plant) beyond what are required to be taken for testing.  Test all Contractor QC cores and maintain records of all tests (core tests and correlated gauge tests) per the QCP.  Destroy all cores immediately after testing is complete. 

The Department will determine the pay factor for each Lot cored by the pay schedule in Table 446.05-1 for Lots with three cold longitudinal joint cores and Table 446.05-2 for Lots with less than three cold longitudinal joint cores.  The Department will verify the MTD if the MSG determination has a deviation from the MTD of less than or equal to 0.020.  If the MTD is not verified, establish a new MTD according to the procedures established in 441.09.  If less than 10 cores are available for determining the mean, the Laboratory will determine disposition of the Lot.

Fill core holes by the next workday with asphalt concrete.  Before filling, ensure the holes are dry and tack them with asphalt material conforming to 407.02.  Properly compact the asphalt concrete used for filling the hole and leave it flush with the pavement.

Fill core holes by the next workday.  Before filling, ensure the holes are dry and tack them with asphalt material conforming to 407.02.  Properly compact the asphalt concrete used for filling the hole and leave it flush with the pavement.

TABLE 446.05-1  FOR LOTS WITH 3 COLD JOINT CORES

Mean of Cores [1]

Pay Factor

Surface Course

Intermediate Course

98.0% or greater

[2]

[2]

97.0 to 97.9%

0.94

[2]

96.0 to 96.9%

1.00

0.94

93.4 to 95.9%

1.04 [4]

1.00

92.4 to 93.3%

1.00

1.00

91.4 to 92.3%

0.98

1.00

90.4 to 91.3%

0.90

0.94

89.4 to 90.3%

0.80

0.88

88.4 to 89.3%

[3]

[3]

Less than 88.4%

[2]

[2]

[1]  Mean of cores as percent of average MSG for the production day.

[2]  For surface courses, remove and replace.  For other courses, the District will determine whether the material may remain in place.  If the District determines the course should be removed and replaced, the Contractor will remove and replace this course and all courses paved on this course.  The pay factor for material allowed to remain in place is 0.60.

[3]  The District will determine whether the material may remain in place.  If the District determines the course should be removed and replaced, the Contractor will remove and replace this course and all courses paved on this course.  The pay factor for such material allowed to remain in place is 0.70.

[4]  No incentive will be paid if any single cold joint core is less than 91.0%.

TABLE 446.05-2  FOR LOTS WITH LESS THAN 3 COLD JOINT CORES

Mean of Cores [1]

Pay Factor

Surface Course

Intermediate Course

98.0% or greater

[2]

[2]

97.0 to 97.9%

0.94

[2]

96.0 to 96.9%

1.00

0.94

94.0 to 95.9%

1.04 [4]

1.00

93.0 to 93.9%

1.00

1.00

92.0 to 92.9%

0.98

1.00

91.0 to 91.9%

0.90

0.94

90.0 to 90.9%

0.80

0.88

89.0 to 89.9%

[3]

[3]

Less than 89.0%

[2]

[2]

[1]  Mean of cores as percent of average MSG for the production day.

[2]  For surface courses, remove and replace.  For other courses, the District will determine whether the material may remain in place.  If the District determines the course should be removed and replaced, the Contractor will remove and replace this course and all courses paved on this course.  The pay factor for material allowed to remain in place is 0.60.

[3]  The District will determine whether the material may remain in place.  If the District determines the course should be removed and replaced, the Contractor will remove and replace this course and all courses paved on this course.  The pay factor for such material allowed to remain in place is 0.70.

[4]  No incentive will be paid for lots where 3 joint cores are required to be taken but less than 3 cores are taken.

446.06  Joints.  Construct joints according to 401.17.  Make a hot longitudinal joint between the mainline pavement lane and the adjoining shoulder and all ramps and the adjoining shoulders.  If a hot longitudinal joint is specified between the mainline pavement lanes, the Contractor may construct a cold longitudinal joint between the mainline pavement lanes and the adjoining shoulders.  Cold longitudinal joints in mainline pavement will be tested according to 446.05.

446.07  Basis of Payment.  The Department will pay for accepted quantities, completed in place, at the contract prices, as modified by 446.05, as follows:

Item           Unit                            Description

446             Cubic Yard                  Asphalt Concrete
                       (Cubic Meter)              Intermediate Course, Type ___

446             Cubic Yard                  Asphalt Concrete Surface
                       (Cubic Meter)              Course, Type ___

ITEM 448  ASPHALT CONCRETE

448.01  Description

448.02  JMF Field Adjustments

448.03  Density

448.04  Reports

448.05  Acceptance

448.06  Basis of Payment

448.01  Description.  This work consists of constructing a surface course or an intermediate course of aggregate and asphalt binder mixed in a central plant and spread and compacted on a prepared surface.  The Department will determine acceptance of the mixture by Lot, based on the composition of random samples taken and tested by the Contractor and verified by the Department.

The requirements of Item 441 apply, except as modified by this specification.

448.02  JMF Field Adjustments.  Determine the need for any JMF gradation adjustments, provided for in 441.05, from the results of quality control and Department verification tests of the first two acceptance lots.  Following adjustment, the Department will apply the adjusted JMF, for acceptance purposes, to the entire production including the first two lots.  Give the DET written notice of JMF adjustments no later than the end of the first workday following the notification of verification test results of the second acceptance lot.

For projects with less than two acceptance lots or for any JMF that will no longer be used on a project, give the DET written notice of any JMF gradation adjustments within 1 workday following the notification of acceptance test results.

448.03  Density.  Conduct density gauge quality control testing on the asphalt mat according to Supplement 1055 (S 1055).  Conduct density gauge testing on uniform courses of 1.0 in (25mm) or more plan thickness.  Conduct density gauge testing on projects of two adjacent lanes or more and with at least one continuous mile (1.6 kilometers) of paving (excepting bridges, intersections etc.).

When Supplement 1055 density gauge testing is required, the requirements of 401.16, except the last four paragraphs, are waived.  The requirements of 401.13 do not apply.  However, rollers must fully and satisfactorily provide the required compaction, be mechanically sound, and meet Hot Mix Asphalt industry standards.  The Department retains the right to reject the use of rollers which are not in good repair, or are not designed to do the work required.  A three-wheel roller per 401.17 is not required.

448.04  Reports.  Refer to Item 403 for reporting requirements of asphalt mixtures tested at the asphalt plant.  Report density gauge QC testing results according to S 1055.

448.05  Acceptance. Refer to Item 403 for acceptance requirements.  If a project includes 448.03 Density, acceptance will include any density deductions according to S 1055.04.

448.06  Basis of Payment.  The Department will pay for accepted quantities, completed in place, at the contract prices, or at the contract price as modified in 448.05, as follows:

Item           Unit                            Description

448             Cubic Yard                  Asphalt Concrete
                       (Cubic Meter)              Intermediate Course, Type ___

448             Cubic Yard                  Asphalt Concrete Surface
                       (Cubic Meter)              Course, Type ___

450  RIGID PAVEMENT

ITEM 451  REINFORCED PORTLAND CEMENT CONCRETE PAVEMENT

451.01  Description

451.02  Materials

451.03  Pavement Quality Control

451.04  Equipment

451.05  Setting Forms

451.06  Fine Grading of Subgrade or Subbase

451.07  Placing Concrete

451.08  Placing Reinforcement

451.09  Joints

451.10  Finishing

451.11  Curing

451.12  Removing Forms

451.13  Surface Smoothness

451.14  Profile Grinding

451.15  Pavement Grooving Corrections

451.16  Sealing Expansion Joints

451.17  Opening to Traffic

451.18  Pavement Thickness and Concrete Strength

451.19  Price Adjustments

451.20  Method of Measurement

451.21  Basis of Payment

451.01  Description.  This work consists of constructing a pavement composed of reinforced portland cement concrete on a prepared surface.

451.02  Materials.  Furnish materials conforming to:

Concrete,
either Class QC 1, QC MS, QC FS.................... 499
* Class RCA................................ Supplement 1117

Joint sealer........................................................... 705.04

Preformed filler................................................... 705.03

Curing materials...... 705.05, 705.06, 705.07 Type 2

Tiebar steel, epoxy coated................................ 709.00

Reinforcing steel.................... 709.09, 709.10, 709.12

Dowel bars and basket assemblies.................. 709.13

*  Use of Recycled Concrete aggregate as part of a concrete mix can be accepted with conformance to Supplement 1117

451.03 Pavement Quality Control. When the concrete pavement bid item includes “with QC/QA”, provide complete quality control of the concrete manufacturing, placing and curing operations and quality control testing of the work conforming to Item 455. The Engineer will review and accept the plan prior to beginning of any paving operations.

When the concrete pavement bid item includes “with QC/QA” the Engineer will perform Quality Assurance conforming to Item 455.

451.04  Equipment.  Furnish self-propelled spreading and finishing machines capable of consolidating and finishing the concrete and producing a finished surface meeting the requirements specified.

Construct pavement using either fixed forms or slip form paving equipment that conforms to the following:

A.      Fixed Form Construction.  Spread, screed, and consolidate concrete using one or more machines between previously set side forms.  Furnish an adequate number and capacity of machines to perform the work at a rate equal to the concrete delivery rate.  Furnish machines capable of uniformly distributing and consolidating the concrete without segregation.

Provide machines capable of operating on two side forms, on adjacent lanes of pavement and one side form or on two adjacent lanes as necessary.  When placing concrete adjacent to an existing pavement lane, take measures to protect the adjacent pavement from damage.  Remove from the work any machine that causes displacement of the side forms from the line or grade or causes undue delay, as determined by the Engineer, due to mechanical difficulties.

Finish small or irregular areas that are inaccessible to finishing equipment using other methods as approved by the Engineer.  Accomplish vibration of these areas using hand held or machine mounted internal vibrators.  Continue vibration to achieve adequate consolidation, without segregation, for the full depth and width of the area placed.

Use straight edge side forms made of steel and of a depth equal to the specified pavement thickness.  Do not use bent or damaged side forms or forms with damaged joint locks or pin pockets.  Provide forms in sections of not less than 10 ft (3m) in length without horizontal joints in the height of the form.   Utilize forms with a nominal base width of at least 3 inches (75 mm). Assure forms are capable of supporting the paving equipment without shifting or deforming during paving.  Clean and oil all forms each time they are used.  If the radius of the circular pavement edge is 100 feet (30 m) or less, use flexible or curved forms of a design acceptable to the Engineer.  Provide adequate devices to securely set forms and withstand operation of the paving equipment.  Do not use built-up forms except to construct pavement of a specified thickness whose total area for the project is less than 2000 square yards (1650 m²).  Provide forms with adequate joint locks to tightly join ends of abutting form sections together.

B. Slip Form Construction.  Place concrete using an industry-standard slip form paver designed to spread, consolidate, screed, and finish the freshly placed concrete in one complete pass of the machine and with a minimum of hand finishing providing a dense and homogeneous pavement.

Consolidate the full width and depth of concrete pavement placed by a single pass of a series of approved internal vibrators operating at a frequency range of 7000 to 11,000 impulses per minute.  Attach vibrators to either the spreading or finishing equipment in such a manner that they do not come in contact with preset dowel basket assemblies, the subgrade, reinforcing mesh or side forms.  Do not operate vibrators in a manner to cause a separation of the mix ingredients (segregation); i.e., either a downward displacement of large aggregate particles or an accumulation of laitance on the surface of the concrete.  Avoidance of segregation of the concrete mix may require reduction in the vibration frequency within the range specified when forward motion of the paver is reduced.  Connect the power to all vibrators so that they cease when the machine motion is stopped.  Stop paving operations if any vibrator fails to operate within the above specified range.

Provide an electronic monitoring device that displays the operating frequency of each internal vibrator on all paving machines used on mainline and ramp paving.  The monitoring device shall have a readout display near the paver operator’s controls that is visible to the operator and the Engineer.  Operate the monitoring device continuously while paving and display all vibrator frequencies with manual or automatic sequencing among individual vibrators.  Using the monitoring system record the following minimum information:  time of day, station location, paver track speed, and the frequency of each individual vibrator.  Make recordings after each 25 feet (8 m) of paving or after 5-minute intervals of time.  If not using a monitoring system with a recorder, make and record readings every 30 minutes.  If requested by the Engineer, provide a record of the data.

Electronic vibration monitoring devices are not required for paving machines used to construct shoulders and gores or for any construction project with a total of less than 10,000 square yards (8000 m²) of pavement.  When electronic monitoring devices are not required, use a tachometer or similar device to demonstrate to the Engineer the paving equipment vibration meets specification.

Operate the slip form paver with as nearly a continuous forward movement as possible, and coordinate all operations of mixing, delivering, and spreading concrete to provide uniform progress with minimal stopping and starting of the paver.  If for any reason it is necessary to stop the forward movement of the paver, immediately stop the tamping elements.  Unless controlled from the machine, do not apply any other tractive force to the machine.

Accurately control the finish grade of the pavement from a pre-set grade line parallel to the finish grade using equipment with controls that will trace the grade line and automatically adjust the grade of the screeds or extension meters.

In areas where adjoining concrete pavement is to be constructed, ensure that the surface at the edge of the pavement on either side of the longitudinal joint does not vary more than 1/4 inch (6 mm) below the typical section.  Ensure that the outside edges of the pavement does not vary more than 1/2 inch (13 mm) below the typical section.  Ensure that all pavement edges are nearly vertical with no projections or keyways exceeding 1/2 inch (13 mm).

In the area of construction joints placed at the end of the days run, the Engineer will allow a reduction of approximately 2 inches (50 mm) in overall width.

451.05  Setting Forms.  Set all forms in conformance to the required grade and alignment and support the entire length of forms on thoroughly compacted material during the entire operation of placing and finishing of the concrete.  Set side forms with the top face of the form varying not more than 1/8 inch in 10 feet (3 mm in 3 m) from true plane, and the vertical face varying not more than 1/4 inch in 10 feet (6 mm in 3 m) from true plane.  Test the forms for variations from the above requirements and reset the forms as necessary.  Do not use loose earth, pebbles, etc., to shim the forms.  Immediately before placing concrete, the Engineer will approve the alignment and grade of all forms set.

451.06  Fine Grading of Subgrade or Subbase.

A.      Fixed Form Construction.  After side forms have been set to line and grade and securely fastened, use a subbase or subgrade planer to remove a slight amount of material and bring the subgrade or subbase to final grade and to a smooth dense condition.  Check the subgrade or subbase using a multiple pin template operated on the forms or other methods approved by the Engineer.  Correct and retest all high or low spots.

Instead of the above operation, the Contractor may place forms on subbase or subgrade prepared according to 451.06.B.

B.      Slip Form Construction.  After the subgrade or base is placed and compacted to the required density, use an automatic subgrading machine to cut the areas for pavement and the areas that will support the paving machine to the plan elevation.  Construct the grade sufficiently in advance of placing the concrete to permit the Engineer to check the grade.

451.07  Placing Concrete.  When constructing on subbase or subgrade, immediately before placing concrete, bring the subgrade or subbase to a thoroughly moistened condition by sprinkling with water at such times and in such manner as directed by the Engineer.

When constructing on asphalt concrete, coat the asphalt concrete with curing membrane at least one day prior to placing concrete.  Apply the curing membrane at a minimum rate of 1 gallon (1 L) for each 150 square feet (3.7 m²) of surface treated using an approved self-propelled mechanical sprayer.  Provide an adequate shield to protect the fog spray from the wind.  Thoroughly agitate the curing material before use.

Deposit concrete on the grade in a manner that requires as little rehandling as possible.  Do not allow workers to walk in the freshly mixed concrete unless wearing clean boots or shoes free of earth or any foreign material.

At expansion and contraction joints, deposit concrete near the joints to ensure the dowel basket assemblies are not disturbed.  Do not allow concrete to discharge onto any dowel basket assembly unless the hopper is well centered on the assembly.  Use a separate internal vibrator to consolidate concrete around dowel basket assemblies.

Provided the curing compound damage caused by sawing is repaired according to 451.11 and to the Engineer’s satisfaction, the Contractor may operate the sawing equipment necessary to saw joints on the newly constructed pavement.  Do not operate other mechanical equipment upon existing lane of pavement for seven days and specimen beams attain a modulus of rupture of 600 psi (4.2 MPa).  If only finishing equipment is carried on an existing lane, paving may be permitted after that lane has been in place for at least 3 days and after specimen beams shall have attained a modulus of rupture of 500 psi (3.5 MPa).

When the width of pavement being placed in one operation is 12 feet (3.6 m) or more and the total area of any given width of pavement on the project exceeds 10,000 square yards (8300 m²), use a separate standard manufacture, self-propelled concrete placer/spreader that receives concrete into a hopper adjacent to the area to be paved and delivers the concrete in front of the slipform paver and uniformly spreads the concrete at the proper thickness for the full width being paved.  When a slipform paver is equipped with a dowel bar inserter the separate placer/spreader requirement may be waived provided the concrete is delivered in front of the slipform paver at a consistent and uniform thickness for the full width being paved and the slipform paver is capable of spreading, consolidating, screeding, and float finishing the freshly placed concrete. Provide the Engineer documentation that the slipform paver will meet this specification.

Do not mix, place, or finish concrete after dark without operating an adequate and approved lighting system.

When the air temperature is 35 °F (2 °C) or below, assure the concrete has a temperature of between 50 and 80 °F (10 and 27 °C) at the point of placement.

When the air temperature is greater than 35 °F (2 °C) before placing, maintain a concrete temperature of not more than 95 °F (35 °C). 

Do not place concrete on any surface that is frozen or has frost.

Make two test beams from each 7500 square yards (6300 m²) of concrete or fraction thereof incorporated in the work each day.

451.08  Placing Reinforcement.  Place pavement mesh of the size and at the locations within the concrete slab shown on the standard construction drawings.  When placing reinforced concrete pavement in two layers, strike off the entire width of the bottom layer to a length and depth that allows laying the mat of reinforcement on the concrete and in its final position without further manipulation.  After installing reinforcement directly upon the concrete, place, strike off, and screed the top layer of concrete.  When reinforced concrete pavement is placed in one layer and in advance of placing concrete, position and securely anchor the reinforcement to the underlying base or pavement.  As an alternative, after spreading the concrete and while it is in a plastic condition, use mechanical or vibratory means to place reinforcement in the concrete.

Where reinforcement is overlapped, securely fasten mats of reinforcement together at the edges of the sheets and at two additional points along the lap.  Use reinforcing steel free from dirt, oil, paint, and grease.

451.09 Joints.  Unless otherwise directed, construct all transverse joints normal to the centerline of the pavement lane and of the type, dimensions, and at locations specified.

Determine contraction and longitudinal joint sawing time limits to protect the concrete from early cracking by using HIPERPAV software.  Obtain the software according to Supplement 1033.  

Twenty four (24) hours before placing concrete pavement create a HIPERPAV project date file according to Supplement 1033.

Provide the completed file and the printout to the Engineer.  When HIPERPAV predicts early age slab cracking will occur, whether due to standard construction practices, joint sawing methods, mix design or curing, either do not start construction until modifications have been made to eliminate HIPERPAV’s predicted slab cracking or do not pave.

Perform a HIPERPAV analysis for each pour.

If software analysis determines joint sawing could exceed twenty four (24) hours, assure all joints are sawed by the 24th hour.

A HIPERPAV analysis showing paving can proceed does not eliminate the requirements of 451.17.

Accurately mark the correct locations of all joints that will be saw cut along both edges of the pavement.  Ensure the method of marking remains clearly visible after the paver passes and until the joint saw cut is completed. 

A. Longitudinal Joint.  Construct longitudinal joints between simultaneously placed lanes by sawing.

When a standard (water cooled diamond bladed) concrete saw is used to make the longitudinal joint between simultaneously placed lanes, saw the joint within the timeframe provided in the HIPERPAV output.  For pavement less than or equal to 10 inches (255 mm), saw the joint to a minimum depth of one-fourth the specified pavement thickness.  For pavements greater than 10 inches (255 mm) thick, saw the joint to a minimum depth of one-third the specified pavement thickness.  Saw joints 1/4 ± 1/16 inch (6 ± 1.6 mm) wide measured at the time of sawing. 

When using early-entry (dry cut, light weight) saws to make the longitudinal joint between simultaneously placed lanes, only use saw blades and skid plates as recommended by the saw manufacturer for the coarse aggregate type being used in the concrete. Perform the early-entry sawing after initial set and before final set. Saw the joint 1/8 inch (3 mm) wide and 2 1/4 to 2 1/2 inches (56 to 63 mm) deep.

Place deformed epoxy coated steel tiebars or the epoxy coated hook bolt alternate (wiggle bolt) with epoxy coated coupling, in longitudinal joints during consolidation of the concrete.  Install them at mid-depth in the slab by approved mechanical equipment.  As an alternate procedure, rigidly secure them on chairs or other approved supports to prevent displacement.  Provide tie bars or wiggle bolts of the size and spaced as shown on the standard construction drawings.  If used, securely fasten hook bolts or wiggle bolts with couplings to the form at the longitudinal construction joint as shown on the standard construction drawings.

B. Transverse Joints

Unless otherwise directed, construct all transverse joints normal to the centerline of the pavement lane and of the type, dimensions, and at locations specified.

For all transverse joints, install round, straight, smooth, steel dowel bars of the size shown in Table 451.09-1.

TABLE 451.09-1  DOWEL SIZE

Thickness of Pavement (T)

Diameter of Steel Dowel

Less than 8 1/2 inches (215 mm)

1 inch (25 mm)

8 1/2 to 10 inches (215 to 255 mm)

1 1/4 inches (32 mm)

Over 10 inches (255 mm)

1 1/2 inches (38 mm) or as shown on the plans

Within 2 hours prior of placing concrete coat the full length of all dowels with a thin uniform coat of new light form oil as a bond-breaking material.

Load Transfer Assemblies. 

Use load transfer (dowel basket) assemblies in transverse contraction joints conforming to and placed according to the standard drawings to hold the dowels in a position parallel to the surface and centerline of the slab at mid-depth of the slab thickness.

Preset all dowel basket assemblies before the day’s paving unless the Engineer determines complete presetting is impractical.

Completely install dowel basket assemblies before shipping and spacer wires are removed.  

Immediately before paving, remove all shipping and spacer wires from the dowel basket assemblies; check the dowel basket assemblies are held firmly in place; check the dowels are parallel to the grade and parallel to centerline of pavement. 

For each joint assembly used to hold dowels in position, provide a continuous assembly between longitudinal joints or between the longitudinal joint and pavement edge.  Drive at least eight 1/2-inch (13 mm) diameter steel pins a minimum of 18 inches (460 mm) long at an angle to brace the assembly from lateral and vertical displacements during the placing of concrete.  Drive two of these pins opposite each other at each end of the assembly, and drive the remaining pins in staggered positions on each side of the assembly.  Where it is impractical to use the 18-inch (460 mm) length pins, such as where hardpan or rock is encountered, and provided the assembly is held firmly, the Engineer may authorize use of shorter pins.  Where the dowel basket assembly is placed on granular material that may allow settlement or distortion, anchor the assembly with a combination of pins and steel plates, or by some other means satisfactory to the Engineer to prevent settlement.

When concrete pavement is placed on an existing concrete pavement or on a stabilized base, secure dowel basket assemblies from lateral and vertical displacement during concrete placement using power-driven fasteners and appropriate clips or pins driven in predrilled holes of a diameter slightly less than the pin diameter.  Use either of the above methods or a combination of the two in sufficient numbers to adequately secure the basket assemblies.

Where widths other than 12 feet (3.6 m) are specified, the Contractor may use standard dowel basket assemblies with dowel spacings adjusted as follows.  Maintain 6-inch (150 mm) dowel spacing at the longitudinal joint and increase the spacing at the outer edge of the lane up to 12 inches (300 mm).  Where an odd width of lane occurs and if the standard dowel basket assembly would provide for a space exceeding 12 inches (300 m), place a dowel 6 inches (150 mm) from the outer edge of the lane).  Hold such a dowel rigidly in proper position by a method satisfactory to the Engineer or cut and splice a dowel basket assembly of greater length than required to attain the required length.

Slip Form Paver with Mechanical Dowel Bar Inserter. 

The Contractor may propose to use a slip form paver with mechanical dowel bar inserter (DBI) to place dowels in transverse contraction joints the full thickness of pavement and spaced per the requirements of the standard construction drawings.  Submit details and specifications of the proposed equipment to the Engineer at least 14 calendar days prior to mobilizing the equipment to the project. 

The use of any slip form paver with DBI is allowed only after acceptable performance is demonstrated with a test section and approved by the Engineer.  Continued verification during all contract paving is required for each production day as detailed below.  

Provide all equipment, perform all testing, and evaluate the slip form paver with DBI as detailed in the following sections. 

1.          MIT Scan-2 Equipment and Reporting

Provide MIT Scan-2 equipment to determine the location of dowel bars in either fresh or hardened concrete including horizontal translation, longitudinal translation, vertical translation, horizontal skew, vertical tilt, and cover.

Provide equipment for determining dowel bar alignment that has an onboard computer that runs the test; collects and stores the test data on a memory card; performs the preliminary evaluation; and provides a printout of results immediately after scanning.  Provide MagnoProof software to provide a detailed report of all required alignment parameters in an Excel spreadsheet and a graphical color representation.

Ensure the equipment is properly calibrated conforming to the manufacturer’s specifications and for the specific project conditions.  Provide calibration documentation to the Engineer prior to the start of construction. Establish a standard protocol for scanning direction.

Provide trained personnel to operate the equipment and documentation of training prior to start of construction.

Provide a print out, at the time of scanning, for horizontal translation, longitudinal translation, vertical translation, horizontal skew, vertical tilt, and cover for each bar in each joint scanned.  For each Test Section and daily, for each day of production, provide a complete report to the Engineer at the completion of scanning along with a digital copy of all data collected in the manufacturer’s native file format as well as all calibration files.  Include the standard report generated using the MagnoProof software in Excel format and with color graphical representation of each joint.  Include in the report project contract number, county-route-section, placement date, scan date, station location and lane, joint ID number, name of operator, and all required alignment parameters.

If non-magnetic dowel bar materials are to be used, propose and demonstrate alternative measurement equipment to the Engineer showing capability to provide measures equal or similar to the acceptance and rejection criteria of Table 451.09-2.  Obtain the Engineer's approval of alternative equipment prior to paving.  If no alternative equipment can demonstrate the required capability, do not use the slip form paver with DBI.

Prior to paving, review the measurement equipment applicability for the project conditions with the Engineer, including: ambient moisture conditions, dowel material, metallic concrete aggregate and potential contributors to magnetic interference (presence of tiebars, reinforcing steel or other embedded or underlying steel items that may affect measurement accuracy).  Establish how the measurement device can meet the project conditions.  If the measurement device cannot meet the project conditions, do not use the slip form paver with DBI.

2.          Acceptance/Rejection

The required dowel bar tolerances are given in Table 451.09-2.  Dowel bar alignment is measured as detailed below.  Any dowel bar exceeding any Acceptance Tolerance in Table 451.09-2 is considered misaligned.  Rejection Criteria is in absolute inches.

TABLE 451.09-2

Individual Dowel Bar Alignment Tolerances

Alignment Parameter

Acceptance Tolerance (inches)

Rejection Criteria (inches)

Horizontal Translation a

±2.0

±3.0

Longitudinal Translation b

±2.0

±4.0

Vertical Translation c

±1.0

± T/6

Horizontal Skew d

±0.60

±1.0

Vertical Tilt e

±0.60

±1.0

Cover f

-

2.5 minimum

a.       Horizontal Translation - the total difference, measured horizontally, between the actual dowel bar location and the plan required dowel bar location along the transverse contraction joint.

b.       Longitudinal Translation - the total difference, measured in the longitudinal direction, from the center of the transverse contraction joint to the actual dowel bar center. Also termed as “side shift”.

c.        Vertical Translation - the total difference, measured vertically, between the centerline of the actual dowel bar location and the mid-depth of the slab. (T = Pavement Thickness in inches)

d.       Horizontal Skew - the total difference, measured from end to end of a dowel bar, of the dowel in the horizontal plane.

e.        Vertical Tilt - the total difference, measured from end to end of a dowel bar, of the dowel bar in the vertical plane.

f.        Cover - the least distance between the surface of embedded reinforcement and the outer surface of the concrete.

Perform a Joint Score Analysis conforming to CPTP Tech Brief Best Practices for Dowel Placement Tolerances (FHWA-HIF-07-021) for every joint.  Joint Score is a measure of the combined effects of horizontal skew and vertical tilt.  To calculate the Joint Score: calculate the Single Dowel Misalignment (SDM) by the square root of the sum of the squares of the Horizontal Skew and Vertical Tilt of each dowel in the joint; determine the weighing factor (W) for each bar from Table 451.09-3; sum the W values for every dowel in the joint and add one (1).

Joint Score (JS) – Evaluated for a single transverse joint between adjacent longitudinal joint(s) and/or pavement edge(s) (i.e., a typical 12 ft [3.6 m] standard lane or up to 14 ft [4.3 m] widened lane), and calculated as:

where:

n =         number of dowels in the single joint

Wi =       weighting factor (Table 451.09-3) for dowel i

TABLE 451.09-3

Weighting Factors in Joint Score (JS) Determination

Single Dowel Misalignment (SDM)

W, Weighting Factor

SDM ≤ 0.6 in. (15 mm)

0

0.6 in. (15 mm) < SDM ≤ 0.8 in. (20 mm)

2

0.8 in. (20 mm) < SDM ≤ 1 in. (25 mm)

4

1 in. (25 mm) < SDM ≤ 1.5 in. (38 mm)

5

1.5 in. (38 mm) < SDM

10

Joint Score Trigger (JST) – A scaling of the Joint Score risk value to account for the actual number of dowels required in a single joint for pavement width other than 12 ft (3.6 m), calculated as:

Include the Joint Score and Joint Score Trigger for every joint scanned in the report to the Engineer.  Any joint with a Joint Score equal to or greater than the Joint Score Trigger is considered locked and rejectable.

3.          Test Section

Prior to production use of a DBI slip form paver, perform at least a 500-foot (150 m) long test section for acceptance of the machine.  Measure the alignment and location of each dowel bar in the test section using the MIT Scan-2.  The test section will be considered acceptable if the following acceptance criteria are met:

1.       Each Joint Score (JS) is less than Joint Score Trigger (JST);

2.       Ninety percent (90%) of the dowel bars meet the Acceptance Tolerances of Table 451.09-2;

3.       None of the dowels exceed the Rejection Tolerances of 451.09-2.

If the test section acceptance criteria is not met, use the data to refine the paving process and reduce/eliminate misalignments and mislocations.  Modify, repair or replace any slip form paver with DBI that does not meet the acceptance criteria and perform another test section.  Do not begin production paving until the slip form paver with DBI test section acceptance criteria is met.

Perform corrective action of all joints in the test section according to Section 5 below.

Perform a new test section for any new slip form paver with DBI that will be used for any contract item of work.

Perform a new test section at the beginning of every construction season; after major paver maintenance/repairs; at mobilization or remobilization to a project, for major concrete mix design changes or different concrete mix designs; and as required by Section 4 of this specification.

If the length of the section to be paved makes it unreasonable to perform the test section, scan all joints for conformance with the requirements of Section 2, Acceptance/Rejection.  Correct any joints with dowels found to be rejectable or JS greater than JST according to Section 5, Corrective Action.

Determine during the test section if embedded tiebars are affecting the Rejection Tolerances and JS’s.  If the test section demonstration shows interference, exclude from the JS and JST calculations any dowel bar(s) closer than 12 in. (300 mm) in any direction to tiebars in the longitudinal joint(s).  At the Engineer’s discretion, establish the location of excluded dowels by another equivalent non-destructive method or by probing.

4.          Paving Quality Control Testing (QCT) for Dowel Bar Inserters

When using the accepted slip form paver and DBI for any contract item of work, perform quality control scans with the MIT-Scan 2 equipment at the following minimum:

a.       Measure the alignments and location for every 10th joint and calculate the JS and JST for each measured joint.  Acceptable QCT is when all measures are within the acceptance tolerances in Table 451.09-2 and JS is less than JST.

                                                                  i.    When the daily QCT finds more than 10 percent of the joints scanned have dowels exceeding the acceptance tolerances of Table 451.09-2 but the JS is less than the JST, increase the scanning frequency to every 5th joint.  Evaluate the paving process to reduce/eliminate misalignments and mislocations and continue to pave.  The QCT frequency will revert back to every 10th joint when two consecutive days of scanning every 5th joint show no dowels exceeding the acceptance tolerances of Table 451.09-2 and all JSs are less than the JST.

                                                                ii.    When QCT finds any individual dowel bars exceeding the rejection criteria of Table 451.09-2 or the JS is found to exceed the JST, the joint is considered to be locked and immediate investigation needs to be made as follows: 

1.       Scan joints in front and behind the locked joint location until five (5) consecutive joints in both directions are found with no dowel bars exceeding the rejection criteria of Table 451.09-2 and no JS is found to exceed the JST.

2.       If the additional scanned joints show no additional dowel bars exceeding the rejection criteria of Table 451.09-2 and no JS exceeding the JST, evaluate equipment to determine what caused the original problem.  Before continuing paving increase the frequency of QCT to conform to 4.a.i.

3.       If the additional scanned joints show additional dowel bars exceeding rejection criteria of Table 451.09-2 or joints with a JS exceeding the JST, stop paving.  Investigate to determine the cause of the dowel bar rejection issues and provide the causes and alternative corrections to the Engineer.

The Engineer will determine if the corrections will correct the problem and may allow paving to temporarily continue to validate if the corrections work.  During any evaluation, scan all joints to determine if the corrections were successful.  If successful, continue QCT scanning at the frequency of 4.a.i.  If not successful, discontinue paving, repair or replace the slip form paver and DBI, and repeat the Test Section

b.       All dowel bars found beyond rejection criteria of Table 451.09-2 or joints with a JS exceeding the JST require a corrective action proposal conforming to Section 5, Corrective Action.

Provide report formats as described in Section 1, MIT Scan-2 Equipment and Reporting.

5.          Corrective Action

Submit a proposal for corrective action to the Engineer for any dowel that exceeds the rejection criteria in Table 451.09-2 or any joint that has a JS greater than the JST.  As a minimum, include the following in the corrective action proposal:

1.  Locations of rejectable dowels with identification information as described in Section 1, MIT Scan-2 Equipment and Reporting.

2.  Locked joint identification information as described in Section 1, MIT Scan-2 Equipment and Reporting.

3.  Proposed method of remediation for each identified location, including supporting documentation of the effectiveness of the means of proposed remediation.

The Department may not require corrective action for random dowels that exceed the rejection criteria of Table 451.09-2 depending on location; what alignment parameter was the cause for the rejection; and the frequency of the rejectable dowels.

The Department may not require corrective action for all JS exceeding the JST, if they are random in nature. Up to two (2) consecutive joints with a JS exceeding the JST may be accepted, provided that the adjacent three (3) joints before or after do not have dowels exceeding Table 451.09-2 rejection limits and have JS’s less than the JST. The Department will require corrective action where there are more than two (2) consecutive joints with a JS exceeding the JST.

Do not proceed with any corrective action until the Engineer approves the proposed method(s) of correction. 

C. Expansion Joints.  Where a pressure relief joint is not provided adjacent to a bridge structure, construct expansion joints at the first two regularly spaced joint locations adjacent to the bridge approach slab on each side of the bridge.  If the pavement is constructed in two or more separately placed lanes, construct the transverse expansion joints in a continuous line for the full width of the pavement and shoulders.

Construct expansion joints according to the standard construction drawings.  Install the face of the expansion joint perpendicular to the concrete surface except when expansion joint is installed at a skewed bridge approach slab.

Use round, straight, smooth, steel dowels, and within 2 hours of placing concrete, coat the dowels with a thin uniform coat of new light form oil as a bond-breaking material to provide free movement.  After coating the dowel, install a sleeve of metal or other approved material approximately 3 inches (75 mm) long, with crimped end, overlapping seams fitting closely around the dowel, and a depression or interior projection to stop the dowel a sufficient distance from the crimped end to allow 1 inch (25 mm) for longitudinal dowel movement with pavement expansion on one free end of each dowel.  If approved by the Engineer, use other means to allow for 1 inch (25 mm) of expansion.

Punch or drill proper size dowel holes into the preformed expansion joint filler to assure a tight fit around each dowel.

Form a 1-inch (25 mm) wide and 1-inch (25 mm) deep opening on top of the expansion joint filler and seal this opening with 705.04 joint sealers.

D. Contraction Joints.   For pavement less than or equal to 10 inches (225 mm) thick, saw contraction joints with a standard (water cooled diamond bladed) concrete saw to a minimum depth of one-fourth of the specified pavement thickness.  For pavement greater than 10-inches (255 mm) thick, saw contraction joints to a minimum depth of one-third the specified pavement thickness.  When cutting joints using a standard (water cooled diamond blade) saw assure the joint is 1/4 ± 1/16-inch (6 ± 1.6 mm) wide when measured at the time of sawing.

When using the option of early-entry (dry cut, light weight) saws, only use saw blades and skid plates as recommended by the saw manufacturer for the coarse aggregate type being used in the concrete. Perform the early entry contraction joint sawing after initial set and before final set. Saw the contraction joint 2-1/4 to 2-1/2-inches (56 to 63 mm) deep. Ensure any early entry saw joints are approximately 1/8-inch (3 mm) wide at the time of sawing.

If the pavement is constructed in two or more separately placed lanes, install the joints continuous for the full width of the pavement.  Saw the pavement with sawing equipment approved by the Engineer as soon as the saw can be operated without damaging the concrete.  Provide saws with adequate guides, blade guards, and a method of controlling the depth of cut.  After wet sawing, clean the joint using a jet of water.  After dry sawing clean the joint using air under pressure.  During sawing of contraction joints, maintain a standby saw in working condition with an adequate supply of blades.

E. Construction Joints.  Install dowelled construction joints at the end of each day’s work and when work is suspended for a period of more than 30 minutes.

Use dowels in transverse construction joints.  Within 2 hours of placing concrete, coat the free half of all dowels with a thin uniform coat of new light form oil.  Use an adequate bulkhead, with openings provided for dowel bars spaced as specified and shaped to fit the typical section of the pavement, to form a straight joint.  During placing of concrete, hold dowels rigidly in position.

Locate construction joints at or between contraction joints.  If located between contraction joints, construct the construction joint no closer than 10 feet (3 m) to the last contraction joint.

451.10  Finishing.  Use 10-foot (3 m) straightedges to continually check the finished concrete surface for trueness.  If the pavement surface is dragged with a diagonal pipe float machine, occasionally check the surface while the concrete is plastic.  Do not add water to aid finishing.

Before the concrete initially sets, round the edges of the pavement along each side of each slab and on each side of transverse expansion joints to the radius specified using an approved edging tool.  Before texturing the surface, eliminate tool marks left by the edging tool.

Texture the surface in the longitudinal or transverse direction using a broom to produce a uniform, gritty, texture. Immediately following the broom drag texture, tine the pavement in the longitudinal direction using an approved device that produces uniform tine spacing 3/4 inches wide (19 mm), 1/8 inch deep (3 mm) and 1/8 inch wide (3 mm). Do not tine within 3 inches (75 mm) of pavement edges or longitudinal joints. Only use equipment that will tine the full width of the pavement in one operation and uses string line controls for line and grade to assure straight tining texture.

Use transverse tining in small areas only with the approval of the Engineer.   Use equipment that produces a random pattern of grooves [0.05 inch (1.3 mm) to 0.08 inch (2.0 mm) deep and 0.10 inch (3 mm) wide] spaced at 3/8 to 1-3/4 inches (10 to 45 mm), with 50 percent of spacings less than 1 inch (25 mm). Transverse tining may be used as an option for shoulders of main line or shoulders of ramps and gore areas.  Tine all mainline shoulders or all ramp shoulders in a consistent direction if choosing this option.  Request the use of transverse tining and identify the locations for approval at the preconstruction meeting.

Demonstrate to the Engineer methods to assure the groove depth meets this specification.

Before the concrete finally sets, impress complete station numbers into the pavement every 100 feet (50 m), e.g., 1+00 (2+050).  Mark station equations in the pavement as shown on the plans.  Ensure that the numerals are 3 to 4 inches (75 to 100 mm) high and 1/4 inch (6 mm) deep.  Place the station numbers parallel with and facing the right edge of the pavement, and centered 12 inches (0.30 m) in from the right edge.  On divided highways, provide station numbers on both pavements.  When placing concrete shoulders with the traveled lane, place station numbers 12 inches (0.30 m) in from the outside edge of the shoulder and facing the pavement.

451.11  Curing.  Immediately after the finishing operations have been completed and after all free water has dissipated, spray and seal all exposed concrete surfaces with a uniform application of curing membrane in such a manner as to provide a continuous uniform film without marring the surface of the concrete.  Apply a minimum of 1 gallon (1 L) of material for each 150 square feet (3.7 m²) of surface treated using an approved self-propelled mechanical sprayer.  Provide an adequate shield to protect the fog spray from the wind.  Before each use, thoroughly agitate the curing material.

On pavement with integral curb or small and irregular areas that are inaccessible to the mechanical spray machine, apply the curing material by a hand-held sprayer.

As soon as the forms have been removed, immediately correct all honey-comb areas and coat the edges of the pavement with the curing material.

Respray all areas of curing material film damaged during the sawing of joints.

The Contractor may water cure concrete with wet burlap cloth, waterproof paper, or polyethylene sheeting.  Apply curing as soon as possible and without marring the concrete surface.  Unless the specimen beams have attained a modulus of rupture of 600 psi (4.2 MPa) keep the entire surface of the top and sides of the newly placed concrete covered for seven days.  Protect concrete from freezing until beams attain a strength of 600 psi (4.2 MPa).

The above requirements for curing are minimum requirements only.  Repair or replace all concrete showing injury or damage due to noncompliance to curing requirements at no additional cost to the Department.

451.12  Removing Forms.  Remove forms in a manner that doesn’t damage the pavement.

451.13  Surface Smoothness.  After final concrete curing and cleaning the pavement surface, test the pavement surface for smoothness using a 10-foot (3 m) rolling straightedge.  Provide a two or four-wheeled device 10 feet (3 m) in length with an indicator wheel at the center which detects high and low areas in the pavement surface.  Provide equipment which actuates a pointer scale, an audio alert, or marks the pavement with paint or dye when encountering any high or low areas in excess of a preset tolerance.  Tow the 10-foot (3 m) rolling straightedge or walk the equipment over the completed pavement.  Test all wheel paths in the presence of the Engineer.  Locate wheel paths parallel to the pavement centerline and approximately 3 feet (1 m) measured transversely inside all lane edges.  Maintain alignment of the 10-foot (3 m) rolling straightedge with reference to the pavement edge at all times.  Other devices such as approved profilers conforming to S1058 and using ProVAL software may be used with approval of the Engineer. 

Correct all surface variations so indicated to within the specified tolerance and in a manner that provides a surface texture conforming to 451.10.  For corrective grinding provide equipment conforming to 451.14.  Ensure pavement surface variations do not exceed 1/8 inch in a 10-foot (3 mm in a 3 m) length of pavement.  For ramp pavements and for those pavements with curvature greater than 8 degrees, or with grades exceeding 6 percent, ensure the surface variations do not exceed 1/4 inch in 10 feet (6 mm in 3 m).

Repair or replace sections of pavement containing depressions that cannot be corrected by grinding as directed by the Engineer.

451.14  Profile Grinding.  To correct surface variations exceeding tolerances specified in 451.13 use grinding equipment conforming to Item 257.

451.15  Pavement Grooving Corrections.  When pavement tining locations are found out of conformance with 451.10 restore the tining using power driven, self-propelled machines specifically designed to groove concrete pavement with diamond impregnated blades or diamond impregnated cylinder rings.  Furnish blades or cylinder rings mounted on an arbor head so that the resulting grooves comply with 451.10.  Furnish grooving equipment with a depth control device that will detect variations in the pavement surface and enable adjustment of the cutting head to maintain the specified groove depth. 

If a pavement area was diamond ground to bring the pavement’s surface smoothness within the tolerances of 451.13, that pavement area does not require tining restoration conforming to 451.10. 

Vary from these requirements only for small areas and only with written permission from the Engineer.

451.16  Sealing Expansion Joints.  As soon as feasible after completing sawing, but before the pavement is open to construction equipment and traffic, seal expansion joints with material conforming to 705.04.  Just before sealing, thoroughly clean each joint of all foreign material, using approved equipment.  Ensure the joint faces are clean and dry when the seal is installed.

451.17  Opening to Traffic.  When 7 days have elapsed, the Contractor may use the completed pavement for traffic, including construction traffic.  If a modulus of rupture of 600 psi (4.2 MPa) has been attained, the Contractor may open the pavement to traffic when 5 days have elapsed.  If necessary to open a portion of the pavement in less than 5 days, with the proviso that the pavement will be cured for a minimum of 3 days, use a high early strength concrete composed of additional 701.04 or 701.05 cement, or non-chloride accelerating admixture to obtain a modulus of rupture of 600 psi (4.2 MPa) in 3 days or less.

Pavement Repairs before Department Acceptance.  Repair diagonally cracked full depth pavement; longitudinally cracked full depth pavement; spalled pavement surfaces and any Portland cement concrete pavement panels with cement balls or mud balls; at no cost to the Department.  Repair transverse cracks except do not repair a single hairline transverse crack in the middle third of panels with reinforcing conforming to BP1.1.  

Repair transverse or diagonally cracked PCC pavement with a full depth repair according to Item 255 and applicable standard construction drawings.  Repair cracks by replacing the pavement the full width between longitudinal joints, perpendicular to the centerline and at least 6 feet (1.8 m) longitudinally.  Install smooth dowel bars at the interface between the original pavement and the replaced pavement section.  Locate and size the repairs to ensure that the repair limits are at least 7 feet (2.1 m) away from any transverse joint.

Repair longitudinal cracks within 15 inches (380 mm) of a tied longitudinal joint by routing and sealing the crack according to Item 423.  For other longitudinal cracks, repair the same as for transverse or diagonal cracks stated above.

Repair spalled pavement with Item 256 Bonded Patching of Portland Cement Concrete Pavement.

Repair cement balls or mud balls by coring out the area, full depth, with a diamond core bit and replacing the removed concrete with the same concrete as in the pavement.  Remove and replace any pavement panel with 5 or more cement balls or mudballs.  Locate the limits of the repair along the longitudinal joints and at least 1-foot (0.3 m) past the transverse joints to remove any existing dowel bars.  Install smooth dowel bars at the transverse limits of the repairs.  Install Type D (Drilled Tied Longitudinal) Joint along the longitudinal limits.

451.18  Pavement Thickness and Concrete Strength.

A.      Thickness.  As determined by measurement of cores cut as specified in this section, construct the concrete not more than 0.2 inch (5 mm) less than the specified thickness.  Core pavement at the direction of the Engineer and at locations the Engineer determines according to Supplement 1064. 

For the purpose of coring, the Department will consider the entire pavement area of a specified thickness a lot.  To determine the number of cores, each pavement lot will be divided into sublots.  A sublot consists of 2000 yd2 (1650 m2) of a pavement lot or major fraction thereof.

Take one random core for each sublot but not less than 3 cores for any pavement lot cored.  If a core shows a deficiency in thickness of more than 1/2 inch (13 mm) from the specified thickness take additional cores to determine the limits of the deficiency.  Follow the procedures below:

1.      Take a core five (5) feet (1.5 m) longitudinally on both sides of the deficient core.  If both the cores are less than 1/2-inch (13 mm) deficient in thickness the zone of deficiency has been determined. 

2.      If either or both 451.18.A.1 cores are more than 1/2 inch (13 mm) deficient in thickness, cut a core 50 feet (15 m) longitudinally from the deficient core(s).  If  the 50 foot (15 m) core(s) is more than 1/2 inch (13 mm) deficient, cut additional cores at 100 foot (30 m) longitudinal intervals until a core is less than 1/2 inch (13 mm) deficient; until the pavement ends; or until overlapping an adjacent pavement sublot’s core in the same lane.

3.      If a pavement sublot has cores more than 1/2 inch (13 mm) deficient in thickness  and  the sublot’s constructed width is greater than 12 feet (3.6 m) obtain cores transverse to the location of the deficient cores.  Obtain transverse cores at a location 1/2 the distance from the deficient core to the furthest edge of pavement.  Obtain a transverse core for each core more than 1/2 inch (13 mm) deficient.

4.      The Engineer will use the cores that measure less than 1/2 inch (13 mm) deficient in thickness to define the limits of the deficiency.

If any deficient core is greater than 1 inch (25 mm) deficient in thickness determine the limits of over 1 inch (25 mm) deficiency by following 451.18.A.1 thru 4 to determine the limits.  Remove and replace those areas greater than 1 inch (25 mm) deficient in thickness.

The Engineer will calculate average thickness of concrete pavement placed as follows:

When zones of deficient thickness greater than 1/2 inch (13 mm) to 1 inch (25 mm) are allowed to remain in place, the Engineer will calculate two average thicknesses.  A Project Average Thickness (PAT) including all cores not more than 1/2 inch (13 mm) deficient.  Cores that exceed the specified thickness by more than ½ inch (13 mm) will be considered as the specified thickness plus 1/2 inch (13 mm) when calculating the PAT.  A second Deficient Zone Average (DZA) will include all cores with thickness deficiency greater than 1/2 inch (13 mm) to 1 inch (25 mm).  The pavement represented by each of the two averages, PAT or DZA, will be calculated and paid separately. 

The Engineer will determine and apply deductions to each separately placed width of pavement.

For any pavement areas removed and replaced, re-core those areas replaced following this section of the specifications.  Include those core values into the calculations for average pavement thickness.

Unless the Director requests, do not core any widening less than 5 feet (1.5 m) in width or any pavement area less than 2000 square yards (1650 square meters).

Fill all core holes with concrete of the same proportions and materials used in the pavement.

B.      Strength.  Obtain an additional core at the same location as the thickness core from each pavement sublot to determine compressive strength.  .

For concrete pavement bid items “with QC/QA”, the AMRL accredited laboratory will test the QC cores for compressive strength according to ASTM C 42.  Test the QC cores from 28 to 90 days of age.  Notify the Engineer when the QC cores will be tested. 

The Engineer will require one QA core for every 10 sublots for verification testing of compressive strength.  Obtain the QA core from the same location as the QC core tested for compressive strength.  At least one QA core will be required per lot. Provide the QA cores to the Engineer for testing at the Department’s laboratory.  Notify the Engineer of the date that the corresponding QC core will be tested.  The QA cores will be tested on the same date.  The Engineer will verify the QC cores versus the QA cores according to 455.

Calculate an average and standard deviation for each lot according to Supplement 1127.  Determine the pay factors according to table 451.19-2.

Do not calculate an average and standard deviation for high-early strength concrete QC cores.  Determine the pay factors for individual sublots according to Table 451.19-2.

For concrete pavements bid items “without QC/QA”, the Department will perform the strength testing.  Provide the Engineer with the  cores for strength testing.  Pay factors for sublot cores will be calculated based on the high-early strength concrete pay factors in Table 451.19-2.

  451.19 Price Adjustments.  Payment will be made at the unit bid price upon completion of any section of pavement.  Final pay adjustments to the bid price will be made upon completion of the pavement operations and all thickness, strength and smoothness data is tabulated and pay adjustments applied per 451.19.A thru 451.19.D.

A. Pavement Thickness.  Price adjustments for thickness deficiencies will be calculated according to the Table 451.19-1

Table 451.19-1 

Concrete Pavement THICKNESS PAY FACTOR (pft)

Deficiency in Thickness

as Determined by Cores

Proportional Part

of Contract Price

0.0 to .2 inch (0.0 to 5 mm)

100 percent

0.3 to 0.5 inch (6 to 13 mm)

0.6 to 1.0 inch (15 to 25 mm)*

Greater than 1.0 inch (25 mm)

Remove and replace

 * The District Construction Engineer will determine whether pavement areas from 0.6 inch (15 mm) up to 1 inch (25 mm) deficient in thickness will be allowed to remain in place at the reduced price or must be removed and replaced. 

          PAT = Project Average Thickness

          PST = Plan Specified Thickness

          DZA = Deficient Zone Average

B.  Concrete Strength.  Record the compressive strength results for each sublot of concrete.  High-early strength mixes, QC MS and QC FS, mixes, are calculated separately.  Determine the strength pay factor according to Table 451.19-2.

TABLE 451.19-2

CONCRETE PAVEMENT STRENGTH PAY FACTOR

Design  Strength = f’c from 499 or as per plan

Individual Sublot Core Strength = x

Project Average Strength () =

Project Standard Deviation (δ) = 

Project Required Strength (f’cr) = f’c + 1.65 δ

Strength Pay Factor (PFS) =  / f’cr *

* When PFS is greater than 1.00, pay the unit bid price

For high-early strength sublots, determine the pay factor separately as follows:

If the individual sublot core strength (x) is greater than f’c,

PFS = 100% of the Unit bid price for the quantity represented.

If the individual sublot core strength (x) is less than f’c, the

PFS = /f’c) of the Unit bid price for the quantity represented.

C. Pavement Smoothness.  When the Project plans include Proposal Note 420 determine a lump sum payment adjustment following the requirements of Proposal Note 420.

D. Multiple Deficiencies. When a pavement exhibits multiple deficiencies for thickness and strength, the reduced unit price will be calculated for each deficiency and the lowest reduced unit price will be used.  Adjustment for smoothness under 451.19.C will conform to the lump sum requirements of 451.19.C.

451.20  Method of Measurement.  The Department will measure Reinforced Concrete Pavement by the number of square yards (square meters) completed and accepted in place.  The width equals the pavement width shown on the typical cross-section of the plans plus additional widening as the Engineer directs in writing.  The Department will field measure the length along the centerline of each roadway or ramp.  The Department will determine the area based on the above width and length.

451.21  Basis of Payment.  Payment is full compensation for furnishing and placing all materials including reinforcing steel, dowels, and joint materials; for furnishing the 10-foot (3 m) rolling straightedge; and for coring and testing the pavement.  For pavement found deficient in thickness or compressive strength, the Department will pay a reduced price according to 451.19.

The Department will not pay extra for pavement with an average thickness in excess of that shown on the plans.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

451             Square Yard                    Reinforced Concrete Pavement

                       (Square Meter)            

451             Square Yard                    Reinforced Concrete Pavement  with QC/QA
                       (Square Meter)            

451             Square Yard                    Reinforced Concrete Pavement Class    
                       (Square Meter)            

451             Square Yard                    Reinforced Concrete Pavement Class      with                         (Square Meter)                        QC/QA

ITEM 452  Non-Reinforced PORTLAND CEMENT
CONCRETE PAVEMENT

452.01  Description

452.02  Construction

452.03  Method of Measurement

452.04  Basis of Payment

452.01  Description.  This work consists of constructing a non-reinforced portland cement concrete pavement on a prepared surface.

452.02  Construction.  The requirements of Item 451 apply, except as follows.

Do not comply with the requirements of 451.08.

Provide dowels at transverse contraction joints in mainline pavement, ramps, acceleration/deceleration lanes, or collector/distributor lanes.  Dowels for contraction joints in concrete shoulders on mainline pavement, ramps, acceleration/deceleration lanes, or collector/distributor lanes are not required unless the contraction joint is located within 500 feet (150 m) of a pressure relief joint.

Space contraction joints according to the standard construction drawings.  If Item 452 pavement is specified for shoulders and is tied longitudinally to Item 451 or 305 pavement, match the joints in the shoulder pavement to the spacing and alignment of the adjacent pavement.

Do not place construction joints within 6 feet (1.8 m) of another parallel joint.

If making pavement repairs before Department acceptance under 451.17, repair all cracks exclusive of size or location

452.03  Method of Measurement.  The Department will measure Non-Reinforced Concrete Pavement by the number of square yards (square meters) completed and accepted in place.  The width equals the pavement width shown on the typical cross-sections of the plans plus additional widening as the Engineer directs in writing.  The Department will field measure the length along the centerline of each roadway or ramp.

452.04  Basis of Payment.  Payment is full compensation for furnishing and placing all materials, for surface testing, and for coring the pavement. 

For pavement found deficient in thickness or compressive strength, the Department will pay a reduced price according to 451.19.

The Department will not make additional payment over the contract unit price for any pavement with an average thickness in excess of that shown on the plans.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

452             Square Yard                    Non-Reinforced Concrete Pavement
                       (Square Meter)

452             Square Yard                    Non-Reinforced Concrete Pavement, Class QC                      (Square Meter)                        FS

452             Square Yard                    Non-Reinforced Concrete Pavement, Class QC                      (Square Meter)                        MS
452             Square Yard                    Non-Reinforced Concrete Pavement,

                   (Square Meter)                with QC/QA

452             Square Yard                    Non-Reinforced Concrete Pavement, Class QC                                      FS

                   (Square Meter)                with QC/QA

452             Square Yard                    Non-Reinforced Concrete Pavement, Class QC                                      MS

                   (Square Meter)                with QC/QA

         ITEM 455   Quality Control PLAN, TESTING AND ASSURANCE for QC/QA Concrete

455.01  General

455.02  Quality Control Plan Basic Requirements

455.03  Additional Quality Control Plan Requirements for Structures

455.04  Additional Quality Control Plan Requirements for Concrete Pavement  

455.05  Department Quality Assurance

455.06  QCP Submittal and Corrective Action

455.07  Basis of Payment

455.01  General.  Use this specification for items 451, 452, 305 and 511 when the bid item description requires QC/QA.  This specification defines the minimum Quality Control Plan (QCP) requirements, the Contractor’s minimum quality control (QC) materials testing and the Department’s quality assurance (QA) materials verification testing requirements.

Develop a QCP to assure that all materials and construction practices for the item will conform to the specifications.  Establish the responsibilities, duties and frequency for both in-process controls and quality control testing  at the concrete’s source and at the job site.

455.02  Quality Control Plan Basic Requirements.  Submit a complete QCP that includes, at a minimum, the following:

A. Basic Information.  Provide the following information:

1. The name and location of the Department inspected and approved concrete producer.

2. The Department accepted Job Mix Formula (JMF) to be used for each item.

3. The name and accreditation of the AMRL Accredited Laboratory to be used for testing the strength samples for structures or pavements.

4. Name of the person(s) who is responsible for compliance with the QCP; acting as liaison to the Department; reporting any non-specification test results and assuring that adjustments are made to remedy problems.

5. Names of all technicians who will perform plant or field site inspection, sampling and testing. Use ACI Grade I certified technicians to perform concrete sampling and testing. Provide copies of their ACI certificates.

6. Calibration records of test equipment to be used on the project.

7. Develop and provide example forms for reporting QC test results to the Engineer conforming to 455.03.C or 455.04.G.

B. Minimum Quality Control at the Concrete Source.  Address how the following items will be controlled in the QCP:

1. Verify that the material sources are certified for the type of work in which they are to be used.

2. Verify that aggregates, cementitious materials and admixtures sources and design weights match the proposed JMF. 

3. Describe how aggregates will be hauled, stockpiled and handled to minimize segregation, avoid contamination, and assure a uniform gradation.

4. Describe procedures and frequency used to control and measure aggregate moistures.

5. Provide the batching sequence and mixing procedures to be used to assure that material balling does not occur.

6. Describe how adjustments to the SSD aggregate design weights in the JMF are made to compensate for moisture contained in the aggregates during batching. 

7. Describe how adjustments to mix water will be made to compensate for aggregate moistures to assure the JMF’s water-cementitious ratio (W/Cm) is not exceeded.

8. Define how the batching tolerances of 499.06 are assured.

9. Provide the information reported on the batch ticket and how it will be validated that it meets the requirements of 499.07. 

10. Describe the method and frequency of assuring that the combined aggregate gradation remains within Zone II of the Coarseness Factor Chart.  If adjustments are made to the JMF proportions, provide the individual aggregate gradations, combined aggregate gradation, and verification that the proportions remain within Zone II of the Coarseness Factor Chart to the Engineer prior to placement.

11. If using a non-potable water source, describe the procedures and frequency to verify that the water meets the requirements of ASTM C1602. 

   a. If a reclaiming system is used, describe the method and frequency of testing to ensure that the water contains no more than 0.06% chlorides.

12. Describe how and when the water is removed from the mixer prior to batching a new load of concrete.

13. Describe methods to verify that the storage and dispensing methods for the admixtures comply with the manufacturer’s recommendations. 

14. Describe methods to keep the concrete temperature within specifications and how to mitigate effects of changes to the set time.

15. Define the desired slump and tolerance for concrete in each construction item. 

16. Define the acceptable yield range, testing frequency to verify that the concrete is maintained within the range.

455.03  Additional Quality Control Plan Requirements for Structures.  In addition to basic QCP minimum requirements of 455.02, provide the following for structures:

A. Material Quality Control Requirements.  Provide the following controls for the concrete materials:

1. Divide the concrete for the project into lots and sublots and define the placement sequence for each work item as follows:

   a. Division of Lots.  A lot consists of concrete in a structure of the same class of concrete.  Generally this is divided into substructure and superstructure items.  Include approach slab concrete with the superstructure lot.  Combine structural components requiring the same class of concrete with different reference numbers into a single lot.  However, one exception is a slipformed parapet may be considered separately from a bridge deck of same class of concrete.

   b. Division into QC Sublots.  Divide each lot into sublots of not more than 50 yd³ (40 m³) for obtaining QC samples.  In no case should there be less than 3 sublots in a lot.  The Engineer will approve the sublot division.

2. Determine and define the sampling location depending on placement method (i.e. pumping, tremie, direct chute deliver, etc.) and the manpower to be utilized to perform the testing. 

   a. Define in the QCP plan equipment and methods to be used for 455.03.A.3.b.

3. Perform at least the following Quality Control Testing for Air content and Slump as follows:

Air Content.  Sample the concrete to perform the QC air testing at the point of discharge.  Use the following quality control procedures during placement:

   a. Sample and test the air content on at least the first three (3) loads of concrete delivered for each day’s placement. Ensure the air content is within the specified parameters in Table 499.03-1.  If the air content is stabilized to the Engineer’s satisfaction, extend the testing frequency to each sublot.

   b. For concrete delivered to the point of placement by means of pumping equipment, provide a hose at the end of the line that is at least 0.5 inch (12 mm) smaller in diameter than the line on the boom to provide back-pressure in the system in order to minimize the amount of air loss in the concrete.  If proposing an alternate method to produce the back-pressure and minimize the air loss, describe the proposed method in the quality control plan.

     During the first three loads, sample the concrete at the point of discharge and the point of placement and test to verify that the loss of air going through the pump does not exceed 1%. Obtain concrete samples at the point of placement without interrupting the continuous flow of concrete by either passing the pump line over a sampling container or obtain a composite sample from five different portions of the deposited concrete prior to vibration.

     Make adjustments to the pump setup when the air loss is more than 1%.  If successful in controlling the air loss below 1%, the required minimum air content for the concrete at point of discharge will be increased by air loss over the requirements of Table 499.03-1.

   c. If an acceptable air loss cannot be achieved, sample the air at the point of placement on every load tested.

When concrete cannot feasibly be sampled at the point of placement, at the Engineer’s direction, provide a trial placement of concrete with pumping equipment at the most severe condition (e.g. the pump line boomed straight up and down), using the proposed method to verify that the method has acceptable air loss.

If a load of concrete is tested and found to have an air content beyond the limits of Table 499.03-1, do not accept and place that load unless it can be adjusted to be within the specified limits.  Do not adjust the air content using a defoaming agent. 

               i. Notify the Engineer and test at least the next three loads for air to ensure that the air content is again stabilized to the Engineers satisfaction. The sampling frequency may then be extended back to one test for every sublot.

4. Establish who is responsible for reporting air and slump results to the Engineer within 1 day after each placement.

5. Describe the methods for initial curing, transporting, curing, testing and reporting test results of the QC compressive strength specimens to the Engineer within five(5) days or the completion of testing. 

   a. Define the unique sample identification and tracking method of concrete specimens.

6. QC Compressive Strength Testing.  Perform QC sampling for compressive strength for each sublot from the load randomly determined by the Engineer. Sample the concrete at the point of discharge unless the concrete’s air content is being sampled at point of placement.

For each sublot make one (1) set of three (3) – 4 x 8 inch (100 x 200 mm) QC compressive strength cylinders. Perform all required curing, transporting, capping and testing of the samples to conform to the applicable ASTM specifications.

Have the AMRL laboratory perform the compression testing on the cylinders.                              

7.  Field Cured Strengths.  Determine whether field cured cylinders, beams or maturity curve acceptance will be used for 511.13 and 511.14 strength testing.  Define how many cylinders or beams will be made per placement.

If developing a maturity curve, provide the maturity curve to the Engineer with the QCP.

   a. Field Cured Samples.  Describe the methods for transporting, testing and reporting the test results of field cured samples for falsework removal and opening to traffic or propose in the QCP maturity testing and provide the maturity curves for the concrete conforming to Supplement 1098.

   b. Define the reporting methods to be used to keep the Engineer informed that field cured strength results conform to the requirements for construction, falsework removal and opening to traffic.

B. Construction Process Quality Control Requirements. In addition to the requirements of 455.02, Provide the following for the construction processes:

1. Establish and define in the QCP the minimum required rate of concrete delivery for continuous placement for each construction item; determine if the plant capacity is capable of providing the concrete at the established rate; and determine how many trucks will be used to provide the concrete at the specified rate of delivery.

2. Describe the procedures and equipment to be used for delivering and placing concrete for each item; methods of consolidating, finishing and grooving the concrete; and methods of curing the concrete.

3. Describe methods and frequency of assuring the grade, super elevation, slab thickness, reinforcing steel cover, etc. meets the plan dimensions.

4. Establish the orientation of the finishing machine on a skewed superstructure to conform to 511.07.

5. Describe the methods to be used to meet cold or hot weather procedures as necessary.

6. Describe methods to prevent the evaporation rate from exceeding the specification requirements and actions to be taken when ambient and concrete temperatures exceed the requirements of 511.07.

7. Describe the methods of protecting concrete if inclement weather occurs.

8. Describe how and when the vibrator frequency is verified to conform to 511.07.

9. Describe the placement procedures to be used to assure that the tolerances for slipformed concrete meets the requirements of 511.08.

10. Describe the methods and schedule for providing control joints in parapets according to 511.08.

11. Describe the lighting plan equipment and methods, when necessary for placement according to 511.07.

C. Reporting. For the Laboratory tested QC air content results report the following information within one day of completing the testing.  For the Laboratory tested QC compressive strength results report the following information within five(5) days of completing the testing:

1. Sample ID, as provided by the Department *

2. Project number

3. Producer name

4. Class of concrete

5. Batch Ticket number

6. Date sampled

7. Lot and Sublot identification

8. Placement and sample location

9. Air content

10. Slump

11. Concrete Temperature

12. Batch Weight *

13. Unit Weight *

14. Specimen Size *

15. Date Tested *

16. Age *

17. Individual strength results and average strength *

18. Type of fracture *

19. Laboratory name

20. Technician name

* Not required when reporting air content test results.

455.04  Additional Quality Control Plan Requirements for Concrete Pavement.   In addition to the requirements of 455.02, provide the following information:

A. Division of Pavement into Lots.  For the purpose of thickness and strength determination, a lot consists of the entire pavement area of the same pavement thickness and the same class of concrete.  Areas using high-early strength concrete are considered a separate lot.  In the QCP define the lots for the project.  The Engineer will approve the lot division.

B. Division of Lots into Quality Control Sublots. Provide the placement sequence and placement widths for the pavement work and determine the sublot division conforming to Supplement 1064.   Provide the Engineer the proposed sublots.  The Engineer will approve the sublot division.  

C. Material Control Requirements.  During production of the concrete pavement, perform the following quality checks:

1. Check the aggregate stockpile conditions, gradation and moisture condition daily.

     a. Provide the name and OAIMA Level II certification of the person(s) performing the aggregate gradation.

     b. Define the methods of reporting results to the Engineer including whether the concrete aggregate proportions still conform to the mix’s well graded requirements. 

2. For portable plants, assure that the plant is inspected by the Department prior to placing concrete.  Describe the procedures and frequencies to verify the mixer blades condition and the scale, gage, meter and admixture dispenser operation.

3. During paving, perform the following:

     a. Yield.  Define the tolerance and determine the frequency for testing the yield.  At a minimum, test the first day of paving, then every fifth day of placement thereafter.

     b. Air, Slump and Temperature.   Sample and test the concrete at least each ½ day of operation at the placement location.   

4. Testing for opening the pavement to traffic early according to 451.18.  Describe the methods to be used to assure the modulus of rupture obtains 600 psi (4.2 MPa).  Define the methods to report results to the Engineer.

D. Pavement Cores for Compression and Thickness.   Define at what age the sublot cores for strength and thickness will be taken.  Define the age the cores will be tested for compressive strength.  Take strength cores at the same location as the cores for thickness determination.  Determine sublot core locations according to Supplement 1064.      

1. Pavement Thickness Measurement.  Define who will be measuring the pavement thickness according to Supplement 1064.   Define the frequency of reporting pavement thickness results to the Engineer.    When the sublot core’s thickness is deficient, follow the requirements of 451.18 for additional core locations to determine the deficiency’s limits. 

2. Define how the Engineer will be provided access to witness the measurements. 

3.  Define the method and frequency of reporting pavement thickness results to the Engineer

E. Concrete Strength. For each sublot, test the core strengths using an AMRL accredited laboratory.

1. Propose the method and frequency of reporting the results to the Engineer for acceptance.

F. Construction Process Requirements

1. Define the minimum required rate of concrete delivery for continuous placement and assure that the equipment and transportation is adequate to provide the concrete at that rate.

2. Describe the methods of protecting the concrete in the case of inclement weather.

3. Describe the methods and frequency of  controlling and checking the plastic thickness during paving and reporting issues to the Engineer.

4. Define fine grading methods and equipment

5. Define the procedure and frequency of conditioning the subbase or subgrade before pavement placement.

6. Define who will perform the HIPERPAV analysis required in 451.09 and the proposed timeframe the Engineer will have to review the report.   

7. Describe equipment and methods for consistently delivering and evenly spreading the concrete in front of the paver.

8. Describe the procedure for dowel bar or load transfer device installation and methods for determining proper placement location after concrete placement.  Assure methods conform with 451.09.B.

9. Describe methods of monitoring the vibrator operation and frequency, time of day, station location and track speed according to 451.05.B

10. Define materials, methods and controls for curing and joint sealing and assuring application requirements.

11. Describe joint sawing methods and proposed timing to the sawing operation.

12. Describe finishing and pavement grooving methods.

13. Pavement Smoothness. 

     a. Define methods to check pavement smoothness conforming to 451.13 and reporting to the Engineer

     b. If other smoothness tolerances are required in the contract define the methods to measure, evaluate, and report the results to the Engineer

G. Reporting Requirements.  

1. Report the following QC testing information to the Engineer daily.

a. Project number

b. Class of concrete

c. JMF number

d. Batch Ticket number

e. Date and Time sampled

f. Air content

g. Slump

h. Concrete Temperature

i. Aggregate moistures results

j. Aggregate gradation results

k. Laboratory name

l. Technician name

2.Report the pavement thickness measurements conforming to the form in Supplement 1064. 

3. Report the compressive strength test results from the QC cores sampled according to 451.18.B with the following information:

a. Pavement lot

b. Class of concrete

c. JMF number

d. Sublot number

e. Core Location

f. Placement date

g. Age at time of testing, in days

h. Compressive strength.

i.Name of Concrete Producer

j. Name of Contractor

k. Name of Laboratory

455.05  Department Quality Assurance.  The Department will perform Quality Assurance sampling and testing as specified or as deemed necessary.

A. Structure Concrete.  The Engineer will perform will determine random number locations for QC compressive strength testing of each sublot.

1. Random Number Determination.  The Engineer will determine a random number for each sublot to determine from which load the QC sample will be taken using the table in Supplement 1127 or a random number generator.

The Engineer will perform side-by-side sampling and testing with the contractor and for slump air and compressive strength and compare results.

1. Slump and Air.  The Engineer will perform side-by-side air and slump field testing with the Contractor and compare results. If the difference between the Department’s and the Contractor’s test result is greater than the tolerances listed below, the Contractor and Engineer will determine the reason for slump or air content differences and make necessary adjustments. The Engineer may stop the placement until the reason for the difference is established and corrected. The Engineer will check one of the first three loads delivered. Once the results are within the tolerances listed below, the Engineer may reduce the QA sampling and testing frequency to 10% of the Contractor’s subsequent QC tests.

Slump ±1 inch (25 mm)

Air Content ±1%.

2. Compressive Strength.  The Engineer will obtain compressive strength QA samples from the same location as the Contractor’s quality control samples at a frequency of one QA sample for every 10 sublots, or at least one per lot. The Engineer will make six (6) 4 x 8 inch (100 x 200 mm) cylinders for each sample. The Engineer will mark the cylinders with identification and the Contractor shall provide initial curing at the project.

After the initial curing at the project site, deliver three (3) QA cylinders to the Department’s Laboratory and three (3) QA cylinders to the AMRL accredited laboratory for standard curing and testing.  The Accredited Laboratory will test the QA sample and the QC sample and report the test results on the form accepted by the QCP. Distinguish the QA from the QC results for the sublot.

The Engineer will compare and verify that the Department tested QA, Contractor tested QA and the matching QC test results are within 14% of the Departments QA result. If the comparison is favorable, the Contractor QC testing is considered verified.

     a. When the comparison of the results are more than 14%, investigate the results with the Engineer to determine the reason for the difference.  If the reason for the difference cannot be determined to the Engineer’s satisfaction, the Engineer will require the Contractor to either non-destructively test or core the concrete represented by the cylinder tests to determine compressive strength. Hire an independent laboratory to perform this additional testing. The Engineer will witness the testing and evaluate the results. The Department will reimburse the Contractor for all testing costs when the Department’s results are in error. If the QC results are found to be valid, use the QC results.  If the QC results are not valid, use the core results to determine the compressive strength values for pay factors, 511.22.

B. Pavement and Base Concrete.  The Engineer will perform side-by-side sampling and testing with the Contractor and compare results.

1. Air Content.  The Department will perform side-by-side quality assurance testing of the air content on at least 10 percent of the Contractor’s QC samples. The results will be compared and if the difference between the Department’s and the Contractor’s test results is greater than ±1% the Contractor and Engineer will determine the reason for difference and make necessary adjustments. The Engineer may stop the placement until the reason for the difference is established and corrected.  Make any required modifications or changes to the QCP, the technician, and equipment before continuing paving.

2. Compressive Strength.  The Engineer will randomly select 1 out of every 10 QC core locations to have an additional core obtained as a QA strength sample according to Supplement 1127.  The QA core sample will be provided to the Engineer and the Department will cure and test, the QA core at the date specified by the Contractor. 

The Engineer will compare and verify that the Department tested QA core and  the matching Contractor tested QC core test result are within 13% of the Departments QA result. If the comparison is favorable, the Contractor QC testing is considered verified.

If the difference between core results is greater than 13%, the Engineer will investigate both the Contractor’s laboratory and the Department’s laboratory for the accuracy of the equipment and procedures for conducting the compressive strength testing of the cores. If the investigation does not determine the reason for the discrepancy between cores, the Contractor will re-core the sublot in dispute and the core will be tested in the Department’s Central Laboratory. The Central laboratory core result will be compared to the Contractor’s QC core result.  If the comparison is within 13%, the Contractor’s QC result will be accepted and considered verified.  If not within the 13% range, the project sublots will be re-cored by the Contractor and tested by the Department.  The results will be used for payment under 451.19B.

455.06  QCP Submittal and Corrective Action.  Submit the proposed QCP to the Engineer for acceptance at least 10 days prior to placing concrete. 

If the submitted QCP is not accepted by the Engineer, revise and resubmit the QCP and provide an additional 10 days for acceptance.  Reschedule the concrete placement, when necessary, to allow time for the review and acceptance of QCP.

The QCP acceptance is based on the concept that the proposed QCP procedures will provide work meeting all specification requirements.  If the accepted QCP is not being followed the Engineer will require compliance or re submittal of any modifications for review and acceptance. 

When the actual work produced by the QCP does conform to specification requirements, the Engineer will require modification of the QCP to return the work to conformance.  When notified by the Engineer propose modifications to the QCP for acceptance.  Do not continue work until the Engineer has either accepted the revised QCP or determined work can continue. 

455.07  Basis of Payment.  The cost of developing and implementing the QCP is incidental to the cost of the concrete sold with the QC/QA requirement.

ITEM 499  CONCRETE—GENERAL

499.01  Description

499.02  Materials

499.03  Concrete Mix Design

499.04  Adjustments and Controls

499. 05 Equipment

499. 06 Handling, Measuring, and Batching Materials

499. 07 Batch Plant Tickets

499. 08 Mixing Concrete

499.01  Description.  This specification consists of proportioning requirements for Portland concrete mix designs, mixing, and controls of Portland cement concrete.

499.02  Materials.  Furnish materials conforming to:

Portland cement............................. 701.01, 701.02, 701.04

............................. 701.05 and 701.09 or blended cement[1]

Microsilica............................................................... 701.10

Ground granulated blast furnace slag

.... (GGBFS)............................................................ 701.11

Fly ash..................................................................... 701.13

Fine aggregate [2][3].................................................. 703.02

Coarse aggregate[3].................................... 703.02, 703.13⁽⁴⁾

Recycled Concrete Aggregate (RCA)....... Supplement 1117

Air-entraining admixture.......................................... 705.10

Chemical admixture for concrete[5].......................... 705.12

[1] If blended cement is used, provide mill certification of all the cement and pozzolanic components and final product for approval by the Office of Materials Management

[2]          703.02 natural sand or sand manufactured from stone as specified in Item 703.02.A.3 is required in 255, 256, 451, 452, 526, and 511 deck slabs.

[3] Aggregates may be standard gradation sizes from 703.02 and Table 703.01-1 or they may be a modified gradation defined with the mix design submittal and certified by the office of Materials Management under Supplement 1069.

[4]          Applies only to 305, 451and 452 concrete.

[5]          Admixtures shall contain no more than 50 parts per million chloride ions by weight of cement except for Type C accelerating admixtures or calcium chloride for QC-FS only

Use water for concrete mixing free from sewage, oil, acid, strong alkalis, vegetable matter, clay, and loam.  Potable water is satisfactory for use in concrete.  Non-potable water will meet the requirements of ASTM C1602.  Water from a reclaiming system will contain no more than 0.06% chlorides.  Test the non-potable water monthly and maintain data verifying that the water meets the requirements. Provide the data at Engineer’s request.

499.03 Concrete Mix Designs.  Develop concrete mix designs with 1 inch maximum nominal size coarse aggregate according to ACI 301, Section 4 meeting the requirements of Table 499.03-1.; Limit the pozzolan content of any developed mix designs according to Table 499.03-2.  Conform to the requirements and procedures of this specification and  Supplement 1126 for concrete mix design submittals and approvals.

Only use mix designs accepted by the Department and issued a JMF number.

TABLE 499.03-1 CONCRETE MIX DESIGN REQUIREMENTS

Quantities per Cubic Yard

Provide Concrete with 6±2% Air Content

Class

Design Strength

psi (MPa)

Permeability [1]

Maximum (Coulombs)

Cementitious Content [2]

Minimum.

 lbs (kg)

Aggregate

Requirements

QC 1

4,000 (28.0) at 28 days

2,000

520 (236)

Well-Graded

QC 2

4,500 (31.0) at 28 days

1,500

520 (236)

Well-Graded

QC 3

Special

As per plan

1,500

or as per plan

520 (236)

or as per plan

Well-Graded

QC 4 Mass Concrete

As per plan [3]

2,000

or as per plan

470 (213) [4] [5]

or as per plan

Well-Graded

QC MS [7]

See Supplement 1126

N/A

800 [7] (475)

1 inch nominal maximum size

QC FS [7]

See Supplement 1126

N/A

900 [7] (534)

1 inch nominal maximum size

QC Misc [6]

4,000 (28.0) at 28 days

N/A

550[8](233)

1 inch nominal maximum size

[1]  AASHTO T277 Modified

[2]  Cementitious Content includes cement and pozzolan materials, denoted as Cm

[3] Strength for Mass Concrete (QC 4) may  be tested at either 28 or  56 days.

[4] Do not use Type III cement or accelerating admixtures in mass concrete.

[5] The maximum fly ash or GGBF slag content may be increased up to 50%.

[6] For QC Misc mixes only –Water/Cementitious ratio limited to 0.50 maximum

[7] Cement Only – No pozzolan materials

[8] Cement of cement and up to15% fly ash or up to 30% GGBF slag

Determine the permeability by testing according to AASHTO T277 except moist cure the permeability samples for 7 days at 73oF followed by 21 days of moist curing at 100oF.  Perform permeability testing at 28 days.

Observe the following limitations on the pozzolan materials as a percent of total cementitious content:

TABLE 499.03-2 POZZOLAN MATERIALS

Material

Maximum Content

(%)

Fly Ash

25

GGBF Slag

30

Micro-Silica

10

When using multiple pozzolan materials, do not exceed the individual maximum contents above for each material.  A combination of pozzolan materials may not exceed 50% of the total cementitious content by weight.

A. Slump.  Maintain slump within the nominal slump range in Table 499.03-3.  If below the maximum water-cementititous ratio of the Job Mix Formula (JMF), then adjust the quantity of water to meet slump requirements.  Do not use concrete with a slump greater than the maximum shown in Table 499.03-3.  When the slump exceeds the nominal slump limit of TABLE 499.03-3 but is below the maximum limit, the Contractor may use an occasional load of concrete in this condition, provided the mixture of succeeding loads is immediately adjusted to reduce the slump to within the nominal range.  Conduct tests on the plastic concrete for pavement at the point of placement or at an Engineer-designated location.

TABLE 499.03-3  CONCRETE SLUMP

Type of Work

Nominal Slump

inch (mm)[1]

Maximum Slump

inch (mm)[2]

Concrete pavement (305, 451, 452, 615)

1 to 3 (25 to 75)

4 (100)

Structural Concrete (511, 610, 622)

1 to 4 (25 to 100)

5 (125)

Superstructure concrete (511, 526)

2 to 4 (50 to 100)

4 (100)

Non-reinforced concrete (601, 602,611,  608, 609, 622)

1 to 4 (25 to 100)

5 (125)

[1]  This nominal slump may be increased to 6 inches (150 mm), provided the increase in slump is achieved by adding a chemical admixture conforming to the requirements of 705.12, Type F or G.

[2]  This maximum slump may be increased to 7 inches (180 mm), provided the increase in slump is achieved by adding a chemical admixture conforming to the requirements of 705.12, Type F or G.

B. Air Content.  Ensure that the air content in all concrete at the point of placement is within the percentage range specified in Table 499.03-1. 

499.04 Adjustments and Controls.  Provide the following adjustments and controls during batching and placement of the concrete:

1. Batch the concrete to the proportions of the accepted JMF. Provide a workable and finishable mix.  Adjustments to the JMF’s aggregate proportions up to 100 lbs (44 kg) for workability may be made. Adjustments greater than 100 lbs (44 kg) may be made if approved by the Engineer.  Maintain an absolute volume of  27.0 cubic feet/cubic yard for the adjusted concrete mix. For Well Graded  JMF adjustments, maintain the combined aggregate gradation within the optimal zone II requirements for well-graded mixes as defined in Supplement 1126.  If outside the optimal zone II of the Coarseness Factor Chart adjust the JMF’s proportions to maintain the combined gradation  within Zone II and report the JMF changes to the Engineer. 

2. Handle, haul and store aggregates to minimize segregation, avoid contamination, and assure a uniform grading within the specified gradation.  Do not combine aggregates from different sources or of different gradings in the same stockpile.  Do not use segregated or contaminated aggregates.

3. Remove all wash water by reversing each truck drum at the plant immediately prior to reloading.

4. Adjust the SSD aggregate design weights In the JMF to compensate for the moisture contained in the aggregates and moisture the aggregates will absorb during batching.  Adjust the mix water to compensate for the aggregate moistures.

5. Do not exceed the maximum water-cementitious ratio of the JMF.

6. Use only compatible admixtures in the concrete.  Dispense all admixtures according to the manufacturer’s recommendations.  Furnish a volumetric dispenser for the Type F or G admixture or ensure that there is a gage on each truck-mounted Type F or G admixture dispensing tank.  If any admixture is added at the job site, mix the load for a minimum of 5 minutes.

7. Do not exceed the maximum water/cementitious ratio of the accepted JMF.  Use a water-reducing admixture conforming to 705.12; proportionately increase the cementitious content; or develop and submit for acceptance a new JMF.  Adjust the absolute volume of the aggregates if the cement content is increased.

8. Reject concrete loads, if during placement of any concrete, cement or microsilica balling is observed.  Revise the mixing process and/or loading sequence to prevent further balling.

9. If slump loss occurs before placement of the concrete, the concrete may be “replasticized” with an admixture to restore plasticity.  The Engineer will recheck the slump range and air content to ensure conformance to the specifications.  If after “replasticizing” the components of the load are segregated, the Department will reject the load. 

10. Completely discharge the concrete from each delivery truck within the time requirements of 499.08.

11. Provide sufficient quality control at the plant to assure conformance with this specification and project requirements.

12. Use an approved set-retarding admixture conforming to 705.12, Type B or D when the concrete temperature exceeds a nominal temperature of 75 °F (24 °C).

499.05  Equipment.  Use a Department approved batch plant and trucks.  Provide batching and mixing equipment meeting the following requirements:

A. Batching Plants.  Operate each plant so that aggregate materials are not segregated and there is no intermingling of the materials before batching.  Use weighing mechanisms that allow a visible means of checking weights and produce a printed record.  Use dispensing mechanisms for water and admixtures that allow a visible means of checking quantities and produce a printed record.

Use cement and aggregate weighing mechanisms that are accurate to within ±0.5 percent of the correct weight.  Ensure that devices for weighing or metering water are accurate to ±1.0 percent throughout the range used.

Maintain a certification from a Sealer of Weights and Measures or a scale servicing company attesting to the accuracy of the weighing and metering devices.  Have this service performed within a 12-month period before use of the plant.  A Certificate of Performance issued by the National Ready Mixed Concrete Association may be used instead of the Sealer of Weights and Measures or a scale servicing company.

Maintain the services of a scale servicing company or ten standard test weights to reach a capacity of 500 pounds (227 kg) for testing the weighing devices at the batch plant.  The Ohio Department of Agriculture will seal all device-testing weights every 3 years.

The Engineer will test weighing and dispensing devices as often as deemed necessary to ensure continued accuracy.

B. Mixers.  Provide mixers and agitators conforming to AASHTO M 157, Sections 10, 11.2, 11.5, and 11.6, except that the Department will allow mechanical counters.

For bodies of non-agitating concrete hauling equipment, provide smooth, mortar-tight, metal containers capable of discharging the concrete at a satisfactory controlled rate without segregation.  Provide covers when required by the Engineer.  The Engineer will allow trucks having dump bodies with rounded corners and no internal ribs or projections for non-agitating hauling.

499.06  Handling, Measuring, and Batching Materials.  Do not stockpile aggregates from different sources or different gradations together.  The Engineer may direct reworking or cleaning, or may reject aggregates that have become segregated or mixed with earth or foreign material. 

Prior to and during batching, maintain all coarse aggregates at a uniform moisture content.

For all slag aggregates or other aggregates with a reported absorption above 3.0 percent, only use aggregates with moisture contents at or above the ODOT-reported SSD for that aggregate as follows:

1.       Use appropriate stockpile watering systems capable of raising and maintaining aggregate moisture at or above SSD.  Test the moisture content of the watered aggregate stockpiles at least five (5) locations to assure the stockpile is at or above SSD. 

2.       Have processes to maintain the aggregate stockpile at SSD until stockpile draining for SSD consistency has begun. Twenty-four (24) hours before batching concrete with the aggregate, shut down the stockpile watering process to allow drainage and to establish a uniform moisture content.  

3.       Run moisture content tests at least twice a day during concrete production.  If the moisture content varies between tests by more than 1% increase the moisture testing frequency to assure correct batching information. 

4.       Provide the moisture content test results as part of all quality control plant ticket information.    

Separately weigh the amounts of fine aggregate and coarse aggregate, as determined by the Engineer and outlined in 499.03.  Use a separate weighing device for cementitious materials.

Conduct batching such that the weight of cement is within a tolerance of ±1.0 of the weight required and the weight of each aggregate batched is within ±2.0 percent of the weight required.  Measure water by weight or volume to within a tolerance of ±1.0 percent of the required amount.  Dispense admixtures to within a tolerance of ±3.0 percent of the required amount.

The Engineer will approve methods and equipment used to add admixtures into the batch.  Add air-entraining admixture at the time of batching.

499.07  Batch Plant Tickets.  Furnish a concrete batch plant ticket to the Engineer for each load of concrete delivered for use on the project.  Use computer generated batch tickets.  At a minimum, include the information listed in Table 499.07-1 on each ticket:

TABLE 499.07-1  EVERY BATCH TICKET

Name of ready-mix batch plant

Batch plant No.

Batch plant location

Serial number of ticket

Date

Truck number

Class of concrete

JMF Number

Batch time

Batch size

yd³ (m³)

Actual weights of cementitious material:

   Cement

lb (kg)

   Fly ash 

lb (kg)

   Ground granulated blast furnace slag

lb (kg)

   Microsilica

lb (kg)

   Other

lb (kg)

Actual weights of aggregates:

   Coarse

lb (kg)

   Intermediate

lb (kg)

   Fine

lb (kg)

   Other

lb (kg)

Actual weight of water

lb (kg)

Actual volume of admixtures:

   Air-entrainer

fl oz (mL)

   Superplasticizer

fl oz (mL)

   Water-reducer

fl oz (mL)

   Retarder

fl oz (mL)

   Other

fl oz (mL)

Aggregate moisture contents:

   Coarse aggregate

%

   Intermediate aggregate

%

   Fine aggregate

%

Water-cementitious ratio, leaving the plant

Provide the information in Table 499.07-2 with batch tickets for each day’s first load of concrete and for each JMF.  Include Table 499.07-2 information on the batch ticket or furnish the information on a separate computer-generated or handwritten form attached to the batch ticket.

If during the concrete manufacturing process any of the information listed in Table 499.07-2 changes, resubmit Table 499.07-2 information with the first batch ticket supplied with the changed concrete.

TABLE 499.07-2  FIRST TICKET EACH DAY, EACH JMF

Cementitious Materials:

Source:

Grade or Type:

Cement

Fly ash

GGBF slag

Microsilica

Other

Admixtures

Brand:

Type:

Air-entrainer

Retarder

Superplasticizer

Water-reducer

Other

The provided concrete batch ticket information is according to ASTM C 94/C 94M, Section 13.

The Engineer may require supporting data to validate the basis for furnished aggregate moisture contents.

Include the cost for generating and supplying the information of this section and the concrete batch tickets in the individual concrete items.

499.08  Mixing Concrete.  Use a central mix plant or in truck mixers to mix the concrete.

When using a central mix plant, mix the concrete not less than 60 seconds   Begin the mixing time when all materials are in the drum and end the mixing time when discharge begins.  Include transfer time in multiple drum mixers in the mixing time.  Remove the contents of an individual mixer drum before a succeeding batch is emptied into the drum.

When concrete is mixed using a truck mixer for complete mixing, mix each batch of concrete at the rotation rate designated on the mixer as mixing speed for not less than 70 revolutions of the drum.  Transport mixed concrete from the central mixers in truck mixers, truck agitators, or trucks having non-agitating bodies.  Within 60 minutes after cement and water are combined, deliver and completely discharge concrete.  If an approved set-retarding (705.12, Type B) or water-reducing and set-retarding (705.12, Type D or G) admixture is used at no expense to the Department, complete discharge within 90 minutes after combining the water and the cement.

When concrete is delivered in transit mixers and before discharging any of a batch, the Engineer may allow adding water within the specified water-cement ratio limits.  Perform sufficient mixing, a minimum of 30 revolutions at mixing speed, to adjust the slump and to regenerate the specified air content throughout the batch.  Adding water will not extend the above 60 and 90-minute time limitations.

When approved by the Engineer, the Contractor may use approved admixtures (705.12, Type F or G) for retempering the load to adjust the slump after the start of discharge.  Mix for a minimum of 30 revolutions at mixing speed after addition of the admixture.

Use admixtures containing no more than 50 parts per million chloride by weight of cement only when specified in the Contract Documents, the accepted JMF, or with the Engineer’s written permission.

The procedure to make and test concrete beams for the modulus of rupture is Supplement 1023.

Until discharged in the work, ensure that the temperature of all concrete does not exceed 95 °F (35 °C). 

500  STRUCTURES

ITEM 501  STRUCTURES—GENERAL

501.01  General

501.02  Verification of Dimensions

501.03  Notification of Fabricator

501.04  Shop Drawings

501.05  Submittal of Working Drawing and Calculations

501.06  Test Reports

501.01  General.  This specification includes the general requirements for building the various items that constitute the completed structure.

Perform the work, including fabrication, erection, and construction, so that the entire structure and all its component parts will function as designed.

501.02  Verification of Dimensions.  Verify that all dimensions established by the Engineer are correct.

501.03  Notification of Fabricator.  When furnishing materials under Items 513, 515, 516, 517, and 518, select a fabricator from the pre-qualified fabricators list in effect the date of the Contract letting.  Before or at the preconstruction conference, provide a written notification to the DCA and Office of Materials Management of the selected steel fabricators and precast concrete fabricators.

501.04  Shop Drawings.  Provide shop drawings detailing structural steel, metal structural elements, prestressed concrete members, precast concrete structural elements, and other similar materials requiring either shop or field fabrication according to the appropriate AASHTO Standard Specifications for Highway Bridges and Item 501.

A.      Contractor Acceptance of Shop Drawings for Items 513 and 515.  After preparing the shop drawings for Items 513 and 515, submit the drawings to the Office of Materials at least  3 days before the pre-fabrication meeting, or before the start of fabrication on Item 513, UF Level. 

For structures carrying railroad traffic, submit four copies of the prepared shop drawings at least 40 days prior to the pre fabrication meeting to each railroad company involved for review and approval.  Resolve all railroad comments prior to supplying the letter of written acceptance to the Department. The acceptance submission to the Department shall include one set of shop drawings approved by each railroad company involved; copies of all documentation between the railroad(s) and the Contractor; and four sets of Contractor accepted shop drawings for each railroad company involved.

Include in the shop drawing submission a written acceptance letter and four copies of each drawing, unless additional copies are requested.  For structures carrying railroad traffic, furnish 4 additional sets of shop drawings for each railroad company involved.  Also, furnish the fabricator’s quality control specialist with one additional set of these drawings before the pre-fabrication meeting.

Prepare the shop drawings by or under direct supervisory control of an Ohio Registered Engineer having personal professional knowledge of AASHTO Standard Specifications for Highway Bridges, and Items 513 and 515.  The Registered Engineer shall seal and date each drawing. Have a second Ohio Registered Engineer check, sign, seal and date each drawing, confirming that the drawings meet the intent of the plan (as designed). The preparer and checker shall be two different Engineers. Have all questions and comments addressed before submitting the shop drawings.

The Contractor’s written acceptance letter shall document acceptance of the shop drawings including confirmation of field verification, as required, and descriptions of issues resolved between the Contractor, the fabricator, or the Department.

By accepting these shop drawings, the Contractor represents to the Department that all dimensions and elevations of existing conditions shown on the plans have been field measured and verified, and that these shop drawings comply with all the materials requirements, construction requirements, contract requirements, and performance criteria.  The Contractor further represents that these drawings have been coordinated and verified with the details of the work to be performed by other fabricators and entities on the project.  The Department will not make any allowance for additional cost or delays to the Contractor for incorrect fabrication as a result of failure to coordinate or perform this acceptance.

If the Department requests changes on these shop drawings, or the Contractor makes changes in addition to those expressly requested, ensure that the shop drawings are accepted as above with suitable revision marks to identify the changes.

Schedule the pre-fabrication meeting after the Director receives the drawings.  Fabrication may begin after the pre-fabrication meeting is complete or after receipt of Item 513, UF Level drawings.

B.      Fabricator Coordination of Shop Drawings for Items 516, 517, and 518.  The Contractor and fabricator must coordinate these shop drawings.  Ensure that shop drawings meet requirements for materials, field measurements, construction requirements, contract requirements, performance criteria, and similar data.  The coordination must also include details of the work to be performed by other fabricators and entities on the project.  The Department will not make allowance for additional cost or delays to the Contractor for incorrect fabrication as a result of failure to coordinate or perform this coordination.

Submit two copies of the shop drawings to the Engineer with the materials delivered to the project.  Do not incorporate material into the work until after submitting the drawings.  Department approval of these shop drawings is not required.

C.      Shop Drawing General Requirements.  Specific requirements are specified in Item 513, 515, 516, 517, or 518.

Shop drawings shall be neatly and accurately drawn on 11 x 17 inch or 22 ´ 34-inch (280 x 432 mm or 559 ´ 864 mm) sheets. The shop drawings may be submitted electronically in pdf format or by mail.

After all fabrication is completed for Item 513 and 515, furnish, to the Director, a copy of each final Contractor accepted shop drawing on a digital media storage device according to Supplement 1002.  For structures carrying railroad traffic, furnish an additional digital media storage device or, at the option of each railroad, furnish a set of full-size drawings on Mylar.

501.05  Submittal of Working Drawings and Calculations.  Design and perform all procedures as directed by the AASHTO Standard Specifications for Highway Bridges or the AASHTO LRFD Bridge Design Specifications except as modified below:

Perform daily inspections to ensure the work governed by the working drawing is functioning as designed. Report malfunctioning work to the Engineer immediately.

A.      Projects with Railroad Involvement. Prepare and provide working drawings listed in this section as follows:

Have an Ohio Registered Engineer prepare, sign, seal and date each working drawing. Submit working drawings to all involved railway companies at least 50 days before construction begins. Obtain acceptance from all involved railroad companies. Furnish the Engineer copies of all correspondence with the railroad, documentation of railroad acceptance and the working drawings accepted by the railroad. Department acceptance is not required. The absence of Department acceptance does not supersede the Engineer’s authority as defined in 105.01.

Perform all work in accordance with the accepted working drawings. Immediately cease all operations that deviate from the accepted working drawings. If a deviation is necessary, furnish the Engineer a copy of a revised working drawing including documentation of acceptance from all involved railroad companies as least 24 hours before construction on deviated work begins. The revised working drawing shall be sealed and dated by an Ohio Registered Engineer. Department acceptance of revised working drawings is not required. The absence of Department acceptance does not supersede the Engineer’s authority as defined in 105.01.

The Department will consider delays resulting from working drawing deviations as non-excusable in accordance with 108.06.E.

This section applies to working drawings for the following:

1.      Bracing adjacent to the railroad tracks. Perform work according to 501.05.B.1.

2.      Demolition of structures over or within 14 feet of railroad tracks. Perform work according to 501.05.B.2.

3.      Erection of structural members over or within 14 feet of railroad tracks. Perform work according to 501.05.B.4.

B.      Projects without Railroad Involvement. Prepare and provide working drawings listed in this section as follows:

Have an Ohio Registered Engineer prepare, sign, seal and date each working drawing. Have a second Ohio Registered Engineer check, sign, seal and date each working drawing. The preparer and checker  shall be two different Engineers.

Submit the working drawing to the Engineer at least 7 days before construction begins. Department acceptance is not required. The absence of Department acceptance does not supersede the Engineer’s authority as defined in 105.01.

Perform all work in accordance with the prepared working drawings. Immediately cease all operations that deviate from the prepared working drawings. If a deviation is necessary, furnish the Engineer a copy of a revised working drawing at least 24 hours before construction on the deviated work begins. The revised working drawing shall be signed, sealed and dated by an Ohio Registered Engineer and checked, signed and sealed and dated by a Second Ohio Registered Engineer. Department acceptance of revised working drawings is not required. The absence of Department acceptance does not supersede the Engineer’s authority as defined in 105.01.

The Department will consider delays resulting from working drawings deviations as non-excusable in accordance with 108.06E.

This section applies to working drawings for the following:

1.      .        Excavation Bracing, impacting active traffic, or with an exposed height over eight feet, except when a complete design is already shown in the plans.  Perform all work as specified below:

a.      Locate Excavation Bracing according to the contract, if shown.

b.      Maintain temporary horizontal and vertical clearances according to the contract.

c.      Include the effects of AASHTO live and dead load surcharges as necessary.

d.      Design Excavation Bracing in accordance with the latest AASHTO Guide Design Specifications for Bridge Temporary Works, Section 4

2.      Demolition of structures over or adjacent to active traffic. Perform all work as specified below:

a.      Provide temporary devices or structures necessary to protect traffic during all demolition activities. Provide traffic protection when demolition is located less than 12' horizontally from active traffic on structures of less than 25' vertical clearance. Increase the 12' minimum horizontal distance 1 foot for each 2 feet of additional height greater than 25'.

b.      Never lift the portions of structure being removed over active traffic. Before releasing traffic make the remaining structure stable.

c.      Design traffic protection devices or structures for a minimum load of 50 pounds per square foot plus the weight of equipment, debris and any other load to be carried. Include any portion of the deck that cantilevers beyond the fascia beams or girders.

d.      In lieu of temporary devices or structures required in “a” above, provide a vertical barrier. Design the vertical barrier with rigid or flexible materials specifically designed for demolition containment. Extend the enclosure up to the bottom of the deck and down to the ground. Maintain all materials free of tears, cuts and holes.

e.      Maintain temporary horizontal and vertical clearances according to the contract.

f.       Locate structural members to be reused before performing any removal operations.

g.      Do not damage structural members being reused during any removal operation.

h.      Perform work so that all members are stable during all operation and loading conditions.

i.       Perform work according to 501.05.B.6.

3.      Falsework for cast-in-place concrete slab bridges. Perform all work according to 508 and as specified below:

a.      Provide a camber table to account for the deflection of the falsework loaded with its self weight and the weight of wet concrete. Also include in the table, the specified camber to compensate for slab deflection after the falsework is released.

b.      Maintain temporary horizontal and vertical clearances according to the contract.

c.      As a minimum design falsework over waterways for a five year flood or with 75 percent of the effective waterway opening of the proposed structure. The Contractor is responsible for any damages caused by upstream flooding due to insufficient temporary structure size or the accumulation of debris or sediment in the channel.

d.      Support falsework foundations located within the ten year  flood limits on rock, shale or piles driven to a minimum depth of 15 feet, and to sufficient penetration to carry superimposed loads or until refusal on rock.

e.      The incorporation of structural steel shapes, used as temporary support members, into a finished concrete slab superstructure is prohibited.

f.       Design falsework in accordance with the latest AASHTO Guide Design Specifications for Bridge Temporary Works, Section 2.

4.      Erection of steel or precast concrete structural members as specified below:

a.      Never lift structural members over active traffic. Before releasing traffic make structural members stable.

b.      Supply any temporary supports or braces necessary to maintain structural stability and prevent lateral movement until completion of all construction activities.

c.      Perform work according to 501.05.B.6, 513 or 515.

d.      Do not field weld temporary members to permanent steel members.

e.      Maintain temporary horizontal and vertical clearances according to the contract.

f.       Provide drawings with at least the following information:

(1)     Site Plan of the work area showing permanent support structures (piers and abutments); roads; railroad tracks; waterways; overhead and underground utilities; and other information pertinent to erection.

(2)     Erection sequence for all members, noting any temporary support conditions, such as holding crane positions, temporary supports, falsework etc. Member reference marks, when reflected on the erection plans, should be the same used on the shop drawings.

(3)     Primary member delivery location and orientation.

(4)     Maintenance of Traffic during erection operations.

(5)     Location of each crane for each primary member pick, showing radius and crane support (barges, mats, etc.).

(6)     Capacity chart for each crane configuration and boom length used in the work.

(7)     Center of gravity locations for primary member.

(8)     Rigging weights, capacity and arrangement for primary member picks.

(9)     Lifting weight of primary member picks, including all rigging and pre-attached elements.

(10)  Details of any temporary lifting devices to be bolted or welded to permanent members, including method and time (shop or field) of attachment; capacity; and method, time, and responsibility for removal.

(11)  Blocking details for bridge bearings.

g.      Provide calculations for the following:

(1) Load capacity and stability of temporary supports and crane(s) for each pick and release.

(2) Structural adequacy and stability of members for each step of erection.

(3) Capacity of fabricated rigging, such as lift beams, welded lugs, spreader beams, beam clamps, etc. Submit manufacturers’ certifications of catalog cuts for pre-engineered devices.

5.      Jacking and support of existing structures as specified below:

a.      Support the structure on temporary supports and brace as necessary to maintain structural stability and prevent lateral movement until completion of the permanent supports. Do not use jacks alone to support the structure except during the actual jacking operation. Remove all temporary supports upon completion of the jacking procedure.

b.      Maintain a maximum differential jacking height of 1/4 inch between any adjacent beam lines.

c.      Maintain a maximum differential jacking height of 1 inch between any adjacent abutments or piers.

d.      Place jacks and any load plates at least 2 inches from the edges of any concrete substructure seats.

e.      Do not field weld temporary members to permanent steel members.

f.       Maintain temporary horizontal and vertical clearances according to the contract.

6.      When the total load applied to a structure during construction, (new or structure being rehabilitated), exceeds 75 percent of the legal limit, (The Legal Limit is 80,000 lbs. or percentage thereof if posted), the load effects on the structure shall be analyzed based on the operating level calculated by the Load Factor Rating Method as given in the AASHTO Manual for Bridge Evaluation.

7.      Structures for maintaining traffic in accordance with Item 502.

a.      For structures located over or within 14 feet of railroad tracks, submit plans in accordance with 501.05.A.

b.      Perform work according to 501.05.B.6.

C.      Welded Attachments.  Prepare and provide a detailed request showing weld size, length, type and location for welding permanent or temporary attachments to main structural members not shown or permitted by contract. Submit request to the Office of Structural Engineering for acceptance at least 20 days before construction begins. Perform work according to 501.05.B.6 and 513.

D.      Corrective Work. Unless otherwise noted, before performing corrective work on structure items, 507,511,513,515,516,517 and 524, prepare a Corrective Work Plan (CWP) including supporting calculations. Submit three copies of the CWP to the Engineer for acceptance at least 30 days before construction begins. Have an Ohio Registered Engineer prepare, sign, seal and date each CWP. Obtain Department acceptance before beginning corrective work.

Perform all work in accordance with the accepted CWP. Immediately cease all operations that deviated from the accepted CWP. If a deviation is necessary, furnish the Engineer three copies of a revised CWP. The revised CWP shall be signed, sealed and dated by an Ohio Registered Engineer. Obtain Department acceptance of revised CWP prior to performing corrective work.

Perform all corrective work, including the preparation of the CWP and revisions at no expense to the Department. The Contractor shall reimburse the Department for all CWP review costs of the Designer of Record. The Department will consider delays resulting from all corrective work as non-excusable in accordance with 108.06E.

501.06  Test Reports

A.      Contractor Acceptance of Materials for Item 513.  Submit certified test data to the Director showing compliance with the requirements of Item 711.  Accompany all certified test data with copies of mill shipping notices or invoices showing the quantity and size of material being accepted.

Check this material data and provide a letter of written acceptance.  Submit the material data and letter of written acceptance to the Director so that the Director receives them at least 7 days before final shop inspection Item 513, Levels 1 through 6 or before final shop inspection Item 513, UF Level.

Submit a single copy of this material data for each structure, except where the structure carries railway traffic.  Submit one additional copy to each railway company involved.

Additionally for Item 513, Levels 1 through 6 structural steel members, submit one copy of main material, certified test data with a letter documenting the QCFS acceptance to the QA shop inspector before the material passes check point one.

The Department will not accept materials for final inspection at the fabrication shop until the Director receives the Contractor accepted material data.

B.      Fabricator Certification of Materials for Items 516, 517, and 518.  Ensure that a letter of certification accompanies the fabricated material shipped to the job site, in a format approved by the Director, stating all materials conform to contract requirements.  For these materials, the fabricator must retain certified test data, copies of mill shipping notices, or invoices showing the quantity and size of material being accepted.  This data shall provide complete traceability to the producing mill and proof of domestic origin, as required by ORC 153.011.

Do not deliver materials to the project without the certification letter.

ITEM 502  STRUCTUREs for maintaining traffic

502.01  Description

502.02  Design and Construction

502.03  Maintenance

502.04  Removal

502.05  Basis of Payment

502.01  Description.  This work consists of preparing plans, providing, maintaining, and subsequently removing temporary structures.

502.02  Design and Construction.  As a minimum, design the temporary structure for a 5-year flood or with 75 percent of the effective waterway opening of the proposed structure.  The Contractor is responsible for any damages caused by upstream flooding due to insufficient temporary structure size or the accumulation of debris or sediment in the channel.  Provide a clear roadway width of at least 23 feet (7.0 m) measured from face to face of guardrails.  If the existing structure or approaches or both have sidewalks provide at least one sidewalk at least 5 feet (1.2 m) wide with adequate connections to existing walks and in compliance with accessibility standards.

Design the temporary structure according to the AASHTO LRFD Bridge Design Specifications except that the design live loading, HL-93 may be reduced by 25 percent.

Submit working drawings in accordance with 501.05.

Drive piling to sufficient penetration to carry the superimposed loads according to Item 507, but not less than 24 tons (24 metric tons) per pile.  Perform dynamic load testing to determine required blow count if piles are not driven to rock.

If the plans state that the existing superstructure may be used instead of new construction, do not alter it to meet either the above width or strength requirements.  Instead, move or dismantle and re-erect with sufficient care to avoid any reduction of capacity.  If the superstructure has been restricted by posting to loads less than permitted by statute, move the posting signs to the temporary road, unless the superstructure is strengthened to a legal load capacity.  If planning to use the existing superstructure on the temporary road, notify the Engineer at least 3 days before the superstructure is moved to allow the Department to establish a detour.  Complete the bridge within 48 hours after traffic has been routed over the detour.

502.03  Maintenance.  Maintain all portions of the temporary structure in good condition with respect to both safety and smoothness for travel as long as it is needed for maintenance of traffic. Satisfactorily maintain the channel and waterway opening.

502.04  Removal.  If the temporary structure is no longer needed, take ownership and remove it from the site according to Item 202.

502.05  Basis of Payment.  Payment is full compensation for erection, maintenance, performing dynamic load testing, and subsequent removal of temporary structures.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

502             Lump Sum              Structure for Maintaining Traffic

ITEM 503  EXCAVATION FOR STRUCTURES

503.01  Description

503.02  Classification

503.03  Cofferdams and Excavation Bracing

503.04  Protection for Excavation

503.05  Footings in Rock

503.06  Approval of Foundations

503.07  Disposal of Excavated Material

503.08  Backfill

503.09  Method of Measurement

503.10  Basis of Payment

503.01  Description.  This work consists of designing cofferdams and excavation bracing, and excavating materials not removed under other items of work that must be removed to enable construction of bridges, and other structures.  Included in this work are:

A.      constructing, maintaining, and subsequently removing cofferdams and excavation bracing;

B.      dewatering and backfilling the excavation;

C.      protecting the excavation against collapse; and

D.      disposing of materials not required or suitable for backfill.

503.02  Classification.  Excavation is classified as unclassified excavation, unclassified excavation including rock (or shale), or rock (or shale) excavation.

503.03  Cofferdams and Excavation Bracing.  This item includes the preparation of a working drawing according to 501.05 for all cofferdams and excavation bracing and the construction, maintenance, and subsequent removal of all cofferdams and excavation bracing. A cofferdam is an enclosure within a water environment constructed to allow dewatering for the purpose of creating a dry work environment.  Excavation bracing is that required to safely support the sides of excavations, embankments, adjacent buildings, tracks, or other premises.

Construct cofferdams and excavation bracing such that support members clear the top of the footings by at least 1 foot (0.3 m).  If this is not practical, support members shall be structural steel and left it in place.  If bracing is to be left in place and the ends would not be visible when the structure is completed, burn off the steel ends flush with the concrete surface.  If ends would be visible, form a 6 inch (150 mm) deep recess around the steel embedment and remove the external portion of the embedment to provide at least 3 inches (75 mm) of clearance to the finished concrete face.  Completely fill the resulting recess with concrete.

Where water is not encountered, the Contractor may place excavation bracing at the plan dimension of the footing and use it as formwork for footing concrete.  Leave this sheeting in place at least to the top of the footing, or properly separate it from the footing concrete so that it may be removed without damaging the concrete.

Where water is encountered, and cofferdams are necessary, construct them practically watertight before excavating below water level.  Make provisions outside the footing to drain, collect, and remove water.  When placing concrete, keep the excavation dewatered until the concrete is above the prevailing water level.  Effectively protect footing concrete from erosion.  If using a concrete seal to stop the flow upward from the bottom of a cofferdam, place the seal below the planned footing and consider it as a part of the cofferdam.  The Department will not pay for a seal unless it is shown on the plans.

Unless otherwise shown in the plans, design and construct cofferdams to accommodate a water elevation 3 feet (1.0 m) above the ordinary high water mark shown on the plans. If the actual water elevation exceeds 3 feet (1.0 m) above the stated ordinary high water mark, the Department will reimburse the Contractor for any resulting damage to the work protected by the cofferdam provided the Contractor has exercised normal due diligence.  If the actual water elevation exceeds 3 feet (1.0 m) above the ordinary high water mark and causes a delay to the project, the Department will grant the Contractor an excusable, non-compensable delay in accordance with 108.06.B.

Establish a monument upstream of all proposed cofferdams to visually monitor the water elevation in the waterway. Maintain the monument throughout the project. Provide a visual mark on the monument that identifies the required high water elevation as defined above. Ensure that the monument can be read from the bank of the waterway. Have this elevation set and certified by an Ohio Registered Surveyor.

Cofferdams may be designed and constructed to accommodate a lower water elevation; however, the Department will not reimburse the Contractor for repairs to work damaged nor grant additional time unless the water elevation exceeds 3 feet (1.0 m) above the ordinary high water mark shown on the plan.

Submit any request for reimbursement for repair to work damaged or for delay to the Engineer with information substantiating that the water elevation was more than 3 feet (1.0 m) above the ordinary high water mark shown on the plans.

503.04  Protection for Excavation.  Protect all excavations from caving.  Do not disturb the material below the bottom of footings.  Perform blasting in a manner that avoids damage to the material supporting the structure vertically or laterally and that avoids subsequent slides that damage the structure, road, or adjacent property.  If the material below the bottom of footings not supported by piles is disturbed, remove it and fill the entire space with concrete at no expense to the Department.  Under footings supported on piles, replace and compact the over-excavated or disturbed material as the Engineer directs.  If backfilling is necessary to correct caving or slides, backfill according to 503.08.

Excavation adjacent to railroad tracks are subject to the supervision of the involved railway company.  Provide sufficient bracing to ensure the proper support of the roadbed and tracks.

503.05  Footings in Rock.  Where rock or shale excavation is a separate pay item, fill the portion of the excavation into rock or shale that is below the top of footing with concrete.

If removing rock or shale as part of Unclassified Excavation and the footing is designed to be keyed into the bedrock, confine the excavation into bedrock for the minimum specified depth of keying within the area bounded by the outer edge of the footing.  Fill excavation outside these limits and within and below the keyed depth with concrete.

503.06  Approval of Foundations.  Notify the Engineer when the excavation is to be completed to the depth shown on the plans.  Do not place footings until the Engineer has approved the subfoundation.

503.07  Disposal of Excavated Material.  Dispose of excavated material not needed or not suitable according to 105.16 and 105.17.  Use other suitable excavation material for backfill.

503.08  Backfill.  Backfill all excavations made under this item with materials conforming to 203.02.R, except behind abutments and below the approach slabs use materials conforming to Item 203 Granular Material Type B.

Place and compact the backfill materials according to 203.06 and 203.07, except as modified by this subsection.

Do not place backfill material against any structural element until the Engineer has approved the element.

In bridge abutment areas compact backfill material to meet the compaction requirements in 203.07.  Elsewhere, compact backfill material to 95 percent of the maximum laboratory dry density.

When a test section method is used for compaction acceptance:  Use compaction equipment with a total weight or a centrifugal force of least 1 ton (0.9 metric tons).  Supply the manufacturers’ information to verify this information.  Use at least six passes to construct the production areas.  Use at least 97 percent of the test section maximum dry density for acceptance of the production areas.

The Contractor does not have to place backfill material around piers that are not within the embankment area or adjacent to a roadway or a railway in thin layers or compact it, but should leave the backfill material in a neat condition with a compensating allowance made for settlement.

Backfill in front of abutments and around piers to the ground lines shown on the plans.

Backfill all structural foundation units as soon as practical after the required conditions of this subsection are met to avoid the ponding of surface water and the accumulation of debris.  Simultaneously backfill in front of and behind abutments, piers, wing walls, and retaining walls.

Carefully backfill against waterproofed surfaces to avoid damage to the waterproofing material.

503.09  Method of Measurement.  After the requirements of Items 201, 202, and 203 have been met, the Department will measure excavation on a lump sum basis or by the number of cubic yards (cubic meters) as follows:

A.      Bounded on the bottom. Bounded bottom plane of the footing, crossbeam, or wall.

B.      Bounded on the top

1.      In cut sections, by the surface of the remaining ground.

2.      In fill sections:

a.      If excavation is performed before embankment is placed, by the surface of the original ground.

b.      If excavation is performed after embankment is placed, by the surface of the embankment.

C.      Bounded on the sides

1.      For Unclassified Excavation, 1 foot (0.3 m) outside the outer edge of the footing, crossbeam, or wall.

2.      For Rock Excavation or Shale Excavation:

a.      If Rock Excavation is included in the Contract, by the outer edge of the footing or wall.

b.      If rock or shale is removed as part of Unclassified Excavation Including Rock and/or Shale:

(1)     Above the minimum specified depth of keying, the same as described in 503.09.C.1.

(2)     For the remainder of the excavation, the same as described in 503.09.C.2.a.

For keys below footings, the Department will determine the volume of keys by the number of cubic yards (cubic meters) shown on the plans.

The Department will measure Cofferdams and Excavation Bracing on a lump sum basis.

503.10  Basis of Payment.  If an Item for Cofferdams and Excavation Bracing is not included in the Contract for payment, perform work according to 503.03 and the Department will pay for Cofferdams and Excavation Bracing under the contract unit price for excavation.

The elevations shown on the plans for the bottoms of footings are considered as approximate.  When excavation below plan elevation for footings is required, the Department will pay for the 3 feet (0.9 m) immediately below the plan elevation within the lateral limits described in 503.09.C.1 at the unit price bid for the class of excavation.

The Department will consider additional excavation to a maximum depth of 1 foot (0.3 m) within the lateral limits described in 503.09 as incidental to the lump sum price. Excavation deeper than 1 foot (0.3 m) below plan elevation may be provided for as Extra Work, as described in 109.05.

If Cofferdams and Excavation Bracing is a separate pay item, the lump sum price includes any extra cost involved for cofferdams for additional depth up to 3 feet (0.9 m) below plan elevation. Excavation deeper than 3 feet (0.9 m) below plan elevation and the additional cofferdams necessitated by this excavation may be provided for as Extra Work, as described in 109.05. The Contractor shall provide additional fill material and subsequent excavation to provide the minimum cover over culverts to accommodate heavy earth moving equipment at no expense to the Department.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

503             Lump Sum                      Cofferdams and Excavation Bracing

503             Cubic Yard                      Unclassified Excavation
                   (Cubic Meter)

503             Lump Sum                      Unclassified Excavation

503             Cubic Yard                      Unclassified Excavation Including Rock
                   (Cubic Meter)                    

503             Cubic Yard                      Unclassified Excavation Including Shale 
                   (Cubic Meter)                    

503             Cubic Yard                      Unclassified Excavation 

                       (Cubic Meter)              Including Rock and/or Shale                  

503             Cubic Yard                      Rock Excavation
                   (Cubic Meter)

503             Cubic Yard                      Shale Excavation
                   (Cubic Meter)

ITEM 504  SHEET PILING LEFT IN PLACE

504.01  Description

504.02  Materials

504.03  Driving

504.04  Method of Measurement

504.05  Basis of Payment

504.01  Description.  This work consists of furnishing and driving steel sheet piling to be left in place, including furnishing and installing any specified anchors or other attachments to structures.

504.02  Materials.  Furnish new sheet piling conforming to 711.03.  The Contractor may use used sheet piling in good condition that conforms to project requirements provided it is inspected and approved by the Engineer.

504.03  Driving.  Drive steel sheet piling to the tip elevation shown on the plans.  Thread each sheet pile with adjacent sheets.  Use corner piles, junction piles, and interlocking connectors as necessary so that all sheet piles are interlocked.

504.04  Method of Measurement.  The Department will measure Steel Sheet Piling Left In Place [Minimum Section Modulus of ____ cubic inches per foot (____ mm³/m)] of Wall by measuring the number of square feet (square meters) in the plane of the face of the sheeting, completed and accepted in place.

504.05  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

504             Square Foot                     Steel Sheet Piling Left In Place [Minimum
                       (Square Meter)                Section Modulus of____ cubic inches
                                                               per foot (____ mm³/m)] of Wall

ITEM 505  PILE DRIVING EQUIPMENT MOBILIZATION

505.01  Description

505.02  Basis of Payment

505.01  Description.  This work consists of mobilizing pile driving equipment to and from the project site and, as necessary, to install the required piling.

This work includes the fixed costs that are related to the installation of the required piling.

505.02  Basis of Payment.  The Department will pay for accepted quantities, after the first service pile is installed, at the contract price as follows:

Item           Unit                                Description

505             Lump Sum                      Pile Driving Equipment Mobilization

ITEM 506  STATIC LOAD TEST

506.01  Description

506.02  General

506.03  Test Procedure

506.04  Basis of Payment

506.01  Description.  This work consists of applying a static load to a driven pile and furnishing instruments and facilities to obtain load-displacement data required to determine the ultimate bearing value of the pile.  When subsequent static load tests are specified, the Office of Geotechnical Engineering will determine whether subsequent static load tests are to be performed and the location of all piles to be tested

506.02  General.  Perform the static load test according to ASTM D1143, Procedure A: Quick Test, except as modified below.

Use the hammer selected for driving the test pile to drive all piles represented by the test.  If the Contractor finds it necessary to use a different hammer, the Office of Geotechnical Engineering will determine if an additional static load test is necessary.

If using anchor piles to apply the load to the test pile, locate the anchor piles to provide a minimum clear distance of 8 feet (2.5 m) from the test pile.  The Contractor may use battered piles as anchor piles, provided the horizontal forces in the anchor system are balanced and excessive bending stresses are not induced in the piles.  The Contractor may also use bearing piles meeting these requirements as anchor piles.  After the test has been completed, remove or cut off at least 1 foot (0.3 m) below the bottom of the footing or finished surface of the ground all anchor piles outside the limits of the footing.  Cut off anchor piles, other than bearing piles, within the limits of the footing 3 inches (75 mm) above the bottom of the footing.  Redrive all bearing piles used as anchor piles that are displaced upward during the application of the test load according to the plan requirements.

For the duration of the test, provide adequate facilities to record load and displacement readings.  To avoid column buckling of the pile, ensure that tested piles are substantially vertical and that the load is applied to the pile at a point as near the ground surface as possible.

Provide equipment and loading apparatus to apply a maximum test load of twice the ultimate bearing value.  Have a Registered Engineer design the loading apparatus.  Determine if piles on the plan order list for cast-in-place reinforced concrete piles have a pile wall thick enough to support the maximum test load of twice the ultimate bearing value.  The minimum pile wall thickness to support twice the ultimate bearing value is:

t (inch) =

2 R (lb)

t (mm) =

2 R (N)

113,000 D (inch)

780 D (mm)

Where:

                       t = pile wall thickness in inches (mm)

                      R = ultimate bearing value in pounds (N)

                      D = diameter of pile in inches (mm)

If the pile wall thickness for the test pile is less than t, before performing the static load test, either drive a test pile with a thicker pile wall, or fill the pile with concrete and allow the concrete to cure for 5 days.  The static load test is unacceptable if the pile fails internally during the test due to improper installation or procedure by the Contractor.

506.03  Test Procedure.  Apply the load at least 5 days after placing concrete in the pile or 72 hours after driving both the test pile and the anchor piles.

Use displacement indicators as the primary system to measure axial movement of the test pile top, with a redundant secondary system as described in ASTM D1143.

Apply the test load in increments of approximately one-tenth the ultimate bearing value.  Between each load increment, keep the test load constant for 15 minutes.  Add load increments until the test load reaches twice the ultimate bearing value or until continuous jacking is required to maintain the test load.  Remove the test load in five approximately equal decrements, keeping the test load constant for 15 minutes between decrements.  If it is necessary to remove and reapply the load during the test, use the same loading procedure to reapply the test load.

Record test readings taken at 1, 2, 4, 8, and 15 minutes after completing application of each load increment.  Record test readings taken at 1 and 15 minutes after each load decrement and after removing all load from the test pile.

Determine the load test ultimate bearing value (Qf) using the Davisson criteria.  First plot the displacement versus load on the pile (Q).  Next, draw a line representing the theoretical elastic deformation of the pile, using the following equation.

d =

Q L

A E

Where:

                          d =  Elastic deformation of pile in inches (mm)

                         Q =  Test load in pounds (N)

                          L =  Length of pile in inches (mm)

                          A =  cross-sectional area of pile in square inches (mm²)

                          E =  Elastic modulus of pile in lb/in² (MPa)
for steel E=29,000,000 lb/in² (200,000 MPa)

Draw the Davisson criteria line parallel to the theoretical elastic deformation but offset by the following formula:

0.15 inch + 0.008×D   (3.8 mm + 0.008×D)

Where:

                         D =  Diameter or width of the pile in inches (mm). 

The test load ultimate bearing value (Qf) is the load corresponding to where the Davisson criteria line crosses the load-displacement curve. See the figure below.

Within four days of completing the static load test, submit a report to the Engineer which contains the information required according to ASTM D 1143 and the load displacement graph described above.

506.04  Basis of Payment.  If the Contractor subsequently finds it necessary to use a different hammer, the Office of Geotechnical Engineering will determine if an additional static load test is necessary; the Contractor shall complete any such additional test at no additional cost to the Department.

The cost of furnishing test piles with thicker pile walls is included under Static Load Test.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

506             Lump Sum                      Static Load Test

506             Each                                Subsequent Static Load Test

ITEM 507  BEARING PILES

507.01  Description

507.02  General

507.03  Materials

507.04  Driving of Piles

507.05  Determination of Required Driving Criteria

507.06  Cast-in-Place Reinforced Concrete Piles

507.07  Steel H-Piles

507.08  Timber Piles507. 09          Splices

507.10  Defective Piles

507.11  Prebored Holes

507.12  Method of Measurement

507.13  Basis of Payment

507.01  Description.  This work consists of furnishing and driving bearing piles.

507.02  General.  Install piles of the specified type, length, and sizes shown on the plans.  Furnish the piles according to the itemized order list shown on the plans.  If additional length is needed to obtain bearing, furnish the additional length as determined by the Engineer.  The length of the piles given in the order list is not necessarily based on available or practical lengths, but the estimated length from the bottom of each pile to the elevation of the cutoff.  The Contractor may increase or decrease the pile lengths to suit the lengths available, to facilitate the method of operation, which may involve providing fresh heading as a result of hammer misalignment or a worn hammer cushion, or to provide lengths determined practical to have delivered to the project site and driven.

507.03  Materials.  Furnish materials conforming to the following:

Reinforcing steel........................................................... 509

Concrete, Class QC1.................................................... 511

Chemical admixture for concrete, Type F................ 705.12

Steel H-piles............................................................ 711.03

Steel pile points........................................................ 711.07

Steel for reinforced concrete piles…………………711.03

Galvanized steel....................................................... 711.02

Timber..................................................................... 711.26

Provide a concrete slump from 6 to 8 inches (150 to 200 mm) with the use of a superplasticizer.

507.04  Driving of Piles.  Drive piles to refusal on bedrock; until obtaining the required ultimate bearing value, which may include a modification for scour, set-up, or negative skin friction; or to the minimum penetration pile tip elevation shown on the plans.

If piles begin to crush, immediately cease driving and repair or replace the pile.  The counting of blows will cease until the crushed pile is either repaired or replaced. 

For piles subject to scour, notify the DGE if the required ultimate bearing value is obtained before the pile has penetrated 80 percent of its estimated depth before appreciably overdriving the pile.  The DGE will study the conditions and determine the final penetration, the driving requirements, the use of another pile type, and the use of prebored holes.

All piles raised during the driving of adjacent piles shall be driven down again.

Use a hammer that will achieve the required ultimate bearing value for the pile and large enough to permit a dynamic load test to verify that the ultimate bearing capacity shown on the plans can be achieved.

The ram of an air-operated or diesel hammer shall weigh at least 2700 pounds (12,000 N).

The ram of a drop hammer for permanent piles shall weigh at least 3000 pounds (13,300 N).  The height of fall for drop hammers shall not exceed 7 feet (2.1 m).  Do not use drop hammers to drive piles that are to be driven to an ultimate bearing value in excess of 70 tons (620 kN).

When using open ended diesel hammers, provide electronic equipment, such as a saximeter, or equivalent, for the Engineer’s use to accurately measure and record the average stroke for each unit of length driven.

Attach a gage to closed end diesel hammers, accessible to the Engineer, to monitor the pressure in the bounce chamber.  Include a graph with the gage to convert pressure to energy.

Attach an impact energy monitor, or a method to accurately measure the stroke within 2 inches (50 mm) to hydraulic hammers, accessible to the Engineer, to monitor the energy of each blow.

Use securely anchored driving leads and a cap device with sliding jaws to engage the leads to guide the pile and maintain the pile alignment with the stroke of the hammer.  Accurately align the travel of the hammer with the axis of the pile.

Cushion the hammer and pile to prevent the impact of driving forces from damaging the top of the pile.  Shape the cap and pile top to uniformly distribute the hammer blow to the top surface of the pile.

Do not use a follower unless approved by the Office of Structural Engineering.  If the Office of Structural Engineering does approve the use of a follower, account for the increased energy loss when determining the required driving criteria.

If a static load test is required, the Contractor may not drive piles except the test and anchor piles before conducting the test and the required depth of penetration has been determined.

Do not use water jets.

After being driven, cut off the piles at the elevation and angle shown on the plans. Ensure that the actual pile embedment into the concrete is within 2 inches (50mm) of the embedment shown in the plans.

507.05  Determination of Required Driving Criteria.  Determine the required driving criteria to achieve the ultimate bearing value of a driven pile as if the pile was a single isolated pile using the results of dynamic pile testing as specified in Item 523.  The driving criteria may consist of a minimum blow count with a minimum hammer stroke, a minimum depth of penetration, or both.

To determine the minimum blow count for battered piles, divide the minimum blow count for vertical piles with the same ultimate bearing value by an efficiency factor (D) that is less than one.  This will result in an increased minimum blow count for the battered piles.  Compute the efficiency factor (D) as follows:

D=

1 - (U × G)

(1+G²)0.5

Where:

                          U =  Coefficient of friction
use 0.05 for double-acting air operated or diesel hammers,
use 0.1 for single-acting air operated or diesel hammers, and
use 0.2 for drop hammers.

                         G =  Amount of batter (H/V; 1/3, 1/4, etc.)

507.06  Cast-in-Place Reinforced Concrete Piles.  Provide cast-in-place reinforced concrete piles conforming to one or more of the types described below.  Measure the pile diameter as follows:

A.      Plain cylindrical casing, the outside diameter.

B.      Cylindrical casings with vertical fluting, the diameter of a circle circumscribing the outermost points or ridges.

C.      Cylindrical casing with circumferential corrugations, the average of the outside diameters measured at the bottom and top of the corrugations or continuously welded helical corrugations with diameters measured at tops of the corrugations.

D.      Tapered piles, the top diameter as determined in 507.06.A, 507.06.B, or 507.06.C, but the pile tip diameter shall not be less than 8 inches (200 mm).

Ensure that the pile casings are watertight after being driven.  If furnished, shoes or points shall not project more than 1/4 inch (6 mm) outside the vertical surface of the casing.

For plain cylindrical casings, the minimum pile wall thickness, t, is the greater of either 0.250 inches (6.66 mm) or the thickness determined using the following formula:

t (inches) =

R (lb)

t (mm) =

R (N)

900,000

157,606

Where:

                             R = Ultimate bearing value in pounds (newtons)

For fluted piles, the minimum pile wall thickness shall be t/1.4.

For cast-in-place piles containing reinforcing steel, place reinforcing steel as stated in the second and third paragraph of 524.09 and place concrete according to 524.11.

After installation, cover the tops of driven casings until the concrete is placed.  Before placing concrete, remove accumulated water or other foreign matter in a driven casing.  Maintain a minimum radius of 15 feet (4.5 m) between simultaneous work of placing concrete and driving pile casings.  If concrete is placed within the 15-foot (4.5 m) radius, suspend driving operations until the concrete has cured for 5 days.  Place concrete for cast-in-place piles using methods that prevent voids, however, do not vibrate the concrete.

507.07  Steel H-Piles.  Steel H-piles shall consist of structural steel shapes of the kind and size specified.

The Engineer may allow installation of steel piles of the specified type, which the Contractor has from previous projects or stock, if the Contractor furnishes mill certifications and the pile sections are identified with the material specification number, grade, and heat number.  This identification may be in the form of information painted on the steel piles or a tag physically attached to the steel.

507.08  Timber Piles.  Provide timber piles of sufficient length to remove broomed or split portions caused by driving.  Symmetrically trim piles right truncated cone at the tip.  If steel shoes or points are specified, carefully shape the tip of the pile so that the steel shoe or point fits snugly and symmetrically.

Handle and store timber piles to prevent warping.

If specified, provide creosoted piles conforming to 712.06.

507.09  Splices.  To the fullest extent practical, avoid splicing steel casings and structural shapes.  Splice pile casings and structural shapes either before or after driving a segment.  If spliced after driving a segment, splice the piles at least 3 feet (1 m) above the ground and inspect the splice while the pile is driven a minimum of 150 blows.

Align segments to make the axis of all segments common.

Use full penetration butt welds to splice structural shapes according to 513.21, except delete the requirement to use temporary extension bars.

Do not splice timber piles.

Pile Points. When specified in the plans, select a product from the Department’s approved list. Weld the pile points to the pile according to AWS D1.5 or the manufacturer’s written welding procedure supplied to the Engineer before the welding is performed. Submit a notarized copy of the mill test report to the Engineer.

507.10  Defective Piles.  Piles entirely underground are defective if the pile location at the ground surface is more than the 1 foot (0.3 m) from the location shown on the plans.

Piles projecting above the ground are defective if the pile location at the ground surface is more than 3 inches (75 mm) from the location shown on the plans.

Pipe piles are defective if not water tight or if damage reduces the cross-sectional area by more than 20 percent.  Provide the Engineer with a light that allows inspection of the entire length of the interior of a driven casing.

Replace, repair, or drive a substitute pile beside the defective pile.  The location tolerance for underground piles does not apply to substitute piles beside defective underground piles.  The off-location limits do apply to the substitute pile that project above the ground.  If a defective pile is removed, fill the hole remaining in the ground with sand.  Cut off a defective pile left in place under a footing 3 inches (75 mm) above the elevation of the bottom of the footing.  Cut off a defective pile left in place but not under a footing at least 1 foot (0.3 m) below ground level.  Fill defective pipe piles left in place with concrete.

When the outside rows of bearing piles are not located within tolerances specified above, increase the size of the footing to provide a minimum distance between the pile and footing edge of at least 75 percent of that shown on the plans.

507.11  Prebored Holes.  Locate prebored holes as shown on the plans.  Provide augured hole diameters:

A.      For round piles, from 2 inches (50 mm) less to 4 inches (100 mm) more than the pile diameter.

B.      For steel H-piles, from 6 inches (150 mm) less to 2 inches (50 mm) more than the pile’s diagonal dimension but shall be such as to produce satisfactory pile driving results.

Backfill voids between the pile and the prebored hole with a granular material satisfactory to the Engineer.

507.12  Method of Measurement.  The Department will measure piles driven by the number of feet (meters).  The Department will determine the sum as the lengths of all non-defective piles measured along the axis of each pile from the bottom of each pile to the elevation of cutoff.  Unless a separate pay item is specified in the Contract, the Department will include Steel Points or Shoes in the measured length of driven piles.  If a separate pay item is specified in the Contract, the Department will measure Steel Points or Shoes by the number of each.

The Department will measure piles furnished by the number of feet (meters) of plan specified order length plus any additional order length specified by the Engineer.  The Engineer will include the length of undriven piles as furnished, but the Contractor will not receive additional compensation for hauling the piles off the project.

For plan specified prebored holes, the Department will measure Prebored Holes by the number of feet (meters) of prebored hole lengths for non-defective piles measured from the surface of ground at the time of boring to the bottom of the hole.  The Department will not measure preboring to facilitate the pile driving operation.

507.13  Basis of Payment.     When the Contractor elects to prebore to facilitate the pile driving operation, include the cost for preboring in the unit price bid for piles driven.

The Department will consider the cost of furnishing and installing the reinforcing steel to be included in the unit price bid for piles driven.

The Department will not pay for any splices due to the Contractor furnishing pile lengths shorter than plan order lengths.  The Department will not pay for increased pile lengths made by the Contractor unless the Engineer determines that the additional lengths are needed to achieve bearing.  If additional penetration is necessary in order to achieve the required bearing, the Department will pay for required splices at a negotiated price.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

507             Foot (Meter)                    Steel Piles HP____´____, Furnished

507             Foot (Meter)                    Steel Piles HP____´____, Driven

507             Foot (Meter)                    ___" (___ mm) Cast-In-Place,
                                                               Reinforced Concrete Piles, Furnished

507             Foot (Meter)                    ___" (___ mm) Cast-In-Place,
                                                                Reinforced Concrete Piles, Driven

507             Foot (Meter)                    Timber Piles, Creosoted

507             Foot (Meter)                    Timber Piles, Untreated

507             Foot (Meter)                    Prebored Holes

507             Each                                Steel Points or Shoes

item 508  FALSEWORK AND FORMS

508.01  Description

508.02  Falsework

508.03  Forms

508.04  Oiling Forms

508.05  Basis of Payment

508.01  Description.  This work consist of designing and building of falsework and forms for the purpose of holding concrete in place until it has set up.

508.02  Falsework.  Provide substantial and rigid falsework that does not unduly obstruct any waterway, highway, or railway.  Arrange intermediate supports in the completed structure to produce the camber necessary to conform to the plan profile of the roadway.

Do not allow the maximum deflection in the longitudinal falsework members at the edges of the concrete deck to exceed 1/2 inch (13 mm) or the amount obtained by the following formula, whichever is greater.

Where:

                          d =  the maximum deflection in inches (millimeters)

                          S =  the distance between supports in inches (millimeters)

For transverse falsework members, and for longitudinal falsework members other than those near the edges of the deck, increase the permissible deflection obtained from the above formula by 75 percent.

To compensate for falsework deflection, build camber into the falsework.  In addition to falsework defection, build the following amounts of camber into the falsework to compensate for slab deflection after falsework is released:

A.      Equal to 1/800 of the span for continuous spans.

B.      Equal to 0.000018 S3 (0.016 S3) for simple spans, where S is the length of the slab span in feet (meters) for camber expressed in inches (millimeters).

Provide camber to conform to the profile grade.

If the falsework does not rest in rock, shale, or other firm foundation material, support falsework on piling driven to sufficient penetration to carry the superimposed loads according to Item 507, but not less than 16 tons (16 metric tons) per pile.  Perform dynamic load testing to determine required blow count if piles are not driven to rock.  Do not use expansion anchors to support falsework on piers or abutments.  Use double hardwood wedges as necessary to facilitate vertical adjustment.

Remove and replace any part of the structure made unsatisfactory by incorrect camber, settlement or form deformation.

Construct falsework for arches so it may be released gradually.

Remove falsework only after the concrete conforms to 511.16 and before final acceptance of the structure.  Cut off or pull falsework piling.  Cut off piles to at least the slope line, riprap line, or stream bed.

Locate the lower contact point of overhang falsework within 8 inches (200 mm) of the top of the rolled beam or steel girders bottom flange.

Submit falsework plans for cast-in-place concrete slab superstructures according to 501.05.

If a thickened edge is shown on the plans, the Contractor may develop the edge by sloping the bottom of the slab for a minimum of 9 feet (2.7 m) from the edge, instead of the section shown.

Do not place spandrel walls, decks of arches, sidewalks and curbs, or any superimposed concrete to be completed after constructing the main supporting member or the deck until the falsework for the main supporting member has been removed or released.

For continuous concrete slab or beam superstructures, do not place concrete on a span until the falsework and forms are complete for the adjacent spans.  Do not release or remove falsework from a span until the concrete in adjacent spans has been placed a sufficient length of time to meet all requirements for the removal of falsework as set forth in 511.16.

508.03  Forms.  Place all concrete in proper forms.  Do not use unprotected sides of the excavation, instead of forms, unless as specified in 503.04 for rock or shale excavation.  For dry excavation specified in 503.03, the Contractor may use the sheeting as forms for footings.

Construct substantial, unyielding, and mortar tight forms, designed to produce a finished concrete conforming to the proper dimensions and contours.  Make forms for exposed surfaces of approved material requiring a minimum number of joints or of dressed lumber of uniform thickness using form liner approved by the Engineer.  Use forms and form liners to reduce the joints showing on the finished surface to a minimum.  Arrange joints to coincide with rustication grooves shown on the plans.  Properly brace or tie forms together using approved form ties that do not allow metal within 2 inches (50 mm) of an exposed surface of the finished structure after the forms are removed.  For ties in the region of exposed surfaces, use an approved insert.  Remove all forms and do not allow material, except reinforcing supports specified in 509.08, to remain in the concrete.

In forming pier, intermediate, or end diaphragms for prestressed or post-tensioned concrete members, do not damage reinforcing steel, strands, or precast concrete in the placement of post installed anchors in these members. Properly brace diaphragm forms externally or use approved form tie inserts cast into these members.

For concrete decks separated by an open median or temporarily separated by a closure section, construct falsework and forms for each deck or section of deck independent of the adjacent structure or remaining superstructure.

Immediately before placing concrete, provide temporary openings at the base of column and wall forms and in the bottom of all narrow, deep members where necessary to facilitate cleaning or inspection.

Provide a 3/4-inch (20 mm) bevel on all exposed edges using a triangular strip built into the forms.

If rustication is used, fasten molding that is surfaced on all sides to the forms in such a manner that the molding remains in the concrete when the forms are removed.  Do not remove this molding until the concrete has set sufficiently to prevent damage to the edges of the concrete.

If weep holes through abutments or retaining walls are shown on the plans, form weep holes to obtain a smooth circular opening between 3 and 4 inches (75 and 100 mm) and a straight gradient of 0.08 through the wall.

508.04  Oiling Forms.  Before placing reinforcing steel, coat the inside of forms with non-staining mineral oil or other approved material.

508.05  Basis of Payment.  The Department will not separately pay for falsework and forms.  The cost of this work is included for payment in the price bid for the item for which falsework and forms are used.

The Department will not pay for removal and replacement of any part of the structure made unsatisfactory by settlement or form deformation.

The Department will not pay for dynamic load testing required to determine blow count if piles are not driven to rock.

ITEM 509  REINFORCING STEEL

509.01  Description

509.02  Materials

509.03  Care of Material

509.04  Method of Placing

509.05  Bending

509.06  Approval of Placing

509.07  Splicing

509.08  Supports

509.09  Epoxy Coated Reinforcing Steel

509.10  Method of Measurement

509.11  Basis of Payment

509.01  Description.  This work consists of furnishing and placing supports, mechanical connectors, tie wires, and reinforcing steel of the quality, type, size, and quantity designated, including steel dowels.

509.02  Materials.  Furnish materials conforming to:

Epoxy coated reinforcing steel................................. 709.00

Reinforcing steel,

.... deformed bars........................... 709.01, 709.03, 709.05

Spiral reinforcing steel............................. 709.01 or 709.08

Bar mats and wire fabric................ 709.09, 709.10, 709.12

Plastic supports........................................................ 709.15

For metal bar supports used at or near the surface of the concrete, furnish either galvanized steel, stainless steel, epoxy coated steel or plastic coated steel.

Provide sufficient additional reinforcing steel to replace reinforcing steel removed by the Department for sampling.  Replace random samples in the structures with additional steel, spliced according to 509.07.

When providing reinforcing steel for spiral cages, galvanized steel conforming to ASTM A767, Class 1, may be provided only for the spiral reinforcing steel in lieu of epoxy coated reinforcing steel. The galvanized coated reinforcing steel will meet all other requirements of 509. Where a sample splice is needed use the lap length requirements for epoxy coated. The Galvanized coating will be applied after the reinforcing has been fabricated. If the galvanized surface becomes damaged during handling in the field, repairs will conform to ASTM A780. Use bar supports and tie wires which are plastic coated or epoxy coated. Only suppliers certified under S1068 may provide this reinforcing.

509.03  Care of Material.  Upon delivery to the project and before use, stack reinforcing steel off the ground and keep it free from dirt, oil, grease, or avoidable rust.  Before placing in the concrete, ensure the reinforcing steel is clean and free of loose rust.

509.04  Method of Placing.  Place reinforcing steel in the positions shown on the plans, and firmly secure the steel during the placing and setting of concrete.  Tie bars in the superstructure at all intersections, except tie bars at alternate intersections where bar spacing is less than 1 foot (0.3 m) in any direction.  The Contractor may place up to 25 percent of the upper longitudinal bars in a bridge deck slab beneath the upper transverse bars to support the top mat.  Do not drive or force reinforcing steel into concrete after its initially set.

Welding on reinforcing is prohibited, except as permitted by 709.10 and 709.12.  The Engineer will allow the Contractor to fabricate reinforcing bar cages for prestressed beams if fabrication is done in a manner satisfactory to the Director.

Install reinforcing steel with at least the following clearances from the concrete surface:

A.      2 1/2 inches (65 mm) to the top of sidewalks.

B.      3 inches (75 mm) at the faces of footings placed against rock or earth.

C.      1 1/2 inches (38 mm) to the bottom of a cast-in-place deck slab.

D.      2 inches (50 mm) at all other surfaces.

E.      2 1/4 to 2 1/2 inches (60 to 65 mm) between the reinforcing steel and the top surfaces of cast-in-place concrete deck slabs.

509.05  Bending.  Bend reinforcing steel to the dimensions shown on the plans and in Table 509.05-1 (509.05-1M).  Reject reinforcing steel showing transverse cracks.

TAble 509.05-1  STANDARD BENDS

Bar

Nominal Dimensions

180° Bend

90° Bend

135° Bend

Bar

Diameter

Area

Weight

D

A

D

A

D

A

Size

in

in²

lb/ft

in

in

in

in

in

in

3

0.375

0.11

0.376

2 1/4

5

2 1/4

5

1 1/2

4

4

0.500

0.20

0.668

3

6

3

7

2

4 1/2

5

0.625

0.31

1.043

3 3/4

7

3 3/4

8 1/2

2 1/2

5 1/2

6

0.750

0.44

1.502

41/2

8

4 1/2

10

7

0.875

0.60

2.044

5 1/4

10

5 1/4

12

8

1.000

0.79

2.670

6

11

6

131/2

9

1.128

1.00

3.400

9 1/2

15

9 1/2

15 1/2

10

1.270

1.27

4.303

10 3/4

17

10 3/4

18

11

1.410

1.56

5.313

12

19

12

20

14

1.693

2.25

7.65

18 1/4

27

18 1/4

25

18

2.257

4.00

13.60

24

36

24

33

Tolerances:  For diameter of bends, “D”, the tolerance may be plus or minus the diameter of the bar.  Standard fabricating tolerances shall be in accordance with the CRSI Manual of Standard Practice.  No weight allowances will be made for tolerances.

TAble 509.05-1M  STANDARD BENDS

Bar

Nominal Dimensions

180° Bend

90° Bend

135° Bend

Bar

Diameter

Area

Weight

D

A

D

A

D

A

Size

mm

mm²

kg/m

mm

mm

mm

mm

mm

mm

#10M

9.5

71

0.560

60

130

60

130

40

105

#13M

12.7

129

0.994

75

155

75

180

50

115

#16M

15.9

199

1.552

95

180

95

215

65

140

#19M

19.1

284

2.235

115

205

115

255

#22M

22.2

387

3.042

135

255

135

305

#25M

25.4

510

3.973

150

280

150

345

#29M

28.7

645

5.060

240

380

240

395

#32M

32.3

819

6.404

275

430

275

455

#36M

35.8

1006

7.907

305

485

305

510

#43M

43.0

1452

11.38

465

685

465

635

Tolerances:  For diameter of bends, “D”, the tolerance may be plus or minus the diameter of the bar.  Standard fabricating tolerances shall be in accordance with the CRSI Manual of Standard Practice.  No weight allowances will be made for tolerances.

509.06  Approval of Placing.  Before placing concrete, obtain the Engineer’s approval of reinforcing steel in place.

509.07  Splicing.  Splice reinforcement only as specified or determined by the Engineer.  Splice spiral reinforcement by lapping 1 1/2 turns.  Do not replace spiral reinforcement removed for a material sample if the sample is from the end of the spiral and less than or equal to 30 inches (0.8 m) long.

Mechanical connectors shall be capable of developing 125 percent of the yield strength of the connected bars.  The total slip of the bar within the splice sleeve of the connector after loading in tension to 30.0 ksi (207 MPa) and relaxing to 3.0 ksi (21 MPa) shall not exceed the following measured displacements between gage points clear of the splice sleeve:

A.      For bar sizes up to No. 14: 0.01 in. (0.25 mm)

B.      For No. 18 bars: 0.03 in. (0.76 mm)

Splice Nos. 14 and 18 (Nos. 45M and 55M) reinforcing steel bars with mechanical connectors.

The Department will not permit lap splices for these size bars.

Splice Nos. 14 and 18 (Nos. 45M and 55M) reinforcing steel bars with mechanical connectors.  The Department will not permit lap splices for these size bars.

Splice additional steel used to replace random samples as follows:

Table 509.07-1                                   Table 509.07-1M

Bar

Lap Length (inches)

Bar

Lap Length (mm)

Size

Uncoated

Epoxy Coated

Size

Uncoated

Epoxy Coated

4

22

27

13M

560

690

5

29

35

16M

740

890

6

34

41

19M

870

1040

7

43

52

22M

1090

1320

8

57

69

25M

1450

1750

9

72

87

29M

1830

2210

10

92

111

32M

2340

2820

11

113

137

36M

2870

3480

509.08  Supports.  Use precast mortar blocks, metal supports, or plastic supports of adequate strength, of the proper depth, and in sufficient number to support reinforcing steel.  Space supports for reinforcing steel no more than 4 feet (1.2 m) apart transversely and longitudinally.  Metal supports shall have a shape that is easily enveloped by the concrete.

Mortar blocks may only be used to support the lower matt of reinforcing steel in concrete that is cast directly against bedrock or soil.

509.09  Epoxy Coated Reinforcing Steel.  Use plastic coated or epoxy coated bar supports and tie wires to protect the epoxy coating from physical damage, as specified in 709.00, during placement and to prevent electrical coupling between mats.  Carefully handle and install bars to perform minimal patching at the job site.  Repair physical damage to the epoxy coating with a patching material all damaged coating areas greater than 1/4-inch (6 mm) square or 1/4-inch (6 mm) diameter; approximately 1/8-inch (3 mm) square or 1/8-inch (3 mm) diameter if the opening is within 1/4-inch (6 mm) of an equal or larger opening; or, a length of 6 inches (150 mm) regardless of area. Coating damage in cases where the damaged area is less than specified above need not be repaired.  Use patching material of the same composition and quality as the original coating. Prepare the surface to a near white metal.

If repair is required, clean and repair the damaged areas and allow adequate cure time before placing concrete.  The Engineer will approve the installation once patching has been done as outlined above.

509.10  Method of Measurement.  The Department will measure Epoxy Coated Reinforcing Steel by the number of pounds (kilograms) shown on the plans.  Additional measurements or calculations are not required.

If the Contractor believes the pay weight, as shown on the plans, is in error, the Contractor is responsible to prove this discrepancy by recalculating the total weight for the reference number involved.  The Contractor shall submit its figures to the Engineer for review and approval.  The number of pounds (kilograms) of reinforcing steel shall be the actual number of pounds (kilograms) of the various sizes incorporated in the concrete as shown on the plans, completed and accepted.

If the weight of the reinforcing steel is recalculated, determine the number of pounds (kilograms) from the number, length, and weight of the bars as shown on the steel list of the plans, based on the weight per foot (meter) shown in the Table 509.05-1 (509.05-1M) with deductions for bars not used, and addition for extra bars used as directed by the Engineer.

509.11  Basis of Payment.  The Department will not include the supports, mechanical connectors, and tie wires in the calculated weights but will consider them incidental to the price bid.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

509             Pounds (Kilograms)        Epoxy Coated Reinforcing

ITEM 510  DOWEL HOLES

510.01  Description

510.02  Materials

510.03  Drilling of Holes

510.04  Placement

510.05  Curing and Loading

510.06  Basis of Payment

510.01  Description.  This work consists of drilling holes into concrete or masonry, and furnishing and placing grout into the holes.  The furnishing and placing of steel for dowels is included in Item 509.

510.02  Materials.  Cement grout consists of one part of hydraulic cement conforming to Item 701 and three parts sand conforming to 703.03, by volume, and water.

Furnish nonshrink, nonmetallic grout conforming to 705.20.

510.03  Drilling of Holes.  Drill holes at the location and the depth shown on the plans without spalling the concrete.

Drill holes for cement grout at least 1/2 inch (13 mm) larger in diameter than the dowel bar.  Drill holes diameters for nonshrink, nonmetallic grout at least 1/16 inch (1.5 mm) larger in diameter than the dowel bar.  Drill hole for encapsulated type nonshrink, nonmetallic grout as recommended by the manufacturer.

Instead of drilling holes, the Contractor may install formed holes with laitance removed.

510.04  Placement.  Do not install grout if the temperature of the concrete into which the grout is being placed is below 40 °F (4 °C).  Force dowel bars into the holes, to the specified depth, spreading the grout around the bar and solidly filling the hole.

Before installing cement grout and dowels, saturate cement grout dowel holes with water then blow out all excess water.  Place enough cement grout to completely fill the holes during dowel installation.  If cement grout does not completely fill the hole, remove the dowel, pour additional grout into the hole, and reinstall the dowel.

Before installing nonshrink, nonmetallic grout and dowel, clean and dry the grout holes.  Immediately after mixing, place a sufficient amount of nonshrink, nonmetallic grout to provide complete coverage around the dowel to ensure anchorage.  If nonshrink, nonmetallic grout does not completely fill the hole, pour additional grout in until the hole is filled flush.

Obtain the correct protrusion of the anchors or dowels, and hold dowels in the plan position within the holes until the grout has initially hardened.

If horizontal holes are specified, provide a means of retaining the grout in the hole flush with the vertical face and remove this material after the grout has hardened.  Do not use material for retaining the grout that bonds to the grout.

510.05  Curing and Loading  Before applying any stresses to dowels, cure nonshrink, nonmetallic grout as follows:

Daily Minimum Ambient Temperature

Minimum Curing Time

33 to 50 °F (1 to 10 °C)

3 hours

51 to 68 °F (11 to 20 °C)

1 1/2 hours

above 68 °F (above 20 °C)

1 hour

510.06  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

510             Each                                Dowel holes with cement grout

510             Each                                Dowel holes with nonshrink, nonmetallic
                                                               grout

ITEM 511  CONCRETE FOR STRUCTURES

511.01  Description

511.02  Materials

511.03  Concrete

511.04  Quality Control Requirements and Mass Concrete 

511.05  Mixing of Concrete

511.06  Slump

511.07  Placing Concrete

511.08  Slipform Construction of Bridge Railing

511.09  Construction Joints

511.10  Work Stoppage

511.11  Depositing Concrete Under Water

511.12  Depositing and Curing Concrete During Cold Weather

511.13  Removal of Forms

511.14  Curing and Loading

511.15  Surface Finish

511.16  Roadway Finish

511.17  Bridge Deck Grooving

511.18  Sidewalk Finish

511.19  Sealing Joints and Cracks

511.20  Compressive Strength

511.21  Air Content

511.22  Pay Factors

511.23  Method of Measurement

511.24  Basis of Payment

511.01  Description.  This work consists of providing falsework and forming, furnishing, placing, consolidating, finishing, and curing portland cement concrete.  This work also includes diamond saw cutting longitudinal grooves into the surface of superstructure concrete.  Construct falsework and forms as required in Item 508.

 511.02  Materials.  Furnish materials conforming to 499.02, except as modified below.

Use the same kind and color of aggregate for all concrete above the ground line in a given substructure unit and for all concrete in a given superstructure.

Use high molecular weight methacrylate resin sealer conforming to 705.15.

Use curing materials conforming to 705.05; 705.06 (white opaque); or 705.07;Type 1 or 1D.

Use 1/4-inch (6 mm) gray sponge joint filler conforming to 711.28, or use preformed filler conforming to 705.03.

Use preformed elastomeric compression joint seals conforming to 705.11.

511.03  Concrete.  Provide concrete for structures according to 499.03, using Class QC 1, QC 2, QC 3 or QC 4 as specified in the Contract.

At least 10 days before placing concrete, submit, in writing, the Department accepted Job Mix Formula (JMF) to the Engineer.  The Engineer will review the mix design for conformance to contract requirements; otherwise the mix design is for the Engineer’s information.

511.04  Quality Control Requirements and Mass Concrete.  When the concrete bid item requires QC/QA, develop and submit a Quality Control plan (QCP) for the work and perform quality control testing of the concrete conforming to Item 455.

When the concrete bid item requires QC/QA, The Engineer will perform Quality Assurance conforming to 455.

When the concrete bid item does not require QC/QA, the Engineer will make acceptance test cylinders as follows:

1.          Structures over 20-foot (6.1 m) span. A set of test cylinders from each 200 cubic yards (150 m³) of concrete, or fraction thereof that is incorporated into the work each day.

2.          Structures of 20-foot (6.1 m) span or less. At least one set of test cylinders for each 50 cubic yards (35 m³) of concrete.

With any 511 concrete bid item provide and maintain a Concrete Cylinder Curing Box (CCCB) capable of holding at least 12 4 × 8 inch (100 × 200 mm) cylinders at a temperature of 60 to 80 °F (15 to 27 °C) degrees no matter what the ambient temperature.  The box will have a sealed lid.  If the project has numerous 511 concrete bid items CCCB are not required for each bid item.  Locate the CCCB at a site that is convenient to the concrete work and will eliminate handling damage to both the Contractor QC or QA cylinders and the Department Cylinders.  Move the CCCB as needed during the project when the distance from the concrete work increases the possibility of cylinder handling damage. 

A. Mass Concrete Requirements.  For concrete components with a minimum dimension of 5-ft (1.5-m) or greater, develop a concrete mix design QC-4 for mass concrete according to 499.03. Develop a Thermal Control Plan (TCP) to control placement of the mass concrete so that the highest maximum internal temperature of the placed concrete is not greater than 160⁰ F (71⁰ C) and the maximum differential concrete temperature does not exceed 36⁰ F (20⁰ C) over 28 days from time of placement.

For drilled shafts with a dimension of 7-ft (2.1-m) diameter or greater, develop a concrete mix design QC-4 for mass concrete, QC 4 according to 499.03. Develop a TCP to control placement of the mass concrete so that the highest maximum internal temperature of the placed concrete is not greater than 160ºF (71ºC).

Submit the TCP to the Engineer for acceptance at least 10 calendar days prior to placement along with the approved JMF (s).

As a minimum, the TCP shall include the following information:

1. Duration and method of curing.

2. Procedures to control concrete temperature at the time of placement. The mix shall contain no frozen pieces of ice after blending and mixing components.

3. Methods and equipment used for controlling temperature differentials.

4. Temperature sensor types, locations and installation details. As a minimum, concrete temperatures shall be monitored at the calculated hottest location, on at least 2 outer faces, 2 corners, and top surfaces.

5. Temperature monitoring and recording system; operation plan; recording and reporting plan with example output; and a remedial action plan.

Criteria for form removal to control the maximum temperature differential.

As an alternative to the maximum differential concrete temperature specified above, the Contractor may propose maximum differential temperature limits based on strength gain with time.   The TCP for the alternative proposal shall include the methods used to determine the temperature and supporting data and design to support the accuracy of the method chosen.  Provide complete calculations and basis for increasing the maximum differential temperature specification. The TCP for the alternative proposal shall also provide the Engineer with tables that define ambient temperatures for acceptable concrete placement, the required temperature of the concrete for the ambient air temperature, the maximum predicted concrete temperature, the maximum predicted differential temperature, the time for removal of forms, the allowable air temperature for form removal, and the predicted maximum and differential temperature from placement to age of 28 days.  The Department will consider all cracking of a mass concrete  placement where the differential temperature exceeded 36 ºF (20ºC) the responsibility of the Contractor.

Upon the Engineer’s acceptance of the TCP, continuously monitor all temperature sensors over the required age of the concrete. If the maximum limit or differential temperature limits are exceeded at any time, immediately take action to retard and reduce the out-of-specification temperatures.  If a mass concrete placement temperature exceeds the specification limits of the currently accepted TCP, re-engineer, revise and resubmit the TCP.  Do not place additional mass concrete until the revised TCP is accepted.

The Department will consider in-place mass concrete that exceeds the temperature limits or that cracked, as defective and resulting delays as non-excusable. Determine the extent and effect of the damage and submit a proposed repair plan to the Engineer to return the concrete to acceptable quality.  The Department will determine if the proposed repair methods are acceptable or if removal is required.

511.05  Mixing of Concrete.  Mix concrete according to 499.08.

When an air temperature of 60 °F (16 °C) or higher prevails at the time of placing concrete in a bridge superstructure over 20-foot (6.1 m) span, add a chemical admixture conforming to 705.12, Type B or D to the concrete unless waived by the Engineer. 

511.06  Slump.  Within the slump ranges specified in 499.03, provide a slump that produces concrete that is workable in the required position, flows around reinforcing steel, and coats individual particles of coarse aggregate with mortar containing the proportionate amount of sand.

511.07  Placing Concrete.  Submit to the Engineer a description of proposed placing procedures and notify the Engineer at least 24 hours in advance of placing concrete.  If the concrete bid item requires QC/QA, include the submittal as part of the QCP.

Place and finish concrete to the lines and grades shown in the plans.

Provide coverage over or around reinforcing steel as described in 509.04.

Conform to the following tolerances from plan dimensions:

TABLE 511.07-1

PLACEMENT TOLERANCES

Deviation from plumb for exposed surfaces

      ± ¾ inch (19 mm)

Vertical alignment (Deviation from a line parallel to the grade line)

± ½ inch in 20 feet (13 mm in 6 m)

Longitudinal alignment (Deviation from a line parallel to the centerline or baseline)

±½ inch in 20 feet (13 mm in 6 m)

Width dimensions of walls for exposed surfaces

    ±½ inch (13 mm)

Bridge Slab thickness

±¼ inch (6 mm)

Elevations of beam seats

±1/8 inch (3 mm) 

Slope, Vertical Deviation from Plane

±0.2%

Slope, Horizontal Deviation from Plane

±0.4%

Until discharged in the work, ensure that the temperature of all concrete does not exceed 95 °F (35 °C).  . 

When placing superstructure concrete assure the ambient air temperature is 85 °F (30 °C) or less and not predicted to go above 85 °F (30 °C) during the concrete placement; and evaporation rates, determined according to Figure 1 in ACI 308, do not exceed 0.1 lbs/ft²/hour (0.5 kg/m²/hour).

Determine and document the ambient air temperature, concrete temperature, deck surface temperature, relative humidity, and wind velocity, subject to verification by the Engineer.  Measure data required in Figure 1 from within 10 feet (3 m) of the area where the superstructure concrete is placed.

Figure 1 does not apply to substructure items and formed parapets.  Figure 1 applies to slip-formed parapets.

To meet favorable atmospheric conditions, may require the Contractor to place concrete at night.  At least 24 hours before placing concrete at night, submit a lighting plan for the work area to the Engineer.  Obtain the Engineer’s approval of the lighting plan before placing the concrete.  Direct lights so that approaching traffic is not affected or distracted.

Before placing a concrete deck on continuous steel beams or girders, complete all of the main beam or girder splices at least two piers beyond the pier or piers supporting the concrete.

Before placing concrete for backwalls above the approach slab seat with steel expansion joints, backfill the abutments to within 2-feet (0.6 m) of the bridge seat elevation, erect structural steel or prestressed concrete beams and place superstructure concrete in the adjacent span,.  Use the steel expansion joint as a template for the top of the backwall.  If temporary bolts are used to support the backwall portion of an expansion device during the placing of the backwall concrete, remove the bolts after the concrete has taken its initial set and before a change in temperature causes superstructure movement sufficient to damage the backwall.

Before placing concrete, assure the Engineer of an adequate and uniform source of supply of concrete to allow proper placing and finishing, and of the availability of coverings to protect the concrete from rain.

Do not add or apply water to the concrete after it has left the truck and before applying curing materials according to 511.14.

Before placing concrete, thoroughly clean all forms and structural steel that contact the concrete and ensure that the space to be occupied by the concrete is free of laitance, silt, dirt, shavings, sawdust, loose and built-up rust, and other debris.

Deposit concrete using methods that ensure reinforcing steel is completely enveloped in concrete mortar and that allow inspection of concrete enveloping the reinforcing steel.  Use a method or device to convey the concrete from the mixer to the work that prevents coarse aggregate separating from the mortar.  If depositing concrete in shallow members, such as slabs, place it with as short a vertical drop as possible.  Place the concrete over a section to maintain a practically horizontal surface.  If using a chute, slope the chute to allow concrete to flow without segregation.  Place concrete as near as possible to its final position.

Drop concrete into the forms with a free-fall distance of 5 feet (1.5 m) or less.  As necessary, use drop chutes to limit the free fall to 5 feet (1.5 m) and to ensure the delivery ends as vertical as possible.

Deliver and distribute the concrete at a uniform and adequate rate no more than 10 feet (3 m) directly in front of the finishing machine by suitable mechanical equipment. For structures with a skew angle greater than fifteen (15) degrees, Orient the finishing machine according to 511.16.  For structures with a skew angle greater than fifteen (15) degrees and up to fifty (50) degrees, load the concrete at the skew angle.  For structures with a skew angle greater than fifty (50) degrees, load the concrete as close to the skew angle of the structure as possible, but do not allow the leading edge of the concrete placement to exceed twenty (20) feet (6.1 m) ahead of the finishing machine.

Place concrete in structures using vibration.  Furnish and use sufficient vibration equipment of the type and size approved by the Engineer to properly compact the concrete immediately after it is placed in the forms.  The vibrators shall generally be of a type that is applied directly to the concrete and have a frequency of at least 4500 impulses per minute.  If the concrete is inaccessible for this method of vibration, apply the vibrators to the outside of the forms.

Do not move concrete using a vibrator.  Vibrate freshly deposited concrete at the point deposited.  Slowly insert and withdraw the vibrators vertically into the concrete until the concrete is thoroughly compacted but not segregated.  During vibration, do not disturb partially hardened concrete.

As necessary, spade along form surfaces, in corners, and in locations impossible to reach with vibrators to ensure smooth surfaces and dense concrete.  Closely observe the results obtained on the first concrete placed, and, if necessary, modify the mix according to this specification to secure the best results.

Figure 1 ACI 308-81

511.08  Slipform Construction of Bridge Railing.  If slipforming, provide finished concrete conforming to the following tolerances from plan dimensions:

TABLE 511.08-1

SLIPFORMED BRIDGE RAILING TOLERANCES

Reinforcing steel cover

-1/2 inch, +1/2 inch (-13 mm, +13 mm)

Top width dimension

-0, +1/4 inch (+6 mm)

Bottom width dimension

-0, +1/2 inch (+13 mm)

Surface flatness

1/4 inch in 10 feet (6 mm in 3 m)

Vertical alignment (Deviation from a line parallel to the grade line)

1/2 inch in 20 feet (13 mm in 6 m)

Tie all joints and splices in bridge railing reinforcing steel.  Before placing concrete, perform a slipforming dry run to verify reinforcing clearance and rigidity of the reinforcing cages.  Adjust and stabilize the cage as necessary to establish the required clearances and to ensure the cage will not move during slipforming.  The Contractor may add any additional diagonal reinforcing steel between the front and rear vertical reinforcing faces to establish the required rigidity.

Repair or patch honeycombing, cracking, tearing, and other defects immediately after concrete exits the slipform equipment.  Completely fill defects with concrete without using water to smooth or close the surface.  If the slipforming exhibits more than infrequent defects, stop work and make adjustments to produce a slipformed surface that does not require repairs. Do not broom finish the surface of the bridge railings.

After the concrete initially sets, but before any shrinkage cracks develop, saw control joints 1 1/4 inches (32 mm) deep into the perimeter of the parapet.  Generally, initial set is within 6 hours of batching of the concrete.  Ensure that all joints are sawed within 24 hours of placement. Saw control joints using an edge guide, fence, or jig to ensure that the joint is straight, true, and aligned on all faces of the parapet.  The joint width shall be the width of the saw blade, a nominal 1/4 inch (6 mm).  Caulk the control joints with a polyurethane or polymeric material conforming to ASTM C 920, Type S.

Slip formed concrete requires different slumps than those listed in Item 499 or other plan specified concrete.  Provide a slump such that the concrete exiting the slipform does not pull but is stiff enough to prevent waviness and sags in the finished surfaces.  Cure slipform concrete according 511.14, Method A.  Because slipformed concrete has a low water-cement ratio, timely application of the water cure is critical in helping control shrinkage cracks.

Furnish platforms as necessary to protect traffic passing under the bridge from falling debris during the slipforming operation, to allow access for completing the finishing operation, and to allow the Engineer access to the outside of the parapet.

The Engineer will inspect the slipformed surface for horizontal cracking no earlier than 21 days after completion of the slipforming operation.  Repair all horizontal cracks by epoxy injection.  If a concrete sealer was applied, repair damage to the sealer after completing the epoxy injection.

511.09  Construction Joints.  If construction joints are shown on the plans, place all concrete between consecutive joints in a continuous operation.  Do not place concrete against a joint for at least 12 hours, or as required by 511.14.

Obtain the Director’s approval before placing any construction joint not shown on the plans or required by 511.07.

Before placing concrete, determine the location where the day’s concrete placing ends.  If practical, end placing the day’s concrete perpendicular to the lines of principal stress and in regions of small shear.  Do not install horizontal joints in concrete girders and beams.

Form construction joints using bulkheads with keyways.  Locate keyways clear of exposed surfaces by approximately one-third the thickness of the joint. Construct transverse or longitudinal construction joints in deck slabs with keys located between the reinforcing mats and having a depth of 3/4 inch (19 mm).

Where practical, avoid horizontal joints in piers, abutments, and retaining walls, otherwise locate horizontal joints 2 feet (0.6 m) or more above the normal water level.

For construction joints not shown on the plans and above ordinary low water, in abutments, and in retaining walls that retain earth fills, install a 36-inch (1 m) strip of Type 2 membrane waterproofing according to Item 512 to the back of the joint.

Avoid joints in cantilevered members.

Dampen the surface of the concrete of the horizontal construction joints immediately before placing adjoining concrete.

Place and protect horizontal construction joints between bridge slabs and superimposed curbs, parapets, sidewalks, and median strips in the same manner as the remainder of the slab.  Cure the construction joints according to 511.14.

Avoid disturbing the bond between protruding reinforcing steel and the deck concrete.  If using the curb areas to place the deck, tie and brace the reinforcing steel to prevent its movement.

Where walls or columns support slabs or beams, place concrete in wall or column to the bottom of the slab or beam and allow the concrete to settle for at least 2 hours before placing concrete in the slab or beam.

511.10  Work Stoppage.  If the work is unexpectedly interrupted by breakdowns, storms, or other causes, rearrange the freshly deposited concrete to provide a suitable construction joint.  If this joint occurs at a section with shear stress, prevent a plane of weakness by providing an adequate mechanical bond across the joint by forming a keyway, inserting reinforcing steel, or by some other means satisfactory to the Engineer.

511.11  Depositing Concrete Under Water.  Except for cofferdam seals and drilled shafts, do not place concrete under water.

511.12  Depositing and Curing Concrete During Cold Weather.  If placing concrete when the atmospheric temperature is 32 °F (0 °C) or less, or if weather forecasts predict these temperatures during the curing period, follow the procedures of this subsection.

Heat the water or aggregate, or both, as necessary to produce concrete with a temperature when placed of at least 50 °F (10 °C) but not greater than 70 °F (21 °C).

Place concrete against materials with a temperature of greater than 32 °F (0 °C).  If necessary, heat the forms, reinforcing steel, and foundation materials before placing the concrete.

Maintain the concrete surface temperature between 50 and 100 °F (10 and 38 °C) for a period of not less than 5 days, except as modified in 511.12.C.  After the minimum cure period of 5 days, reduce the concrete surface temperature at a rate not to exceed 20 °F (11 °C) in 24 hours until the concrete surface temperature is within 20 °F (11 °C) of atmospheric temperature.

Install sufficient high-low thermometers to readily determine the concrete surface temperature.  For deck slabs, install high-low thermometers to measure deck bottom surfaces, deck fascia surfaces, and deck top surfaces.

Maintain the concrete curing temperature using a heated enclosure, insulated forms, or by flooding, except cure deck slabs less than 10 inches (250 mm) thick using more than just insulated forms.

Remove falsework and open cold weather concrete to traffic according to 511.14.

A.      Heated Enclosure.  Construct the heated enclosure to surround the top, sides, and bottom of the concrete.  Construct strong and wind proof enclosures that contain adequate space to allow free circulation of air around the forms and concrete.

Before placing concrete, construct the enclosure and heating devices to the extent allowed by the concrete operation.  As the concreting operation progresses and as soon as possible after placing concrete, complete construction of the enclosures and apply heat.  Supply heat by a method that continuously maintains a reasonably uniform temperature throughout the enclosures and does not discolor the concrete.

Vent combustion-type heating devices outside the enclosure.

If dry heat, other than free steam, maintains the enclosure temperature, immediately cover exposed concrete with two thicknesses of burlap.  Continuously wet the burlap and, except for required rubbing of the concrete, do not remove the burlap during the heating period.

If wood forms without liners are left in place more than 2 days after the placing of concrete, thoroughly wet the forms at least once each day for the remainder of the heating period.  If forms are removed during the heating period, thoroughly drench the concrete with water and, for the remainder of the heating period, cover and wet the concrete with burlap as specified above.

B.      Insulation.  Install sufficient thermometers to readily determine the concrete surface temperature.  If the surface temperature approaches 100 °F (38 °C), loosen or otherwise vent the forms or insulation to keep the surface temperature within the limits specified above.  If insulation does not maintain the minimum required temperature, promptly enclose the concrete as specified in 511.12.A or flood the concrete as specified in 511.12.C.

Use a wind and water resistant insulating material.  Ensure edges, corners, and other points of extreme exposure are adequately insulated.  Place a tarpaulin or other Engineer approved waterproof cover over the insulation to protect the concrete top surface.

C.      Flooding with Water.  The Contractor may flood the concrete with water provided flooding does not damage the concrete.  Heat the water to a temperature from 50 to 100 °F (10 to 38 °C).  The Contractor may stop using heated water after 48 hours if the concrete remains flooded to a depth of 1 foot (0.3 m) above its highest elevation for at least the next 120 hours.

511.13  Removal of Forms.  To facilitate finishing, remove forms from vertical surfaces that receive a rubbed surface finish as soon as the concrete has hardened sufficiently that rubbing will not damage it.

511.14  Curing and Loading.  Remove falsework and open structures to traffic only after the concrete has reached the strength specified by Table 511.14-1A for concrete bid items requiring QC/QA.  Use Table 511.14.1B for concrete items not requiring QC/QA. Do not shorten the minimum required Method A curing time regardless of strength test results.

Table 511.14-1a

Loading requirements For concrete requiring QC/QA

Span[1]

Required Strength [2]

Removing Falsework

Any Span

Compressive Strength ≥ 0.85% f’c

orFlexural Strength (Center point)

≥ 650 psi (4.5 Mpa)

All pier caps

Traffic [3]

Any

[1]  Span is defined as the horizontal distance between faces of the supporting elements when measured parallel to the primary reinforcement.

[2]  Field cured samples.  The maturity curve method may be used for determining the strength according to Supplement 1098 in lieu of field curing samples

[3]  When placing concrete for a superstructure between October 15 and March 15, open the deck to traffic no sooner than 30 days after placement.

Table 511.14-1b

Loading requirements for concrete not requiring qc/qa

Span[1]

Age of Concrete in Days

No Beam Test

Beam Test [2]

Removing Falsework

Over 10 feet (3 m)

14

5

10 feet (3 m) or less and all pier caps

7

3

Traffic [3]

Any

14

7

[1]  Span is defined as the horizontal distance between faces of the supporting elements when measured parallel to the primary reinforcement.

[2]  Applicable only when the average modulus of rupture for two tests is not less than 650 psi (4.5 MPa).

[3]  When placing concrete for a superstructure between October 15 and March 15, open the deck to traffic no sooner than 30 days after placement.

Take enough specimens to verify compliance with the strength requirements of Table 511.14-1A.  Obtain samples from the first and last sublots of continuously placed concrete for quantities of 500 yd³ or less, and one extra set of specimens for each additional 500 yd³ or fraction thereof.  Obtain samples in equally spaced increments throughout the placement as directed by the Engineer.  Delays in placements of more than 4 hours are not considered continuously placed and are to be treated as separate placements.

If the air temperature surrounding the concrete is maintained between 32 and 50 °F (0 and 10 °C), and if the provisions of 511.12 do not apply, maintain the concrete above 32 °F (0 °C) for 7 days or until a successful strength test conforming to Table 511.14-1, except this time shall not be less than 5 days.

Do not install compression rings on pier columns or similar items of construction for supporting falsework or subsequent construction until after a 72-hour curing period.

Do not apply loads to or perform work on new concrete until workers and  construction materials will not damage the concrete or interfere with its curing.  Allow at least 36 hours or until the field cured compressive strength cylinders or maturity results reach 85% f’c; or if using flexural beams, or the average of two beam tests is greater than 650 psi (4.5 MPa) before working on new concrete. Do not interfere with curing of new concrete.

Cure concrete as follows:

TABLE 511.14-2

CURING REQUIREMENTS

Location

Curing Method [1]

Superstructure concrete

Method A

Concrete to which sealer is applied

Method A

Construction joints

Method A

Top surface of concrete deck superstructure concrete

Method A followed by Method B

Concrete with waterproofing

Method A or Method B

All other concrete

Method A or Method B

[1]  Method A is water curing.  Method B is membrane curing.  If using Method B on areas to be waterproofed, remove the curing membrane.

Concrete curing methods are as follows:

A.      Method A, Water Curing.  With the exception of the top surface of deck superstructure concrete, protect surfaces not covered by forms immediately after final finishing with two thicknesses of wet burlap.  Keep burlap wet for at least 7 days by the continuous application of water.  If forms are removed before 7 days, immediately drench the exposed concrete with water and cover it with burlap.  Continuously apply water to the burlap for the remainder of the curing period.

Instead of continuous application of water, with the exception of the top surface of deck superstructure concrete, the Contractor may cover the wet burlap with white polyethylene sheeting or plastic coated burlap blankets conforming to 705.06.  Place plastic coated burlap blankets wet and with the burlap side against the previous layer of wet burlap.  Sufficiently lap and secure adjoining plastic coated blankets or polyethylene sheets at the laps and edges to form a seal that maintains the concrete wet at laps and edges.  Cover white polyethylene sheeting or plastic coated blankets containing holes or tears with an additional covering of plastic sheeting or blankets as directed by the Engineer.

Cover the top surface of deck superstructure concrete with a single layer of clean wet burlap after it is bull floated if necessary, and finished.  Keep the burlap wet by a continuous flow of water through soaker hoses and cover the hoses with a 4 mils (100 mm) white opaque polyethylene film for 7 days.  After 7 days, allow the surface of the deck to dry.

After curing the top surface of the deck superstructure concrete for 7 days, remove the burlap and standing water.  Within 12 hours after removing the burlap, apply a curing membrane and cure the concrete according to Method B.

B.      Method B, Membrane Curing.  Immediately after the free water has disappeared on surfaces not protected by forms, apply curing material conforming to 705.07, Type 1 or 1D.  If forms are removed before the end of the 7-day curing period, apply curing material on the concrete exposed by removing the forms.

Thoroughly mix curing material immediately before use.  Apply the membrane curing material at the rate of at least 1 gallon per 200 square feet (1 L/5 m²) of surface and in a fine mist to provide a continuous, uniform, and water impermeable film without marring the concrete surface

Do not allow workers, materials, and equipment on the concrete during the curing period, unless adequately protecting the membrane curing material from damage. .

 If the film is broken or damaged during the specified curing period, reapply curing material as specified above to the damaged or affected areas.

511.15  Surface Finish.  Immediately after removing forms, clean, dampen, and fill with mortar all cavities produced by form ties, honeycomb spots, broken corners or edges, and other defects.  Use a mortar of the same proportions used in the concrete being finished.  Substitute sufficient white cement for the regular cement in the mortar used to fill holes and perform other corrective work to produce finished patches of the same color as the surrounding concrete.  Finish other contiguous exposed surfaces on the structure in a similar manner and to the extent required to produce a uniform appearance.

On all exposed surfaces, remove fins and irregular projections with a stone or power grinder, taking care to avoid contrasting surface textures.

A.      Grout Cleaning.  If grout cleaning is shown on the plans or necessary for corrective work, wet the concrete surface and then uniformly cover the concrete with a grout consisting of one part cement, 1 1/2 parts fine sand conforming to 703.03, and sufficient water to produce a mortar with the consistency of thick paint.  Use white portland cement in the grout in the quantity determined by the Engineer necessary to match the color of the concrete.  Uniformly apply the grout with brushes or spray guns, completely filling air bubbles and holes.  Immediately after applying the grout, vigorously scour the concrete surface with a cork or other suitable float.  While the grout is still in a plastic condition and while the grout does not pull from the holes or depressions, finish the surface with a sponge rubber or other suitable float, removing excess grout.  After the grout thoroughly dries, vigorously rub the surface with dry burlap, removing dried grout until there is no visible film of grout remaining on the surface.  Perform the entire cleaning operation of each area on the same day.  Remove dark spots or streaks that remain after the cleaning operation using a fine grained silicon carbide stone.  Stop rubbing with the silicon carbide stone before the surface texture changes.  Unless otherwise directed by the Engineer, perform grout cleaning during the final project clean up.

B.      Rubbed Finish.  If a rubbed finish is shown on the plans, if possible, remove forms within 2 days after placing concrete.  Finish the surface as specified above to correct defects.  After the mortar used for finishing is thoroughly set, and for a minimum of 2 hours before starting the rubbed finish, thoroughly saturate the concrete with water.

Rub surfaces to be finished with a medium coarse silicon carbide stone until all form marks, projections, and irregularities are removed, all voids are filled, and a uniform surface is obtained.  Leave the paste produced by rubbing in place.  Other than water, do not apply additional material to the surface.  After placing concrete above the finishing area, obtain the final finish by rubbing the concrete with a fine silicon carbide stone and water until the entire surface is of a smooth texture and uniform in color.  Protect surfaces with a rubbed finish from damage caused by subsequent construction operations.  If damaged, clean and refinish the surface as specified above.

511.16  Roadway Finish.  Finish and test concrete deck slabs according to 451.12. Do not groove or broom finish a strip of surface 9 to 12 inches (220 to 300 mm) wide adjacent to curbs and barriers.  Provide a broom drag finish on concrete deck slabs in the longitudinal or transverse direction.

The Engineer will approve the finishing machine.  Provide a self-propelled machine with forward and reverse drive mechanisms that enable precise control of machine velocity in both directions.  The machine shall have two rotating rollers, leveling augers, and either a vibrating pan or vibrating rollers.  Field verify that the vibrating frequency of the pans or rollers are from 1500 to 5000 pulses per minute.  Do not use vibrating rollers that have fins protruding more then 1/4 inch (6 mm) from the roller.  Use a finishing machine capable of finishing transversely while traveling in both directions across the deck.  Provide screeds capable of rising above the concrete surface.  Provide a finishing machine capable of finishing the full width of the decks between curbs or parapet walls.  The wheels of the finishing machine shall run on temporary riding rails adequately supported on the structural steel or falsework of the deck.  Make the rail and rail supports of steel and arrange the rail and rail supports so that the weight of the finishing machine and the operator cause zero vertical deflection while traveling across the deck.  Ensure the rail is straight, with no sections exceeding a tolerance of 1/8 inch in 10 feet (3 mm in 3 m) in any direction.  Elevate support rails a sufficient distance above the slab to allow the simultaneous hand finishing of areas not machine finished.  Fabricate and install rail supports to allow removal to at least 2 inches (50 mm) below the top of the slab.  Fill holes formed by the removal of rail supports during the final finishing of the slab. 

For structures with a skew angle greater than fifteen (15) degrees and up to fifty (50) degrees, place the finishing machine within 5°of the skew angle of the structure.  For structures with a skew angle greater than fifty (50) degrees, place the finishing machine at fifty (50) degrees.

511.17  Bridge Deck Grooving.  After water curing the concrete and either before applying curing compound or some period after applying curing compound and before opening the bridge to traffic, saw longitudinal grooves into the deck. If sawing grooves after applying the curing compound and the concrete deck is less than 30 days old, reapply the curing compound after removing standing water, within 12 hours after sawing grooves in the deck.

Use diamond blades mounted on a multi-blade arbor on self-propelled machines that were built for grooving of concrete surfaces. The groove machines shall have depth control devices that detect variations in the pavement surface and adjust the cutting head height to maintain the specified depth of the groove. The grooving machines shall have devices to control alignment. Do not use flailing or impact type grooving equipment. More than one size grooving machine may be required in order to saw the grooves as specified.

Provide an experienced technician to supervise the location, alignment, layout, dimension, and grooving of the surface.

Saw grooves parallel to the bridge centerline in a continuous pattern across the surface. Begin and end sawing 9 to 12 inches (220 to 300 mm) from any device in place in a bridge deck, such as scuppers or expansion joints. Stop sawing a minimum of 2 inches (50 mm)  to a maximum of 24 inches (600 mm) from skewed expansion joints. Maintain a clearance of a minimum of 2 inches (50 mm) and a maximum of 4 inches (100 mm) from the grooves to longitudinal joints in the deck.  Maintain a minimum clearance of 9 inches (220 mm) to a maximum of 30 inches (750 mm) clearance between the grooves and the curb or parapet toe. However, at no point shall un-grooved portions of deck extend beyond edge line and into the temporary or permanent travelled lanes.  Saw grooves in a uniform pattern spaced at 3/4 inch minus 1/4 inch or plus 0 (19 mm minus 6 mm or plus 0). Saw grooves approximately 0.15 inches (4 mm) deep and 0.10 inches (3 mm) wide.

For staged, or phase bridge deck work, saw the grooves parallel to the final, permanent bridge centerline. If the different stages or phases of the bridge deck work occur within one construction season, any stage opened to traffic shall receive an interim coarse broom finish during placement, then saw the longitudinal grooves after the final stage. The interim broom finish will not be allowed as a surface texture when opened to traffic over a winter season. Saw longitudinal grooves in the deck prior to opening to traffic for a winter season.

For bridge decks that widen from one end to the other, saw the longitudinal grooves parallel to the centerline of the roadway. On the side of the bridge that widens, saw the longitudinal grooves to follow the edge line. Saw longitudinal grooves in the gore areas, avoiding the overlapping of grooves.

At the beginning of each work shift, furnish a full complement of grooving blades with each saw that are capable of cutting grooves of the specified width, depth, and spacing.

If during the work, a single grooving blade on a machine becomes incapable of cutting a groove, continue work for the remainder of the work shift.  The Contractor is not required to cut the groove omitted because of the failed blade.  Should two or more grooving blades on a machine become incapable of cutting grooves, cease operating the machine until it is repaired.

Continuously remove all slurry and remaining residue from the grooving operation and leave the deck surface in a clean condition.  Prevent residue from grooving operations from flowing across shoulders or across lanes occupied by public traffic or from flowing into gutters or other drainage facilities.  Remove solid residue before the residue is blown by passing traffic or by wind.

Provide water as necessary to saw grooves according to this subsection.

511.18  Sidewalk Finish.  After placing, strike off the concrete with a template and finish the concrete with a float to produce a sandy texture.

511.19  Sealing Joints and Cracks.   After completing all curing operations and allowing the deck to thoroughly dry, seal the following areas with a high molecular weight methacrylate (HMWM) sealer. Flood the areas and squeegee off the excess material as specified in Item 512 before opening the deck to traffic:

A.      Transverse joints in the deck.

B.      Joints between the concrete deck and steel end dams.

C.      Longitudinal joints in the deck.

D.      Longitudinal joints between the deck and safety curb, barriers, and parapets, etc.

E.      Cracks discovered in the deck that will be checked on the top and bottom surface before opening the deck to traffic.

511.20  Compressive Strength.  Sample and test concrete strength according to 511.04.

A. Concrete Requiring QC/QA.  When the bid item requires QC/QA, the Engineer will evaluate the QC compressive test sublot results according to Supplement 1127 and as follows: 

If a single reported compressive strength test result for a sublot of concrete is less than 88% f’c reevaluate the in-place concrete as follows:.

The Engineer will determine the location for evaluating the strength of the sublot represented by the low compressive strength concrete. Evaluate using either nondestructive testing or cores. The Engineer will accept the concrete if the reported nondestructive test results are greater than the specified f’c. The Department will use the original cylinder results for calculating the compressive strength pay factor (PFc) if non-destructive testing is used. If cores are tested the core results will be used in place of the original cylinder results for pay factor determination.

If the nondestructive test results are less than the specified f’c, the Department will require the concrete to be cored. The Engineer will determine the locations for the required concrete cores. Provide all concrete cores to the Engineer for testing by the Department. Patch core holes with approved patching material. If the core results are above 88% f’c, the Department will use the core strength results for calculating the compressive strength pay factor (PFc).

If the core results indicate that the compressive strength of the concrete is below 88% f’c, submit a plan for corrective action to the Engineer for approval. If the corrective plan is not approved, the Engineer will require the Contractor to:

1. Remove and replace the unacceptable sublot and retest the new sublot at no cost to the Department or

2. Leave the unacceptable material in place and pay for the sublot with a pay factor of 0.75.

If three or more sublot compressive strength acceptance test results are less than f’c but greater than 88% f’c the Engineer will require an investigation of the reasons for the consistent low strengths. Until the investigation is completed to the satisfaction of the Engineer no additional placements of the concrete JMF will be made. Investigations should include all facets of the concrete operation including batching, mixing, delivery, clean up, sampling, testing, quality control plan, etc.  If the Engineer is unsatisfied with the results of the investigation, the JMF and the quality control plan will become not approved. Develop and submit a new JMF and quality control plan conforming to the requirements of 499.03 and 511.04.  Pay factors under 511.22 for these low strength sublots will be based on the original reported cylinder strengths.

B. Concrete Not Requiring QC/QA.  When the bid item does not require QC/QA, the Engineer will evaluate the strength results following the requirements of Table 511.22-2 and as follows:

If a single compressive strength test result is less than f’c the material will be considered unacceptable material and the Department will determine acceptance according to Item 106.07.

If three or more compressive strength test results are less than f’c the Engineer will require an investigation of the reasons for the consistent low strengths. Until the investigation is completed to the satisfaction of the Engineer no additional placements of the concrete JMF will be made. Investigations should include all facets of the concrete operation including batching, mixing, delivery, clean up, sampling, testing, etc.  If the Engineer is unsatisfied with the results of the investigation, the JMF will become not approved. Develop and submit a new JMF conforming to the requirements of 499.03.

  511.21         Air Content.  For concrete that requires QC/QA, test the air content of the concrete according to Item 455.  When QC/QA concrete is not required, the Department will test the air content as directed by the Engineer.

A. Concrete Requiring QC/QA.  Any concrete with air results outside the requirements of Table 499.03-1 that is placed into the structure is unacceptable material according to item 106.07.  The amount of unacceptable material will be the amount represented by the test result. Reevaluate the unacceptable material at no cost to the Department as follows:

1.       Core the location containing the unacceptable concrete.  Patch the core hole with approved material.

a.       For concrete with high air content, test a core for compressive strength.  Concrete with a minimum strength of f’c may be left in place.

b.       For concrete with low air content, test the core to determine the in-place hardened air content, specific surface and spacing factor according to ASTM C 457.  Remove and replace unacceptable materials with specific surface results less than 600 in⁻¹ (25 mm⁻¹) or spacing factor results are more than 0.008 in (0.20 mm).

Hire an independent laboratory acceptable to the Department to perform the testing.

B. Concrete Not Requiring QC/QA.  Any concrete with air results outside the requirements of Table 499.03-1 that is placed into the structure is unacceptable material, according to item 106.07.  The amount of unacceptable material will be the amount represented by the test result. Reevaluate the unacceptable material at no cost to the Department as follows:

1.       The Department will core the location containing the unacceptable concrete. Patch the core hole with approved materials.

a.       For concrete with high air content, the Department will test a core for compressive strength.  Concrete with a strength of f’c may be left in place.

b.       For concrete with low air content the Department will determine the in-place hardened air content, specific surface and spacing factor according to ASTM C 457. Remove and replace unacceptable materials with specific surface results less than 600 in⁻¹ (25 mm⁻¹) or spacing factor results of more than 0.008 in (0.20 mm).

511.22 Pay Factors.  Apply pay factors as follows:

A.       Concrete Requiring QC/QA

The Department will use pay factors based on the percent within limits (PWL) to establish a final adjusted price.  The PWL will be established per lot(s) accepted in the QCP for each bid item quantity of concrete.  The Department will calculate a PWL according to Supplement 1127 using either the Contractor’s verified QC compressive test results or core results when the QC could not be verified.  The compressive strength pay factor (PFC) from Table 511.22-1for the lot will be applied to each bid item represented in the lot.   The Department will combine approach slab and deck concrete test results in the same lot to determine final pay factors.

TABLE 511.22-1

  PAY FACTORS FOR CONCRETE REQUIRING QC/QA

PWL

PFC

85 % – 100 %

1.00

84%

0.995

83%

0.990

82%

0.985

81%

0.980

80%

0.975

79%

0.970

78%

0.965

77%

0.960

76%

0.955

75%

0.950

< 75%

See below

If the PWL value determined for the lot of concrete is below 75%, submit a plan for corrective action to the Engineer for approval. If the corrective plan is not approved, the Engineer will require the Contractor to:

1. Remove and replace the lot of unacceptable material at no cost to the Department, or

2 Leave the unacceptable material in place and pay for the lot of with a pay factor of 0.75.

B.       Concrete Not Requiring QC/QA

For concrete items that the Department performs compression testing, the Department will use pay factors based on the individual compressive strength results for the quantity represented by the test results to establish an adjusted price to the items.  The pay factors from Table 511.22-2 will be applied to items represented by the tests.

TABLE 511.22-2

  PAY FACTORS FOR CONCRETE NOT REQUIRING QC/QA

Individual Test Results

Pay Factor (PFC)

≥ f’c

1.00

< f’c

Follow 106.07

511.23  Method of Measurement.  The Department will measure the appropriate concrete item by the number of cubic yards (cubic meters) determined by calculations from plan dimensions, in place, completed and accepted.

The Department will make deductions for portions of primary structural members embedded in concrete.  The Department will not make deductions for the volume of reinforcing steel, conduits or embedded piles.

Superstructure concrete includes the concrete in deflective parapets not having a metallic railing.

The Department may measure deck concrete by either volume or area using plan dimensions.

The Department will calculate separate quantities of concrete due to unacceptable compressive strength, 511.21 and air content, 511.22.

511.24  Basis of Payment.  The Department will pay for accepted quantities of concrete as follows.

The Department will not pay for additional reinforcing steel required to adequately stabilize the cages.

The Department will not pay for repairs to horizontal cracks by epoxy injection or, if a concrete sealer was applied, for repairs to the sealer after the completing the epoxy injection.

The Department will not pay extra for any type of surface finish specified in 511.15, the cost being considered as included in the price bid for concrete.

If the Contractor elects to saw the deck after applying the curing compound, the Department will not pay to reapply the curing compound.

All costs for sealing as specified in 511.19 are incidental to the appropriate concrete item.  The Department will not make separate payment for sealing.

The Department will not pay separately for the concrete cylinder curing box (CCCB).

The Department will not pay for the re-evaluation of low strength test results, 511.20.A.

The Department will initially pay the full bid price to the Contractor upon completing the work.  The Department will calculate the final adjusted payment for each item as follows:

PF1 - The final adjusted pay per cubic yard (cubic meter) or square yard (square meter), for accepted quantities of concrete:

PF1 = (Contract Bid Price) x PFC

PF2 - The final adjusted pay per cubic yard (cubic meter) or square yard (square meter) for unacceptable quantities of concrete due to compressive strength or low air content and allowed to stay in place, according to 511.20 or 511.21.

PF2 = (Contract Bid Price) x 0.75

Calculate the adjusted price per bid item by multiplying PF1 or PF2 by the appropriate quantities of concrete, then sum the values. Subtract the full bid price paid to the Contractor from the adjusted price to determine the difference. The Department will execute final adjustments by change order upon receipt of all test data.

The Department will pay for accepted quantities at the contract prices as follows:

Item

Unit

Description

511

Cubic Yard

  (Cubic Meter)

Class ___ Concrete, _____

511

Cubic Yard

  (Cubic Meter)

Class ___ Concrete, _____ with QC/QA

511

Cubic Yard

  (Cubic Meter)

Class QC 1 Concrete, Substructure

511

Cubic Yard

  (Cubic Meter)

Class QC 1 Concrete, Substructure with QC/QA

511

Cubic Yard

  (Cubic Meter)

Square Yard

  (Square Meter)

Class QC 2 Concrete, Bridge Deck

511

Cubic Yard

  (Cubic Meter)

Square Yard

  (Square Meter)

Class QC 2 Concrete, Bridge Deck with QC/QA

511

Cubic Yard

  (Cubic Meter)

Class QC 2 Concrete, Bridge Deck (Parapet)

511

Cubic Yard

  (Cubic Meter)

Class QC 2 Concrete, Bridge Deck (Parapet) with QC/QA

511

Cubic Yard

  (Cubic Meter)

Class QC 3 Concrete,  _____     with QC/QA

511

Cubic Yard

  (Cubic Meter)

Class QC 4 Mass Concrete, Substructure with QC/QA

ITEM 512  TREATING CONCRETE

512.01  Description

512.02  Materials

512.03  Sealing of Concrete Surfaces

512.04  Sealing Concrete Bridge Decks with HMWM Resin

512.05  Soluble Reactive Silicate (SRS) Concrete Treatment

512.06  Treating Concrete Bridge Decks with Gravity-Fed Resin

512.07  Sealing Cracks by Epoxy Injection

512.08  Waterproofing

512.09  Method of Measurement

512.10  Basis of Payment

512.01  Description.  This work consists of sealing and treating concrete surfaces, sealing cracks in concrete, and applying waterproofing to structures.

512.02  Materials.  Furnish materials conforming to:

Asphalt cement................................... 702.01 (PG 64 - 22)

Asphalt primer for.................. 702.02 (RC-70 or RC-250),

.... waterproofing...................................................... 702.05

HMWM Resin......................................................... 705.15

Epoxy-Urethane Sealer........................................ 705.23.A

Non-epoxy Sealer................................................ 705.23.B

Soluble Reactive Silicate (SRS)............................... 705.24

Gravity Fed Resin.................................................... 705.25

Epoxy injection Materials........................................ 705.26

.... Sand........................ 703 with the following exceptions:

.... Maximum moisture content of 0.5 of the percent of absorption when treated according to California Test 226.

.... Gradation:

Sieve Size

Total Percent Passing

No. 4

(4.75 mm)

100

No. 8

(2.36 mm)

90 to 100

No. 20

(850 µm)

5 to 15

No. 50

(300 µm)

0 to 5

Emulsified asphalt primer,................ 702.04 (MS-2, SS-1)

Asphalt for waterproofing....................................... 702.06

Hot applied joint sealer............................................ 705.04

Type 3 membrane primer......................................... 705.04

Waterproofing fabric................................................ 711.24

Sheet Type 2 membrane waterproofing................... 711.25

Sheet Type 3 membrane waterproofing................... 711.29

512.03  Sealing of Concrete Surfaces. This work consists of applying an approved sealer on existing and new concrete surface areas after the concrete is cured and repairs completed and cured. Apply the sealer to locations described in the plans. Apply the sealer listed in the pay item description. Choose a type of sealer if no sealer is listed in the pay item description.

A.      Equipment. Use application equipment recommended by the sealer manufacturer. Use spray equipment, tanks, hoses, brooms, rollers, coaters, squeegees, etc., that are clean, free of foreign matter, oil residue and water.

B.      Mixing. Mix the sealer according to the manufacturer’s recommended procedures. Furnish the Engineer with the manufacturer’s application instructions. Do not mix or apply the sealer until the manufacturer’s written recommendations are supplied to the Engineer. Mix and maintain materials at a uniform consistency during application.

C.      Storage. Store all sealer components in tightly sealed containers, in a dry location, and as recommended by the manufacturer. Deliver unopened drums or containers of the sealer or sealer components to the job site with the manufacturer's numbered seal intact.

D.      Application submittals.  At least five (5) days before sealing, provide the Engineer the sealer manufacturer’s written requirements for application equipment, mixing equipment, mixing procedures, mixing time, storage requirements, recoat times and temperatures, and MSDS sheets.

E.      Surface Condition. Apply sealers only to surfaces which are dry, free from dust, dirt, oil, wax, curing compounds, efflorescence, laitance, coatings and other foreign materials. Visually inspect all surfaces before applying sealer. Remove all structurally unsound surfaces and weak sections.

Perform all concrete patching prior to surface profiling. Perform concrete patching on areas identified by the Engineer according to 519. Cure repaired areas for at least seven (7) days.

Air dry all concrete surfaces for at least ten (10) days after completion of required curing.

For accelerated cure of precast concrete, obtain the required 28 day strength and air dry the surfaces at least ten (10) days after completing accelerated cure.

F.      Surface Preparation and Profiling. Remove dust, dirt, oil, wax, curing compounds, efflorescence, laitance, coatings and other foreign materials from surfaces to be sealed.

Use one or both of the following methods to produce a surface profile that feels and looks like 100 grit sandpaper or coarser. Provide the Engineer sandpaper for comparison.

1.      Water blast at 7,000 psi (48 MPa) minimum, or

2.      Abrasive blast, followed by air brooming or power sweeping, to remove dust and sand from the surface and opened pores.

Install suitable traps, filters, drip pans and other separation devices in the cleaning equipment so oil and other foreign material are not deposited on the surface.

If the concrete surface had curing compound applied, acid test the surface after blasting to see if the curing compound was removed.  Perform the acid test for every 500 square feet (47 square meters).  Use a solution of 1 part 20º Baume muriatic acid and 2 parts water.  Apply 4 to 5 drops to the concrete surface.  If foaming/fizzing occurs the curing compound is removed.  Rinse the tested location with an ammonia solution to neutralize the concrete area tested (1 cup ammonia to 5 gallons water).

(NOTE: Muriatic acid and ammonia can be bought in a hardware store.  Muriatic acid is used to clean masonry.  Only dilute by pouring the acid into the water.  DO NOT pour the water into the acid.)

When surfaces show intermittent or no foaming, use chemicals or other cleaning compounds to remove the curing compounds.  Only use products approved by the sealer manufacturer. Furnish the Engineer documentation of the sealer manufacturer’s approval and method to test if materials are removed.

Ensure that all wastes generated by the surface preparation operation are managed in accordance with 107.19. 

G.     Application and Coverage.  Apply the sealer between twelve and (12) hours and 48 hours after surface preparation by water blasting methods. Apply the sealer within 48 hours after surface preparation by abrasive blasting methods Do not apply sealer if rain is anticipated within six (6) hours after application. Clearly mark where the sealer application stops if not continuous.

1.      Epoxy-Urethane sealers

a.      Apply the epoxy coat of the epoxy-urethane sealer at the coverage rate of 120 square feet per gallon (2.9 square meters per liter).  Use a coverage rate of 150 square feet per gallon (3.6 square meters per liter) when the Laboratory’s qualified products list for the epoxy authorizes it.  Apply the urethane coat of the epoxy-urethane sealer at a rate of 200 square feet per gallon (4.8 square meters per liter). When surfaces are not smooth and flat, adjust the given coverage rates by the following formulas to determine the correct coverage rate.

(1)     For surfaces using large stone liners and standard concrete =
                                      specified coverage rate (sq ft/gal [sq m/l]) × 0.8

(2)     For surfaces using large stone liners and porous concrete =
                                      specified coverage rate (sq ft/gal [sq m/l]) × 0.7

(3)     For surfaces using fluted liners and standard concrete =
                                      specified coverage rate (sq ft/gal [sq m/l]) × 0.5

b.      Only apply sealer when the surface temperature is 50 °F (10 °C) or above

c.      Apply with a brush, squeegee, roller or spraying equipment and as recommended by the manufacturer.

d.      Apply one coat of epoxy and one coat of the urethane top coat. Time between coats shall meet the manufacturer’s written recommendation provided to the Engineer during 512.03.D. Use epoxy and urethane from the same manufacturer. Achieve specified coverage regardless of the number of passes per coat.

e.      Tint so the final color is Federal Color Standard No. 17778 - Light Neutral. Pigment content shall be limited so as not to reduce sealing effectiveness of the second coat. Refer to the plans for colors for specific projects.

f.       Sags and runs are not acceptable in the sealer.

g.      For sealed sidewalks or other horizontal surfaces with repetitive foot traffic or vehicular traffic, integrate 1 1/2 lbs per square yard (0.8 kg/m²) of silica sand into the surface of the second coat to produce a nonskid surface satisfactory to the Engineer.

2.      Non-epoxy sealer

a.      Apply the sealer according to the manufacturer’s recommended mode of application and under the observation of the Engineer.

b.      Coverage.

(1)     Surfaces subject to abrasive wear (bridge decks, bridge deck shoulders and sidewalks); Minimum, one gallon (3.875 liter) of sealer for each 100 square feet (9.0 square meters).

(2)     Curbs, vertical surfaces of beams and deck slabs subject to direct roadway drainage; Minimum, one gallon (3.875 liter) for each 125 square feet (11.5 square meters).

(3)     Other surfaces (for example, parapets, abutments, pier caps and median dividers); Minimum, one gallon (3.875 liter) for each 150 square feet (14.0 square meters).

Stone or fluted formed concrete surfaces may require additional sealer materials for coverage.

c.      Apply sealer on horizontal surfaces in a one-pass operation at the required coverage. An acceptable application procedure consists of saturating the surface and waiting a few seconds for the sealer to completely penetrate the concrete surface. Broom in the sealer if recommended by the manufacturer.

d.      Apply sealer on vertical surfaces to saturate the surface.  The surface is saturated when runs of 6 to 12 inches develop. Apply additional passes in 10 to 15 minute intervals until the coverage rate is achieved. Apply sealers with brush or roller if recommended by the manufacturer.

e.      After 10 to 15 minutes, squeegee off excess material on smooth finished or dense concretes where the required coverage is not absorbed.

f.       For sealed sidewalks or other horizontal surfaces with repetitive foot traffic or vehicular traffic, integrate 1 1/2 lbs per square yard (0.8 kg/m²) of silica sand into the sealer application to produce a nonskid surface satisfactory to the Engineer.

g.      Tint clear non-epoxy sealers with a vanishing dye that will not damage the concrete.

h.      Do not apply sealer if the ambient temperature is below 40 °F (5 °C) or will fall below 32 °F (0 °C) within 12 hours after application.

H.     Test Site/Application. Apply epoxy-urethane or non-epoxy sealer to measured coverage areas, both on horizontal and vertical surfaces, and on different concrete types, demonstrating:

1.      The project’s visual effects for the epoxy-urethane sealer application at the required coverage rate.

2.      Visually, the absorption necessary to achieve the specified coverage rate for the non-epoxy sealer. Use at least 1/2 gallon (2 liter) of sealer, following the manufacturer’s recommended method of application, for the total of the test surfaces.

3.      Apply to the deck, safety curb or sidewalk for the horizontal test surfaces and use an abutment parapet or pier face for the vertical test surface so different textures are tested.

I.       Appearance. Epoxy-Urethane sealers: Uniform appearance and the final color shall visually match the test section.  Recoating, removal and re-application or other methods recommended by the manufacturer will be required to correct final appearance.  Non-Epoxy Sealers: The sealer shall result in a uniform appearance.

J.      Traffic. Allow traffic on deck shoulder areas after 12 hours of drying time for an epoxy-urethane sealer. Keep traffic off a non-epoxy sealer until the sealer is dry.

K.     Safety Precautions. Follow precautions defined on the manufacturer’s MSDS. Provide the Engineer a copy of the MSDS sheet for information before any work commences.

L.      Protection of Adjoining Surfaces and the Public. Protect the public during all operations, especially when applying sealer to the fascia or the underside portions of a bridge that spans an area used by the public.

During sealing, mask off, or use other means of protection, for surfaces not being sealed. Protect asphalt and mastic type surfaces from spillage and heavy overspray. Do not apply sealers to joint sealants which have not cured according to the manufacturer’s instructions. Joint sealants, traffic paints and asphalt overlays may be applied to the treated surfaces 48 hours after the sealer has been applied. Protect nearby steel, aluminum or glass surfaces when non-epoxy overspray could be deposited on those surfaces.

M.     Environmental Requirements.  Protect plants and vegetation from overspray by covering with drop cloths.

N.      Superintendent. In addition to the requirements of 105.06, the Superintendent must successfully complete a Sealing of Concrete Surfaces training prequalification course offered by the Department. The course must have been completed within the past four years and an individual course certificate must have been received by the Superintendent. Present certificate to the Engineer prior to beginning the sealing of concrete surfaces work. Work will not be permitted to begin until after the Superintendent provides a valid course certificate.

512.04  Sealing Concrete Bridge Decks with HMWM Resin.  This work shall consist of preparing and treating the concrete wearing surfaces of bridge decks with a penetrating sealer in accordance with these specifications, in reasonably close conformity with the plans and the manufacturer’s recommendation and as directed by the Engineer.

A.      Limitations. Do not perform this work during the period beginning November 1st and ending March 31st.

B.      Surface Preparation. Remove roadway dirt and debris from the area of the deck to be treated. Sweep, sandblast, then with the use of a manual or power broom sweep and blow with compressed air so that the surfaces to which the sealer is to be applied is dry and free of dust and dirt. Use high pressure compressed air to blow all loose material from visible cracks. Fit the cleaning equipment with suitable traps, filters, drip pans, driers and other devices to prevent oil and other foreign material from being deposited on the surface. Do not allow traffic on the clean surface prior to application of the sealer. Remove existing pavement markings according to Section 641.10 of the Specifications. Remove all traces of asphalt or petroleum products and concrete curing seals by abrasive blasting prior to air sweeping.

C.      Installation. Provide a compatible promoter/initiator system capable of providing the same physical qualities of the hardened resin as if promoted/initiated with 2 percent cobalt naphthanate (6 percent) and 2 percent cumene hydroperoxide. Store materials at 65 to 80 °F (18 to 27 °C). Provide a system that has a resin gel time of not less than 40 minutes to not more than 1 1/2 hours at the time and temperature of application.

Adjust the gel time to compensate for the change in temperature throughout the day. The temperature of the surfaces to be treated may range from 50 °F (10 °C) to 120 °F (49 °C). Arrange to have a technical representative on site to provide mixing proportions equipment suitability, and safety advice. Any conflict between these provisions and representative's advice shall be resolved at the job site. The technical representative shall remain at the job site until such time as he and the Engineer agree that the Contractor is qualified in all aspects of the application of the sealer.

Do not allow the promoter and initiator, if supplied separate from the resin, to contact each other directly. Do not store containers of promoter or initiators together in a manner that will allow leakage or spillage from one to contact the containers or materials of the other. 

Machine application of the resin may be performed by using a two-part resin system utilizing a promoted resin for one part and an initiated resin for the other part. This two-part resin system may be combined at a spray bar through positive displacement atomization of the resin. Do not use compressed air to produce the spray.

Use appropriate cleaning and flushing of equipment, tools, etc., with an appropriate solvent, as approved by the Engineer, in such a manner to minimize personal and environmental hazards. Advise workman that the resin will soften gum rubber soles, and a face-mask should be used to protect from accidental splashes. Clothing and leather saturated with resin will harden and become useless.

Prior to resin application the surface to be treated shall be visibly dry and its temperature between 50 °F (10 °C) and 120 °F (49 °C). Do not apply the resin within 24 hours after a rain or when rain is forecast within 12 hours or when the ambient air temperature is below 50 °F (10 °C). Pre-mark the deck to control mixed material usage and to provide a rate of application of approximately 100 square feet per gallon (2.45m²/L). The exact rate shall be determined by the Engineer prior to commencing full-scale deck treatment operations.

Before using the material submit to the Director copies of the manufacturer’s certified test data showing that the material complies with the requirements of this specification. The test data shall be developed by an independent approved testing laboratory, and shall include the brand name of the material, name of manufacturer, number of the lot tested and date of manufacture. When the material has been approved by the Director, further testing by the manufacturer will not be required unless the formulation of manufacturing process has been changed, in which case new certified test results will be required. The manufacturer shall certify that the formulation is the same as that for which data has been submitted. The state reserves the right to sample and test delivered lots for compliance.

Flood the deck surfaces resin, allowing penetration into the concrete and filling of all cracks. Limit the initiated mix of promoted resin to 5 gallons (19 L) at a time for manual application. A significant increase in viscosity shall be cause for rejection. Apply the treatment within 5 minutes after complete mixing. Redistribute excess material by squeegee or brooms within 10 minutes after application.

Take all steps necessary to prevent the resin from flowing into lanes open to traffic. Broadcast sand over the entire treated area of the bridge deck by mechanical means to affect a uniform coverage of 0.80 to 1.2 pounds per square yard (0.43 kg/m² to 0.65 kg/m²). The sand shall be uniformly graded aggregate conforming to the quality requirements of 703 and shall conform to the following limits for grading:

Sieve Size

Total Percent Passing

No. 4

(4.75 mm)

100

No. 8

(2.36 mm)

90 to 100

No. 20

(850 µm)

5 to 15

No. 50

(300 µm)

0 to 5

It is the intention of the specification to allow the use of commercially available blast sands applied by a common lawn broadcast type seeder/spreader. Place sand between 10 to 15 minutes behind the resin spreading front and before any jelling of the resin occurs. If the surface contains large deep cracks, the low-viscosity liquid could run completely through the concrete slab. Apply a second coat in these areas after the first coat has started to cure.

Before the monomer hardens, fill imperfections or spalls with standing liquid with commercial quality concrete or sandblast sand, and finished to a uniform surface. The sand shall have a maximum moisture content of 0.5 of the percent of absorption when tested in accordance to a California Test 226.

Do not permit traffic and equipment on the tested deck until it is tack free and a minimum of 6 hours have elapsed since treatment and the sand cover adheres sufficiently to resist brushing by hand. Protect the treatment from moisture for not less than 4 hours after placement.

512.05  Soluble Reactive Silicate (SRS) Concrete Treatment.  This item consist of the necessary labor, materials and equipment to prepare and treat portland cement concrete surfaces with a reactive silicate sealer meeting these specifications.

A.      Equipment. Use application equipment that is recommended by the manufacturer. Use spray equipment, tanks, hoses, brooms, rollers, coaters, squeegees, etc., that are thoroughly clean, free of foreign matter, oil residue and water prior to applying the treatment.

B.      Cleaning and Surface Preparation.  Insure that surfaces which are to be treated meet the approved product’s requirements for surface condition. Do not begin sealing until all concrete repairs have been completed and cured. Furnish the Engineer with written instructions for surface preparation requirements and have a representative of the manufacturer present to assure the surface condition meets their requirements.

At a minimum, thoroughly clean the surface to remove dust, dirt, oil, wax, curing components, efflorescence, laitance, coatings and other foreign materials. Obtain the approval of the manufacturer or its representative before the use of chemicals and other cleaning compounds to facilitate the removal of these foreign materials. Apply the treatment within 48 hours following surface preparation.

Fit cleaning equipment with suitable traps, filters, drip pans and other devices to prevent oil and other foreign material from being deposited on the surface.

C.      Test Application. Treat a measured test coverage area on horizontal and vertical surfaces of the different components of the structure to be treated for the purpose of demonstrating the desired physical and visual effect of an application or of obtaining a visual illustration of the absorption necessary to achieve the specified coverage rate prior to final application. In the latter case, use at least 1/2 gallon (2 L) of treatment following the manufacturer’s recommended method of application for the total of the test surfaces. Locate horizontal test surfaces on the deck and on the safety curb or sidewalk and locate vertical test surfaces on an abutment parapet and pier face so that the different textures are displayed.

D.      Application. Apply the concrete treatment to concrete surfaces as designated on the plans. Apply the SRS by thoroughly saturating the concrete surfaces at an application rate specified by the manufacturer.

Apply the SRS when the concrete surface temperature is above 35 °F (2 °C). Use a surface thermometer on the concrete to establish the temperature of the concrete if the air temperature at the time of application is 45 °F (7 °C) or below.

Spread the SRS from puddles to dry areas.

If unable to complete the entire application continuously, note and clearly mark the location where the application was stopped.

E.      Protection of Adjoining Surfaces and the Public. Protect by masking off or by other means adjoining surfaces of the structure which are not to be sealed when applying a treatment. Make provision to protect the public when treating the fascia of a bridge and/or portions of the underside of the deck of a bridge that spans an area used by the public.

Protect asphalt and mastic type surfaces from spillage and heavy overspray. Do not apply joint sealants, traffic paints and asphalt overlays to the treated surfaces until 48 hours after the treatment has been applied. Cover adjoining and nearby surfaces of aluminum or glass where there is a possibility of the treatment being deposited on the surfaces.

Protect plants and vegetation from overspray by covering with drop cloths. Follow precautions as indicated on the manufacturer’s MSDS.

F.      Opening to Traffic. Only allow traffic on a deck after a treated area does not track.

512.06  Treating Concrete Bridge Decks with Gravity-Fed Resin.  This work shall consist of preparing and treating the concrete bridge deck with a gravity-fed crack welding system in accordance with these specifications in reasonably close conformity with the plans and the manufacturer’s recommendations and as directed by the Engineer.

A.      Limitations.   Do not perform this work during the period beginning November 1st and ending March 31st.

Prior to resin application insure that the surface to be treated is visibly dry with a temperature between 40 °F (4 °C) and 100 °F (38 °C). Do not apply the resin within 24 hours after a rain, during rain, when rain is forecast within 12 hours or when the ambient air temperature is below 40 °F (4 °C).

B.      Surface Preparation First remove roadway dirt and debris from the area to be treated. Sweep abrasive blasted surfaces to which the sealer is to be applied, then manual or power broom swept and blown with compressed air so that they are dry and free of dust and dirt. Use high pressure compressed air to blow all loose material from visible cracks. Use a high pressure water blast followed by an air blast if particles are highly embedded in the cracks, to clean cracks. Fit the cleaning equipment with suitable traps, filters, drip pans, dryers and other devices to prevent oil and other foreign material from being deposited on the surface. Do not allow traffic on the clean surfaces prior to application of the sealer. Remove existing pavement marking according to section 641.10. Remove all traces of asphalt or petroleum products and concrete curing by the abrasive blasting prior to air sweeping.

C.      Application  Pre-mark the deck to control mixed material usage and to provide a rate of application of approximately 100 to 150 square feet per gallon (2.45 to 3.68 m²/L). The Engineer will determine the exact rate but will not exceed 150 square feet per gallon (3.68 m²/L). Flood the area to be sealed with resin. Allow the resin to penetrate into the concrete and fill all cracks. Mix the resin to a limit of 5 gallons (19 L) at a time for manual application. Reject resin with a significant increase in viscosity. Redistribute excess material by a squeegee within 10 minutes after application. Front and back movement with the squeegee is recommended over cracks and patch perimeters to enhance penetration. Take all steps necessary to prevent the resin from flowing into lanes open to traffic. Broadcast sand over the entire sealed area of the bridge deck by mechanical means to effect a uniform coverage of 1 pound (0.45 kg) per 2 to 3 square foot (0.1858 to 0.2787 square meter).

Protect the treatment from moisture for not less than 6 hours after placement.

D.      Traffic.  Do not permit traffic on the treated deck until the resin is tack free, a minimum of 6 hours has elapsed since treatment, and the sand cover adheres sufficiently to resist brushing off by hand.

512.07  Sealing Cracks by Epoxy Injection.  This specification covers the repair of dry, moist or wet cracks or fractures that are 2 to 100 mils (50 to 2500 µm) in thickness in reinforced concrete members.  The repair is by means of an epoxy injection system. This system shall consist of a paste epoxy used to seal the surface cracks and an injection epoxy used under low pressure, 200 psi (1400 kPa) max., to penetrate and fill the cracks and bond the crack surfaces together. Material for each epoxy shall consist of a two-component modified resin bonding system. The unmodified resin shall be known as Component A and the hardener as Component B.

Arrange to have a manufacturer’s representative at the job site to familiarize him and the Engineer with the epoxy materials, application procedures and recommended pressure practice. This representative shall direct at least one complete crack or area injection and be assured prior to his departure from the project that the personnel are adequately informed to satisfactorily perform the remaining repairs.

Furnish the Engineer a copy of the manufacturer’s comprehensive preparation, mixing and application instructions which have been developed especially for use with the proposed epoxy injection system. Ensure that any significant changes to these instructions which are recommended by the representative for an unanticipated situation have been approved by the Engineer prior to the adoption of such changes.

Clean concrete surfaces adjacent to the cracks to be sealed only to the extent necessary to achieve an adequate bond with the paste epoxy, and only by procedures which will not cause abrasive grits or concrete dust to penetrate the cracks. Do not permit the use of solvents or thinners in cracks or on bonding surfaces.

Install injection ports or tees in cracks to be injected. Space injection ports or tees at 6 to 12 inches (150 to 300 mm) vertically and 6 to 18 inches (150 to 450 mm) horizontally but in no case closer together than the thickness of the concrete member if full depth penetration is desired unless otherwise specified or directed. Set ports or tees in dust free holes made either with vacuum drills or chipping hammers. Seal all surface cracks in the area to be repaired, after injection ports or tees have been inserted into the holes, with paste epoxy between ports to ensure retention of the pressure injected epoxy within the confines of the member. The Department will allow an alternative procedure of sealing the cracks before the injection holes have been made. Limit the application of paste epoxy to clean and dry surfaces. Limit substrate temperatures to not less than 45 °F(7 °C) during epoxy applications.

Begin the epoxy injection at the bottom of the fractured area and progress upward using a port or tee filling sequence that will ensure the filling of the lowermost injection ports or tees first.

Establish injection procedures and the depths and spacings of holes at injection ports or tees.  Use epoxy with flow characteristics and injection pressure that ensure no further damage will be done to the member being repaired. Ensure that the epoxy will first fill the innermost portion of the cracked concrete and that the potential for creating voids within the crack or epoxy will be minimized.

Remove the injection ports or tees flush with the concrete surface after the fractured area has been filled and the epoxy has partially cured (24 hours at ambient temperature not less than  60 °F (16 °C), otherwise not less than 48 hours). Roughen the surfaces of the repaired areas to achieve uniform surface texture.  Remove any injection epoxy runs or spills from concrete surfaces.

Obtain two 4-inch (100 mm) diameter core samples in the first 100 linear feet (30 m) of crack repaired and one core for each 100 linear feet (30 m) thereafter. Take the core samples from locations determined by the Engineer and for the full crack depth. Cores will be visibly examined by the Engineer to determine the extent of epoxy penetration. Repair the core holes in the concrete with material specified in 705.21.

512.08  Waterproofing

A.      General.  Apply an even and uniform coating of asphalt materials using brushes, squeegees, or spray equipment.

If using spray equipment, provide portable power pressure type spraying equipment capable of being moved to the location of the waterproofing operation.

Protect concrete surfaces not covered with waterproofing from overspray, spilling, or otherwise marring of the surface with the asphalt materials.

Ensure that the edge of any exposed application is sharply defined true to line with a uniform exposure.

Do not apply waterproofing fabric or membranes over attachments and hardware.  Seal the discontinuities in waterproofing with Asphalt, 702.06, or hot applied joint sealer, 705.04.

B.      Preparation of Surface

1.      Asphalt Materials.  Remove concrete projections.  Using wire brushes and clear water, remove dirt and the outside film of cement.  Before applying asphalt materials, ensure that the concrete is clean and dry and the concrete temperature is at least 40 °F (4 °C).

2.      Membranes.  Remove protrusions from the concrete.  Sweep off dirt and dust, and blow the concrete clean.  Fill joints or cracks greater than 3/8 inch (10 mm) wide with portland cement mortar.  In addition to the above, remove oil and grease from surfaces for Type 3 membranes using water and a detergent designed to remove oil and grease from concrete.  Flush residual detergent from the surface.  Do not allow traffic on the cleaned surface.

C.      Primer Coat.  Apply the primer coat at the rate of 0.10 to 0. 20 gallon (0.50 to 1.00 L) of asphalt material per square yard (square meter).

For primer coats applied between June 1 and September 1, use asphalt primer for waterproofing or emulsified asphalt primer conforming to 512.02.

For primer coats applied between September 1 and June 1, use asphalt primer for waterproofing conforming to 512.02.

If practical, apply asphalt emulsion using spray equipment.

If subjected to traffic, spread sand on the primer coat for protection.  Broom off excess sand before applying asphalt waterproofing.

D.      Type A Waterproofing.  This type of waterproofing consists of one primer coat and at least two coats of asphalt material conforming to 702.06 to provide a total of at least 1 gallon (5 L) of asphalt per square yard (m²) on flat areas and at least 1/2 gallon per square yard (3 L/m²) on vertical or sloping surfaces.  Start applying the waterproofing at the lowest point, and progress to a higher elevation.  Uniformly cover the surface except apply more asphalt in corners and over construction joints.  Apply the asphalt material at a temperature from 250 to 350 °F (121 to 177 °C).

E.      Type B Waterproofing.  This type of waterproofing consists of one primer coat, three coats of asphalt material conforming to 702.06, and two layers of waterproofing fabric conforming to 711.24 applied as follows:

1.      On a clean, dry, and well-primed surface, apply a thorough coating of asphalt at a temperature from 250 to 350 °F (121 to 177 °C).

2.      Apply the coating at a rate of at least 1/3 gallon per square yard (1.5 L/m²) of surface.

3.      While the asphalt is hot enough to penetrate the fabric, lay the fabric according to the following:

a.      Surfaces Wider than Normal Fabric Strip.  For the first strip, lay a half-width [normally 18 inches (0.5 m) wide] strip of fabric.  For the second strip use a full-width strip of fabric, and lap the entire width of the first strip.  Lap each succeeding strip 2 inches (50 mm) more than half its full width.  Lap the fabric strips in the direction of water flow.

b.      Surfaces with Same Width as Fabric Strip.  For the first strip, lay a full-width strip.  For the second strip, lay another full-width strip, covering the first.

Lay each strip without wrinkles, folds, or pockets.  Thoroughly coat the strip with asphalt for the full width of the lap before laying the succeeding strip.  Each application shall entirely conceal the texture of the fabric.

4.      Apply a final coat of asphalt to provide a thorough covering for the fabric.

5.      For all three coats, use a total of at least 1 gallon (5 L) of asphalt waterproofing material per square yard (m²).

Lap ends of fabric strips at least 12 inches (0.3 m), and stagger the end joints.

F.      Type D Waterproofing.  This type of waterproofing consists of one primer coat, one layer of waterproofing fabric conforming to 711.24 over joints, three coats of asphalt material conforming to 702.06, and two shingled plies of asphalt saturated waterproofing fabric conforming to 711.24.

Prime the surface to be waterproofed and allow the primer to dry.  Fill joints and irregularities in the surface with asphalt cement.  Lay a layer of fabric extending at least 9 inches (230 mm) on both sides of all joints.  Leave the underside of this layer unbonded to the concrete surface.

Apply the asphalt at a temperature from 250 to 350 °F (121 to 177 °C) and conceal the texture of each layer of fabric with the asphalt.  Use at least 1/3 gallon (1.5 L) of asphalt per square yard (m²) of surface for each application.  Begin applying the asphalt and fabric at the low side or sides of the surface, and proceed toward the apex or high side so that water runs over and not against or along the laps of the fabric.  Lay the fabric without wrinkles, folds, or pockets.  Lap ends of fabric strips at least 12 inches (0.3 m), and stagger the end joints.

Start applying waterproofing by mopping asphalt on a surface slightly wider than half the width of the fabric strip.  Immediately lay a half-width strip of the fabric onto the asphalt.  Mop asphalt on this strip and an adjacent surface slightly wider than half the width of the fabric, and lay a full width of fabric that entirely covers the first strip.  Mop asphalt on the second half of this second strip and an adjacent concrete surface and lay a third strip of fabric that laps the first strip at least 2 inches (50 mm).  Continue this process of applying asphalt and laying fabric until the entire surface is covered and each strip of fabric laps the next to last strip already placed by at least 2 inches (50 mm).  Finish laying fabric with a partial-width strip and mop the entire surface with asphalt.

G.     Type 2 Membrane Waterproofing.  This type of waterproofing consists of a rubberized asphalt and peel-and-stick waterproofing membrane 711.25.  If the ambient temperature is below 50 °F (10 °C), use a manufacturer recommended primer coat for vertical surface application.  After installing the primer coat, if required, remove the membrane’s release liner and place the adhesive side on the prepared concrete surface.  Lay the membrane smooth and free of wrinkles.  Lap joints in membranes by at least 1 inch (25 mm).  Store membrane materials indoors at temperatures not to exceed 120 °F (49 °C).

For precast concrete three- and four-sided structures, install Type 2 membrane on the exterior vertical and exterior top horizontal surfaces.

H.     Type 3 Membrane Waterproofing.  This type of waterproofing consists of a primer coat conforming to 705.04 and a waterproofing membrane consisting of a high density asphalt mastic between two layers of polymeric fabric conforming to 711.29.  The application of this product shall follow the manufacturer’s written recommendations, which shall be provided to the project.

Keep membrane and primer materials dry before installation.

Heat the membrane primer in an oil primer heated, double-jacket kettle.  Use a kettle that is clean and free of other materials with any obvious buildup scraped out.  The Contractor may use a single-jacket kettle if the primer is capable of being heated in direct fire to the application temperature.  Heat primers within the manufacturer’s recommended temperatures.

On bridges with curbs, apply the primer and membrane 3 inches (75 mm) up the curb face.  On prestressed box beam bridges with no approach slab, apply the primer and membrane 6 inches (150 mm) over the ends of the beams.  On prestressed and slab bridges with approach slabs, apply the primer 2 feet (600 mm) out onto the approach slab.

If the plans require a Type 3 membrane on the top exterior surface of precast concrete three- or four-sided structures, apply the primer and membrane to overlay the vertical exterior sides of the structure by 12 inches (300 mm).

Apply primer no further than 5 feet (1.5 m) in front of the membrane using a squeegee to fill all voids and imperfections.  Apply membrane from the low to the high side of the surface.  Apply an extra bead of primer at the edge of the membrane.  Lap joints in membranes by at least 3 inches (75 mm).  After installing the membrane over the entire surface, seal joints in the membrane by applying primer and smoothing with a V-squeegee. If asphalt pavement is to be placed directly over the water proofing membrane, first apply tack coat as specified in 407 without damaging the membrane.

512.09  Method of Measurement.  The Department will measure Waterproofing, of the type specified, by the number of square yards (square meters) or on a lump sum basis.

The Department will measure sealing of concrete surfaces by the number of square yards (square meters) of coated area projected to a two-dimensional surface.

The Department will measure the removal of existing coatings from concrete surfaces in square yards (square meters) removed.

The Department will measure the sealing of concrete bridge decks with HMWM resin and treating concrete bridge decks with SRS as the actual area in square yards (square meters ) of surfaces treated.

The Department will measure the actual length in linear feet (meters) of crack repaired by epoxy injection.

512.10  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

The Department will consider the cost for the obtaining and repairing the two cores used by the Engineer to determine the extent of the epoxy penetration as incidental to the work of repairing the concrete by epoxy injection. 

The Department will consider the removal of dust, dirt, oil, wax, curing compounds, efflorescence, laitance, and other foreign materials as incidental to the surface preparation of the concrete surfaces to be sealed. When the surface to be sealed contains an existing coating, the Department will consider all materials, equipment and labor to remove the existing coating as incidental to the removal of existing coatings.

Item           Unit                                Description

512             Square Yard                    Sealing of concrete surfaces
                       (Square Meter)

512             Square Yard                    Sealing of concrete surfaces
                       (Square Meter)                (non-epoxy)

512             Square Yard                    Sealing of concrete surfaces
                       (Square Meter)                (epoxy urethane)

512             Square yard                     Sealing of concrete bridge
                       (Square Meter)                decks with HMWM resin

512             Square yard                     Treating concrete bridge
                       (Square Meter)                decks with SRS

512             Square yard                     Treating concrete bridge
                       (Square Meter)                decks with Gravity-Fed Resin

512             Foot                                 Concrete repair by epoxy injection
                       (Meter)

512             Square Yard                    Type A Waterproofing
                       (Square Meter)
                       or Lump Sum

512             Square Yard                    Type B Waterproofing
                       (Square Meter),
                       or Lump Sum

512             Square Yard                    Type D Waterproofing
                       (Square Meter),
                       or Lump Sum

512             Square Yard                    Type 2 Waterproofing
                       (Square Meter),
                       or Lump Sum

512             Square Yard                    Type 3 Waterproofing
                       (Square Meter),
                       or Lump Sum

512             Square Yard                    Removal of Existing Coatings from Concrete
                       (Square Meter)                Surfaces

Item 513  STRUCTURAL STEEL MEMBERS

513.01  Description

513.02  Fabricator Approval Procedure

513.03  Levels of Fabricator Qualification

513.04  General

513.05  Fabricator Documentation Responsibility

513.06  Shop Drawings

513.07  Levels 1 through 6, Prefabrication Meeting

513.08  Materials

513.09  Material Control

513.10  Care of Material

513.11  Workmanship and Straightening

513.12  Finish

513.13  Stiffeners

513.14  Fillers

513.15  Horizontally Curved Beams and Girders

513.16  Joints and Splices

513.17  Pin Holes

513.18  Pins and Rollers

513.19  Holes for High-Strength and Bearing Bolts

513.20  High-Strength Steel Bolts, Nuts, and Washers

513.21  Welding

513.22  Stud Shear Connectors

513.23  Threads for Bolts and Pins

513.24  Shop Assembly

513.25  Nondestructive Testing

513.26  Shipping, Storage, and Erection

513.27  Shop Coating

513.28  Cleaning ASTM A 709/A 709M, Grade 50W (345W) Steel

513.29  Method of Measurement

513.30  Basis of Payment

513.01  Description.   This work consists of preparing shop drawings, furnishing and fabricating structural steel members, nondestructive testing, fabricator performed quality control, documentation, cleaning, shop coating, and erecting structural steel and other structural metals. Prepare shop drawings and erect structural steel according to Item 501 and the additional requirements below. Shop painting shall conform to Item 514. The work also includes any work to move existing steel structures to the plan location, making necessary repairs and alterations, and connecting or joining new and old construction.

The terms “main,” “secondary,” or “detail,” as referred to in Item 513, are defined as follows: “main” refers to material, members, and fasteners that are primarily stressed by live load and structure weight; “secondary” refers to material, members, and fasteners that do not directly support live load or main members; “detail” refers to essential non-structural material, members, and fasteners.

513.02  Fabricator Approval Procedure.  Select fabricators that are listed by the Department before the Contract letting date as evaluated by the Office of Materials Management and prequalified according to Supplement 1078.

The Office of Materials Management may accept subletting of processes that require specialized machinery or knowledge.  Submit written requests for subletting to the Office of Materials Management.  The Office of Materials Management will determine if the process is uncommon and will evaluate the qualifications of the proposed sublet fabricator.  The fabricator’s quality control staff shall witness and perform quality control of the sublet work.

513.03  Levels of Fabricator Qualification.  There are eight levels of fabricator qualification.  The Office of Materials Management will classify each fabricator at the highest level of fabrication it is qualified to perform.

Level

Description of Capabilities

SF

Standard fabricated members described and paid for as Item 516, 517, and 518 and detailed by standard bridge drawings.  Material and fabrication acceptance by certification with random Department audits of the work and documentation.

UF

Unique fabricated members not covered by standard bridge drawings and not designed to carry tension live load.  Examples include curb plates, bearings, expansion joints, railings, catwalk, inspection access, special drainage, or other products.  Examples also include retrofit cross frames, retrofit gusset plates, retrofit lateral bracing, or other miscellaneous structural members not included in Levels 1 through 6.  Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078.

1

Single span, straight, rolled beam bridges without stiffeners, Secondary and Detail materials designed to carry tension live loads such as retrofit moment plates.  Case II Loading.  Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078.

2

Multiple span, straight, rolled beam bridges without stiffeners.  Case II loading.  Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078.

3

Single or multiple span, straight, dog legged, or curved, rolled beam bridges including stiffeners.  Case I or II Loading.  Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078.

4

Straight or bent welded plate girder bridges.  Case I or II loading.  Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078.

5

Straight, curved, haunched, or tapered welded plate girder bridges.  Case I or II loading.  Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078.

6

Truss bridges, fracture critical bridges, fracture critical members, or fracture critical components new or retrofitted.  Case I or II loading.  Quality assurance of shop drawings, material test reports, and inspection according to Supplement 1078.

513.04  General.  Perform all steel fabrication including the shop application of coatings in a prequalified structural steel fabricating shop consisting of adequately sized permanent buildings with equipment, heat and light, and experienced personnel to satisfactorily perform all necessary operations.  Perform flame cutting, air carbon-arc gouging, cambering, welding, cleaning, and painting inside permanent buildings that are maintained at the required environmental conditions.  The fabricator may perform shop assembly of large pieces for fit-up of field connections outdoors.  These provisions will not apply to steel requiring fabrication at the bridge site in the repair, alteration or extension of an existing structure.

If repairing, extending, or altering existing structures, take measurements of the existing structure as required to accurately join old and new work.  Include these measurements on shop drawings.  Measurements shown on the plans that indicate the extent and nature of repair, alterations or extension shall not relieve the Contractor of this responsibility.

At least two weeks before starting shop fabrication, the fabricator shall notify the Office of Materials Management and furnish a proposed fabrication schedule for the work.

Unless the Office of Materials Management provides a written waiver of a hold or witness point inspection, the fabricator shall store members completed during the inspector’s absence in a manner that allows the inspector to completely and safely inspect the finished work.

The fabricator shall not ship fabricated members performed under Item 513, UF Level or Levels 1 through 6 from the shop without prior hold point inspections unless the Office of Materials Management waives the inspection.  The Office of Materials Management will not conduct the scheduled final inspection until the fabricator completes and inspects with documentation, final fabrication and shop coatings and the Contractor documents approval of shop drawings and material test reports.

The Office of Materials Management will not conduct a final fabrication inspection of SF Level members.  Instead, the Office of Materials Management will conduct random inspections during the fabricator’s work.

The fabricator shall provide an office with the following attributes:

A.      A minimum floor area of 120 square feet (11 m²).

B.      A minimum ceiling height of 7 feet (2.1 m).

C.      Adequate working and storage facilities with one locking file cabinet for the exclusive use of the Department’s inspector, lighting, and electrical outlets.

D.      Provisions for heating to a minimum temperature of 68 °F (20 °C) and adequately ventilated.

E.      A telephone with direct access to an outside trunk line for the exclusive use of the inspector.

If using steel stamps for identification purposes, use the “mini-stress” or “stressless” type.

513.05  Fabricator Documentation Responsibility.  The fabricator shall keep and maintain documentation records as specified in Supplement 1078.

At the Department’s request, provide access to the above documents for audit, inspection, and copying.

513.06  Shop Drawing.  Provide shop drawings conforming to 501.04 and the following requirements:

Include details, dimensions, size of materials, match mark diagrams for field connections, a diagram identifying, by some unique mark, each area of a welded splice to be covered by a single radiograph, and other information necessary for the complete fabrication and erection of the metal work.

For multiple span beam and girder bridges, include an overall layout with dimensions showing the relative unloaded vertical and horizontal position of beam or girder segments with respect to a full length base or work line.  Account for camber and horizontal curvature of the beams or girders, and the effect of deck surface profile in this layout.  Show required offsets for vertical and horizontal curvature at approximately each one-fourth of span length, at field splices, and at bearing points.  For horizontally curved members, show the offset to a baseline strung from end to end of the member, every 10 feet (3 m) of length.

Identify the grade (ASTM designation), CVN, fracture critical, or any special testing requirements for each piece of steel.  Identify pieces made of different grades of steel with different assembling or erecting marks, even if the pieces have identical dimensions and detail.

Identify the welding procedure by the WPS number at each joint and the location and identification numbers of all radiograph tests.

Detail structural steel to fit under full steel dead load and prior to deck placement with the webs of primary members plumb.

513.07  Levels 1 through 6, Prefabrication Meeting.  After providing the notice and schedule required by 513.04 and at least 3 days after the Department receives shop drawings, conduct a prefabrication meeting at the fabricator’s facilities, or another location agreed to by all parties.  The fabricator and its quality control specialists for fabrication and painting, the inspector, and the Contractor, or its designated representative, shall attend the meeting.  The purpose of this meeting is to review any fabrication issues, including information on shop drawings, inspection, hold or witness points, unique fabrication items, special processes, and both the fabrication and project schedule.  The fabrication quality control specialist shall conduct the meeting and record and distribute meeting minutes that document all issues discussed.  Fabrication may begin after the prefabrication meeting is complete.

513.08  Materials.  Furnish materials conforming to 501.06.

513.09  Material Control.  Identify and mark each piece of steel according to the shop drawings and the following requirements.

Immediately after removing steel that is furnished in tagged lifts or bundles, mark the individual pieces of steel with the ASTM A 6/A 6M specification identification color code and heat number.

The fabricator may furnish material from stock that is marked with the heat number and mill test report.

If separated from the full-size piece furnished by the supplier, mark excess material placed in stock for later use with the heat number and, if provided, with the ASTM A 6/A 6M specification identification color code.

During fabrication, clearly and legibly mark the specification identification color code and heat number on each piece of steel.

Before cutting steel into smaller size pieces, clearly and legibly mark each smaller size piece with the ASTM A 6/A 6M specification identification color code and heat number.

Unless otherwise approved by the inspector, mark pieces of steel that will be subject to fabricating operations such as blast cleaning, galvanizing, heating for forming, or other operations that may obliterate paint color code and heat number markings with steel stamps or with a substantial tag firmly attached to the piece of steel.  At locations acceptable to the Office of Materials Management, stamp the heat numbers into main material tested for CVN.

Issue cutting instructions by cross-referencing the assembly marks shown on the shop drawings with the corresponding item covered on the mill purchase order.  The fabricator’s system of assembly-marking individual pieces of steel and issuing cutting instructions shall provide a direct reference to the appropriate mill test report.

The fabrication quality control specialist shall provide the Engineer with a letter documenting that the fabricator performed material control according to this specification.

513.10  Care of Material.  Store structural material at the shop or field above the ground, upon platforms, skids, or other supports.  Use straight structural steel with clean and dry surfaces before working it in the shop.  Before using, clean all rusted or corroded material.  Only use this material if it conforms to ASTM A 6/A 6M thickness tolerances after cleaning.

513.11  Workmanship and Straightening.  If necessary to straighten rolled material, use methods that will not damage the member.  If carefully planned and supervised, apply localized heat for straightening.  Do not allow the temperature of the heated area to exceed 1150 °F (620 °C) as controlled by pyrometric stick or thermometers.  Do not quench to accelerate cooling.  Do not kink or offset the material if using mechanic or hydraulic force to camber or strengthen material.  Do not cold bend fracture critical materials.

Camber rolled beams as shown on the plans in the prequalified fabricating shop using heat or hydraulic jacks.  Control heating as specified above and follow a formal shop heating procedure.  Camber plate girders by trimming web plates before assembly.  During fabrication, shipping, and erection, support and handle members to maintain camber.

Fabricate structural steel to within the dimensional tolerances specified by Articles 3.5 of the AASHTO/AWS Bridge Welding Code, with the following modifications:

A.      Waviness, the deviation of the top or bottom surface of a flange from a straight line or plan curvature, shall not exceed 1/8 inch (3 mm) when the number of waves in a 10-foot (3 m) length is four or less, or 1/16 inch (1.6 mm) when more than four, but sharp kinks or bends shall be cause for rejection.

B.      For the measurement of camber during lay down, position the bearing points both horizontally and vertically to plan dimensions ±1/8 inch (±3 mm).

C.      Measure camber as the vertical offset between the steel and the common base line extending from abutment bearing to abutment bearing.  The maximum camber tolerance at mid-span shall be 0 inch (0 mm) and the greater of +3/4 inch (+19 mm) or the designed haunch height.  Prorate the maximum camber tolerance at mid-span between the center of the span and each adjacent bearing to provide a smooth unbroken curve.

D.      Permissible difference in horizontal curvature of top and bottom flange at any point on centerline of member, when measured as specified in 3.5.1.4, shall not exceed 3/8 inch (10 mm)

513.12  Finish.  Plane sheared edges of all main material to a minimum depth of 1/4 inch (6 mm) except for ASTM A 709/A 709M, Grade 36 (250) steel having a thickness of 5/8 inch (16 mm) or less.  Remove fins, tears, slivers, and burred or sharp edges from steel members by grinding.  If these conditions appear during the blasting operation, re-grind and re-blast the steel members to the required surface profile.

The fabricator may flame cut structural steel.  Provide a smooth surface, free from cracks and notches, and use a mechanical guide to provide an accurate profile.  Roll and flame cut surfaces according to the AASHTO/AWS Bridge Welding Code, as amended by Supplement 1011.

Provide a surface finish for bearing and base plates and other bearing surfaces that contact each other or concrete according to ANSI B46.1, Surface Roughness, Waviness and Lay, Part I.

ANSI B46.1

Steel slabs

2000 mil

(50.0 µm)

Heavy plates in contact in shoes to be welded

1000 mil

(25.0 µm)

Milled ends of compression members, milled or ground ends of stiffeners and fillers

500 mil

(12.5 µm)

Bridge rollers and rockers

250 mil

(6.4 µm)

Pins and pin holes

125 mil

(3.2 µm)

Sliding bearings

125 mil

(3.2 µm)

513.13  Stiffeners.  Place the bearing end of bearing stiffeners flush and square with the web and in a manner so at least 75 percent of the area of the bearing end is in contact with the inner surface of the flange.  The other end of the bearing stiffener shall have a tight fit as defined below.  Position bearing stiffeners to be vertical after erection.  Weld intermediate stiffeners that are not used in pairs to the compression flange, and provide a tight fit for the tension flange.  Weld intermediate stiffeners connected to cross frame angles to the top and bottom flange.

A tight fit is defined as the contact between the stiffener and flange over some portion of the end of the stiffener and having no gap greater than 1/16 inch (1.6 mm).

Clip stiffeners 2 1/2 inches (65 mm) along the web and 1 inch (25 mm) along the flange to clear flange-web welds and fillet or rolled shapes.

When attaching stiffeners to the web and flanges, do not extend welds to the edge of the stiffeners or into the clip area.  Terminate these welds 1/4 ±1/8 inch at the flange connections and 1/2 ±1/4 inch at the web connection.

513.14  Fillers.  Detail the shop drawings to show fill plates that compensate for the misalignment of abutting elements due to differences in thickness of flanges and webs at the splice locations.  Detail the fill plates to the nearest 1/16 inch (1.6 mm) in thickness, but not less than 1/8 inch (3 mm) thick.  However, in the final shop assembly, furnish fills of sufficient thickness to compensate for misalignment of abutting elements due to standard rolling mill tolerances or due to differences in thicknesses of flanges and webs at the splice location.  The actual fills used shall compensate for differences in total thickness or relative positions of more than 1/16 inch (1.6 mm) but with no fills less than 1/8 inch (3 mm) thick.  Provide fill plates in bolted joints that are flush with the perimeter of the splice plates.

513.15  Horizontally Curved Beams and Girders.  If members are to be heat curved, submit the detailed procedure, including necessary calculations, to the Office of Materials Management.  Obtain the Office of Materials Management’s acceptance of the procedure before starting this work.

Curve beams and girders using heat according to AASHTO Standard Specifications for Highway Bridges, except that the fabricator may cut flanges for girders to obtain the required alignment.

513.16  Joints and Splices.  In bolted construction where tension or flexural members are spliced, maintain a clearance of not more than 1/4 inch (6 mm) between the abutting surfaces of spliced members.  For spliced compression members, face the abutting surfaces to provide a uniform bearing when properly aligned and completely bolted.

In welded construction, prepare abutting surfaces as shown on the shop drawings.  Verify the preparation for field welded butt joints in main members by a complete shop assembly according to 513.24.

513.17  Pin Holes.  Bore pin holes after the member is fabricated and true to size, at right angles to the axis of the member and parallel to each other.  Pin holes for up to 5-inch (127 mm) diameter pins shall not exceed the pin diameter by more than 0.020 inch (0.51 mm) and pin holes for larger pins shall not exceed the pin diameter by more than 0.031 inch (0.79 mm).

513.18  Pins and Rollers.  Use pins and rollers made from cold rolled steel, accurately turned to size, straight and smooth, and entirely free from flaws.  Pins over 9 inches (230 mm) in diameter shall be annealed.  In pins larger than 9 inches (230 mm) in diameter, bore a hole not less than 2 inches (50 mm) in diameter the full length of the axis.  Furnish one pilot and one driving nut for each size of pin.

513.19  Holes for High-Strength Bolts and Bearing Bolts.  Provide cylindrical holes, perpendicular to the member, clean cut, and free of ragged edges.  Remove burrs by countersinking not more than 1/16 inch (1.6 mm) or by grinding.  Provide finished holes with a diameter not larger than the nominal diameter of the bolt plus 1/16 inch (1.6 mm).  The hole diameter shall not vary by more than 1/32 inch (0.8 mm) from a true circle for 85 percent of the holes in a contiguous group, and not more than 1/16 inch (1.6 mm) for the remainder.

Punch holes using a die with a diameter not exceeding that of the punch by more than 1/16 inch (1.6 mm).  Ream and drill holes using twist drills and twist reamers.  Wherever possible, direct the reamer by mechanical means.

Sub-drill holes 3/16 inch (5 mm) less in diameter than the nominal diameter of the bolt, and ream the holes to size with the parts assembled, except:

A.      The fabricator may sub-punch main material conforming to ASTM A 709/A 709M, Grade 36 (250) steel that is less than 3/4 inch (19 mm) thick, and Grade 50 (345) or 50W (345W) steel that is less than 5/8 inch (16 mm) thick.

B.      The fabricator may drill full-size holes in materials assembled and adequately clamped together.

C.      The fabricator may punch full-size holes in secondary and detail material conforming to ASTM A 709/A 709M, Grade 36 (250) steel that is less than 3/4 inch (19 mm) thick, and Grade 50 (345) or 50W (345W) steel that is less than 5/8 inch (16 mm) thick.

D.      The fabricator may make assemblies such as floor beams connected to girders and rolled beam spans connected by diaphragms through steel templates.

Place all sub-punched or sub-drilled holes with sufficient accuracy such that after assembling (before reaming) a cylindrical pin 1/8 inch (3 mm) smaller than the nominal size of the punched hole may be entered perpendicular to the face of the member without drifting in not less than 75 percent of the contiguous holes in the same plane.  All holes shall allow a pin 3/16 inch (5 mm) smaller than the nominal size of the punched holes to be inserted in the above manner.

Do not plug located holes without written approval from the Office of Materials Management.

Provide steel templates with hardened bushings in holes that are accurately located in relation to the centerline of the connection as inscribed on the template.  The fabricator is not required to use hardened bushings when using a roto-broach, shell drill, or other similar tool, to make the holes.

Ream and drill holes through multiple piles only if the plies of the joint are held tightly together with bolts or clamps and if sub-punched or sub-drilled, only if the joint is pinned.  Disassemble and clean the piles of burrs and shavings before final assembly.

The Contractor may drill or punch bolt holes full sized in unassembled pieces or connections, including templates for use with matching sub-sized and reamed holes, using suitable numerically controlled (N/C) drilling or punching equipment.  If using N/C drilling or punching equipment, demonstrate the accuracy of the drilling or punching procedure to the inspector according to 513.24.

After holes are reamed or drilled full size, 85 percent of the holes in any contiguous groups shall have no offset greater than 1/32 inch (0.8 mm) between adjacent plies.  The remainder of the holes shall not be offset more than 1/16 inch (1.6 mm) between adjacent plies.

If requested in writing, the Office of Materials Management may consider other methods of preparing holes for high-strength bolts.

513.20  High-Strength Steel Bolts, Nuts, and Washers.  Provide high-strength steel bolts, nuts, and washers conforming for all bolted connections including erection bolts for cross frames and lateral bracing to 711.09.

A.      General.  Provide the Engineer with access to the work for observing the installation and the tightening and checking of the bolts.

Determine the required bolt length by adding the value from Table 513.20-1 to the grip.  The table values include an allowance for manufacturing tolerances and provide a bolt length for threads to protrude through the nut.  Add 5/32 inch (4 mm) for each hardened flat washer used and 5/16 inch (8 mm) for each beveled washer used.  Adjust the length, as determined by Table 513.20-1, to the next longer 1/4 inch (6 mm); when installed, the end of the bolt shall be flush with or project several thread lengths outside the face of the nut.

TABLE 513.20-1

Bolt Size (inches)

To determine required bolt length, add to grip[1] (inches)

1/2

11/16

5/8

7/8

3/4

1

7/8

1 1/8

1

1 1/4

1 1/8

1 1/2

1 1/4

1 5/8

1 3/8

1 3/4

1 1/2

1 7/8

[1]  Total thickness of all connected material excluding washers.

TABLE 513.20-1M

Bolt Size (mm)

To determine required bolt length, add to grip[1] (mm)

M16

24

M20

28

M22

31

M24

35

M27

38

M30

41

M36

47

[1]  Total thickness of all connected material excluding washers.

Use bolts, nuts, and washers with a residual coating of lubricant when received.  Bolts, nuts, and washers without their original lubrication shall not be used.

B.      Preparation.  With the exception of metalizing, galvanizing, and both organic zinc and inorganic zinc primers, remove coatings from joint surfaces, including surfaces adjacent to the bolt heads, nuts, and washers.  Remove lacquer, dirt, oil, loose scale, rust, burrs, pits, and other substances or defects that prevent solid seating of the parts or interfere with the development of complete frictional contact.  Do not place gaskets or other yielding material between joint surfaces.

C.      Installation.  For each bolt, place a hardened washer under the element (nut or bolt head) turned in tightening.  If an outer face of the bolted parts has a slope of more than 1:20 with respect to a plane normal to the bolt axis, use a smooth beveled washer to compensate for the lack of parallelism.

If necessary, the Contractor may clip washers, at one location, not closer than seven-eighths of the bolt diameter from the center of the washer.

During final assembly of the parts to be bolted, first install a sufficient number of drift pins to provide and maintain accurate alignment of holes and parts, then a sufficient number of bolts tightened to a snug tight condition to bring all the parts of the joint into complete contact.  Replace any bolts that were installed before installing drift pins.  Before releasing the member from the hoisting equipment, fill half the holes with drift pins and bolts tightened to a snug tight condition in at least 50 percent of the holes (preferably, half pins and half bolts) but use at least two drift pines in each flange and web of each beam or girder.  Install bolts starting at the most rigidly fixed or stiffest point and progress toward the free edges.

Use cylindrical drift pines that are not more than 1/32 inch (0.8 mm) smaller than the hole diameter.

Bolts are snug tight when an impact wrench begins to impact the nut or when a man applies full effort using an ordinary spud wrench.

Install bolts in the remaining open holes and tighten the bolts to a snug tight fit, after which all bolts shall be tightened completely by the turn-of-nut method.

Where difficulty is experienced with the fit of the connection and the bolts are used to draw the elements into contact, check all bolts in the affected portion of the connection for a sustained snug tight condition.

Replace drift pins with completely tightened bolts only after all the remaining holes are filled with completely tightened bolts.

Do not field ream holes drilled full size during fabrication.

After bolts are snug tight, the wrench operator shall match-mark the outer face of the nut with the flush or protruding portion of the bolt using a crayon or paint.  The Engineer will use the match-marks to determine the relative rotation between the bolt and nut during final tightening using the turn-of-the-nut method.

Commence tightening at the most rigidly fixed or stiffest point and progress toward the free edges, both in the initial snugging up and in the final tightening.  If required because of wrench operation clearances, tightening may be done by turning the bolt.  If used, provide impact wrenches of adequate capacity to perform the required tightening each bolt in approximately 10 seconds.

Do not reuse galvanized A 325 bolts.  Re-tightening previously tightened bolts that became loose by tightening adjacent bolts is not reuse.

Follow the additional bolting requirements in 513.26.

D.      Bolt Tension.  When all bolts in the joint are tight, the minimum bolt tension for each bolt size is shown in Table 513.20-2.

TABLE 513.20-2

Bolt Size (inches)

Bolt Tension[1]  (kips), minimum A 325

1/2

12

5/8

19

3/4

28

7/8

39

1

51

1 1/8

56

1 1/4

71

1 3/8

85

1 1/2

103

[1]  Equal to 70 percent of specified minimum tensile strengths of bolts, rounded off to the nearest kip.

TABLE 513.20-2M

Bolt Size (mm)

Bolt Tension[1]  (kN), minimum A 325M

M16

91

M20

142

M22

176

M24

206

M27

267

M30

327

M36

475

[1]  Equal to 70 percent of specified minimum tensile strengths of bolts, rounded off to the nearest kN.

TABLE 513.20-3  NUT ROTATION FROM SNUG TIGHT CONDITION

Bolt Length
(as measured from underside of head to extreme end of point)

Disposition of Outer Faces of Bolted Parts

Both faces normal to bolt axis

One face normal to bolt axis and other face sloped not more than 1:20 (bevel washer not used)

Both faces sloped not more than 1:20 from normal to bolt axis (bevel washer not used)

Up to and including 4 diameters

1/3 turn

1/2 turn

2/3 turn

Over 4 diameters but not exceeding 8 diameters

1/2 turn

2/3 turn

5/6 turn

Over 8 diameters but not exceeding 12 diameters

2/3 turn

5/6 turn

1 turn

Attain the bolt tension specified in Table 513.20-2 by tightening all bolts, the applicable amount of nut rotation specified in Table 513.20-3 by the turn-of-nut method.

Nut rotation is relative to bolt, regardless of the element (nut or bolt) being turned.  Tighten bolts requiring 1/2 turn and less within ±30 degrees and tighten bolts requiring 2/3 turn and more within ±45 degrees.

E.      Inspection.

1.      The Engineer will inspect the first completed connection of each bridge according to 513.20.E.2 below and subsequent connections the Engineer deems necessary.  Thereafter, where the Engineer has approved the joint compactness and snug-tight condition of bolts prior to bolt tightening by the turn-of-nut method, the bolt tension as required in Table 513.20-2 shall be considered as attained if the amount of nut rotation specified by Table 513.20-3 is verified by the required match-marking.

2.      Furnish and use manual torque wrenches to inspect bolts.  Perform test to the satisfaction of the Engineer.  Calibrate the inspection torque wrenches at least once each workday using a device, approved by the Engineer, and capable of indicating bolt tension.  Use three bolts, placed and tensioned individually, representative of the grade, size, length, and condition used in the structure to determine the job inspection torque according to 513.20.E.3.  Place a washer under the part being turned.

3.      Tighten each of the three representative bolts, using any convenient manner, to the tension shown in Table 513.20-2.  Then, using the inspection wrench, apply a slow steady pull to the tightened bolt and measure the torque required to turn the nut or head 5 degrees, approximately 1 inch (25 mm) at a 12-inch (300 mm) radius in the tightening direction.  Use the average torque measured in the tensioning of the three bolts as the job inspection torque.

4.      With the Engineer present, randomly select for inspection two bolts or 10 percent of the bolts, whichever is greater, from each connection represented by the 3-bolt sample described in 513.20.E.2.  Using the inspection wrench, apply the job inspection torque in the tightening direction.  The Engineer will accept the connection if the job inspection torque does not turn the nut or bolt head.  If the job inspection torque turns a nut or bolt head, apply the job inspection torque to all the bolts in the connection and reinspect the connection as described above.

F.      Calibration Devices.  The manufacturer of the calibration device or a qualified testing laboratory shall periodically examine each calibration device at least once each year and other times if requested by the Engineer.  After calibration, the manufacturer or testing laboratory shall certify that each calibration device accurately indicates the actual bolt tension.

513.21  Welding.  Perform welding by the shielded metal-arc, submerged arc, flux cored arc, or stud welding process.  Only shielded metal arc (stick) welding is prequalified.  All other welding processes require testing and approval by the Office of Materials Management.  Consideration will be given to other methods of metal-arc welding if a written request is submitted to the Office of Materials Management.

In other respects, the AASHTO/AWS Bridge Welding Code, as amended by Supplement 1011, shall govern the work.

Post copies of the shop welding procedures at each welding location.

Weld only fracture critical and main members when the fabrication quality control specialist and inspectors are physically at the facility.  The fabricator shall not perform fracture critical welding without prior scheduling with the fabrication quality control specialist and the inspector.  The fabrication quality control specialist shall witness the minimum percentages specified in Supplement 1078 and shall check all welding processes.

For non-fracture critical welds, the fabrication quality control specialist shall perform frequent inspections, and check all welding processes.

513.22  Stud Shear Connectors.  Perform stud welding according to the AASHTO/AWS Bridge Welding Code, as amended by Supplement 1011, and this subsection.

In addition to the stud bend tests of Article 7.6.6.1 of the AASHTO/AWS Bridge Welding Code, perform bend tests of stud shear connectors at the start of each workday, when welding has been interrupted for an hour or more, when changing grounds, when changing weld settings, and when changing cable loop due to arc blow.  Do not weld more than 500 studs without the welds being field bend tested in accordance with the specified procedure.  The Contractor may leave in the bent position tested studs that show no sign of failure, as determined by the Engineer.

Weld stud shear connectors to the top flanges of beams or girders after the steel has been erected and suitable scaffolding or deck forming has been provided. Studs may be welded to beam or girder webs, end dams, bearing plates, or to other secondary members and detail material in the shop. For galvanized structures with welded shear connectors, remove the galvanic coating by grinding at each connector prior to welding.

513.23  Threads for Bolts and Pins.  Threads for pins shall conform to the Unified Standard Series ANSI B1.1-UNC (ANSI B1.13M) Class 2A (6g) for external threads and Class 2B (6H) for internal threads, except that pin ends having a diameter of 1 3/8 inches (35 mm) or more shall be threaded 6 threads to the inch (4.23 mm/thread).

513.24  Shop Assembly.  Remove paint, grease, oil, rust, loose mill scale, and protruding edges or burrs from all contact surfaces.  Unless waived by the Office of Materials Management, do not assemble and weld flanges and webs to form girders or other similar members and do not accomplish fabrication or assembly that interferes with the repair of a butt weld until the fabrication quality control specialist for the A rated fabricators or the inspector for B and C rated fabricators examines and approves radiographs of all butt welds in the component parts.

Perform fit-up work with the members assembled in unloaded positions as shown on the shop drawing layout required by 513.06.  During shop assembly, adequately support members, especially at joints, to prevent misalignment or deflection and designate supports that prevent settlement during the fit-up, reaming or drilling of connections.  The fabrication quality control specialist shall maintain records of the actual horizontal and vertical dimensions and relative positions of each assembly for each offset required by 513.06 and, upon request, furnish a copy to the inspector.  Reposition members that become a part of two assemblies for the second assembly to the dimensions recorded for the first assembly.

Using steel stamps, match-mark all connecting parts assembled in the shop for the purpose of reaming or drilling of holes for field connections or for fit-up of field welded connections before disassembly.  Punch mark bearing centerlines.

Continuous beam and plate girders, including sections adjacent to hinged, pin connected, sliding, or rocker bearing joints, shall have at least three adjacent segments assembled, and holes reamed or drilled while assembled.  Check the fit-up of field welded connections by similar shop assembly.

Shop assemble longitudinal or transverse beams and girders that are either framed or connected by diaphragms and floor beams to check fit-up of connections to be field welded, or to ream or drill holes for bolted connections.  Assemble trusses in lengths of at least three abutting panels before drilling or reaming field connections.

Include deck plates in the final shop assembly of bridges that involve railroad deck plates, even if welding of these deck plates takes place in the field.

If the fabricator elects to use numerically controlled drilling or punching, the required assembly shall be performed as specified above.  The Office of Materials Management will consider the Contractor’s written request to use other methods of checking hole alignment and match marking.  If the Office of Materials Management does not consider, or disapproves the fabricator’s proposed methods of assembly, perform the work according to 513.19 and 513.24.

After fabrication, shop assemble deck expansion devices to check fit-up, straightness, and roadway cross-slope changes.  Full width assembly is required with phased construction if expansion devices have interlocking fingers or have mechanical devices that require exact field alignment.

The fabricator may fabricate part-width deck segments without the required shop assembly under the following conditions:

A.      The plans require a phased construction sequence.

B.      Shop drawings incorporate a lay down, similar to 513.06, defining vertical offset dimensions from a full length common baseline to all roadway changes including sidewalks, rounding, crowns, and field splice points of the expansion device.

Secure parts not completely assembled in the shop with temporary bolts to prevent damage in handling and shipping.  In the shop, bolt field splice plates into final position shift the splice plates laterally with respect to their final position so that the ends of the plates are flush with the ends of the member.  Without the Office of Materials Management’s written acceptance, do not weld or tack-weld to bolted assemblies.  Perform authorized welding according to 513.21.

513.25  Nondestructive Testing.  Nondestructive testing shall conform to the AASHTO/AWS Bridge Welding Code, as amended by Supplement 1011 and as specified below.

As the Engineer directs, perform ultrasonic or radiographic inspection of field welded repairs in main members for thick scabs, deep kerfs or nicks, and similar gross flaws.  Ensure that all examined welds and base metal adjacent to a welded joint conform to the quality requirements specified in 513.21.  Submit radiographs, field sketches showing specific locations, lengths and depths of the repair, and two copies of the radiographic or ultrasonic technical reports to the Office of Materials Management for acceptance.  Receive the Office of Materials Management’s acceptance before performing construction activities making welds inaccessible for repair.

The Contractor or fabricator shall notify the Department at least 48 hours before performing nondestructive testing.  Provide this notice even if specific hold or witness point inspections are not required by Supplement 1078.

The Office of Materials Management has the final authority to accept welds and will resolve controversies regarding the interpretation of radiographs, magnetic particle indications, or the acceptability of welds.

A.      Radiographic Inspection of Welds.  Before inspection, grind welds smooth.  Grind web splices only where radiographed, except grind outside fascia surfaces the full length.  Inspect the following welds:

1.      The full length of all butt welds in flange material of plate girders or rolled beams.  One hundred percent of butt welds in back up bars that remain in the structure.

2.      The top and bottom one-third of transverse web splices in plate girders or rolled beams and show any cope holes.  If an unacceptable weld occurs, radiograph an adjoining 12-inch (300 mm) length of weld not previously inspected.  If unacceptable flaws are found in this adjoining segment, radiograph the remainder of the weld.

3.      Butt welds in longitudinal stiffeners attached to tension areas of webs.

4.      Twenty-five percent of each longitudinal web splice as selected by the inspector.

5.      Full length of field flange cut repairs.

6.      Other welds specified in the Contract or AASHTO/AWS Bridge Welding Code.

Use a steel stamp to make the radiograph identification mark shown on the shop drawing layout in the area marked “Weld Identification” of Figures 6.1A through 6.1D of the AASHTO/AWS Bridge Welding Code in a manner to make it visible in the radiograph of the area without resorting to superimposed like markings.  Place steel stamped identification marks on flange plates so that after girder assembly the marks are on the inside of flange and outside the area fastened to the web.  Identify films of repaired welds by the letter “R”.  Do not place steel stamped identification numbers within the weld area.  Use superimposed characters to make other required markings.

Use film locations or a technique employed that will show the top and bottom images of the plate edge.  Use films 4 1/2 ´ 17 inches (114 ´ 432 mm) where practical and a minimum film size of 4 1/2 ´ 10 inches (114 ´ 254 mm).

Supply a technical report for the RT testing similar to Annex III Form III-5 of the AASHTO/AWS Bridge Welding Code, and include the following:  Project identification, member piece mark, description of the repairs made, and the qualification level of the technician.

The Department will take ownership of contact films.  For main material repairs, provide sketches that clearly show specific locations, lengths and depths of field cuts, or damages repaired by field welding.

B.      Magnetic Particle Inspection of Welds.  Before magnetic particle inspection (MPI), complete welding required to fabricate each beam or girder, correct all visual defects, and clean the weld.  If the fabricator’s quality control plan is acceptable to the Department and additional processing does not produce a potential for cracking, the Department may allow the Contractor to perform MPI before complete welding.

Inspect welds using the procedure and techniques for the dry powder magnetic-particle examination of welds using the prod or the yoke method according to AWS 6.7.6.  The prod test equipment shall have a functioning ammeter.  Provide a prod magnetizing current of 100 amperes per inch (25 mm) of prod spacing but not less than 400 amperes.  Use only aluminum prods.

Inspect at least 1 foot (0.3 m) for every 10 feet (3 m), or fraction thereof, for each size of weld in the following:

1.      Flange-to-web welds, including ends of girder after trimming.

2.      Moment plate to flange welds.

3.      Bearing stiffener welds.

4.      Other welds specified in the Contract or AASHTO/AWS Bridge Welding Code.

5.      Field weld repairs as directed by the Engineer.

The inspector or the fabrication quality control specialist will select random test sections.  Unless waived by the Office of Materials Management, the inspector will observe inspection by C-rated fabricators.  Position test sections as necessary for the inspection and after considering the safety and convenience to the inspecting personnel.

If a test section contains unacceptable defects, test 5-foot (1.5 m) segments on both sides of the test section, or, if less than 5-foot (1.5 m) segments are on both sides of the test section, test the full length of the weld.  Retest welds requiring repair after repairs are complete.  If the fabricator’s quality control plan is acceptable to the Department and additional processing does not produce a potential for cracking, the (WHO) may allow the Contractor to perform MPI before complete welding.

MPI will not locate all surface defects of Article 9.21 of the AASHTO/AWS Bridge Welding Code.  Unacceptable welds have MPI results that indicate defects exceed the above quality standards.

For each unacceptable defect, the fabricator shall record the piece mark, the location of the defect on the member, the defect description, and the proposed repairs.

C.      Ultrasonic Testing of Welds.  Perform ultrasonic inspection of the following welds:

1.      Complete joint penetration flange-to-web, T, or corner joint welds: 25 percent for non-FCM, 25 percent compression or shear FCM, and 100 percent tension FCM.

2.      Complete penetration butt welds:  100 percent tension FCM and 25 percent compression FCM.

3.      Other welds:  as specified in the Contract or AASHTO/AWS Bridge Welding Code.

The fabrication quality control specialist shall provide the Engineer with specified certification, sketches, technician reports, and a letter documenting that the Contractor performed nondestructive testing according to this specification.

513.26  Shipping, Storage, and Erection.  Repair or replace, at the discretion of the Office of Materials Management, members damaged by improper handling, storing, or erection.

During transportation, place adequate blocking between members to prevent movement and facilitate unloading.  Unless reinforced by additional plates, angles, or other material bolted in place, do not use field connection holes for tie-down.  Band together bearing components.

Place material stored in the fabricating shop or in the field on skids or blocks to prevent the metal from contacting the ground.  Place and shore girders and beams in an upright position for shipping, and field and shop storage.  Field splice plates shall be bolted with temporary bolts, which shall be removed and replaced, when field splice plated are placed in their final position or shifted laterally with respect to their final position.  Keep material clean and properly drained.  Install bearing devices and anchorages according to Item 516.

Thoroughly clean bearing surfaces and surfaces to be in permanent contact before the members are assembled in the field.

Before erecting structural steel, completely bolt up field splices and connections that started before steel erection.

During erection, the Engineer will allow drifting to draw the parts into position, but do not enlarge the holes or distort the metal.  Install drift pins and bolts according to 513.20.  Fill at least three-fourths of the holes with completely tightened bolts in splices and connections subject to construction loads during erection.  Complete permanent fastening of steel truss tension chord members before removing falsework.  Permanently fasten compression chord members after the span is released sufficiently from the falsework to bring the compression chord joints into full bearing.  Properly regulate and maintain elevations of panel points and ends of floor beams until the falsework is removed.

Do not enlarge the holes of splices and connections between segments or elements of main members without approval by the Office of Materials Management.

Adjust structures to the correct alignment and to the marked bearing centerlines before beginning permanent fastening.  Do not permanently fasten cross frames and lateral bracing in continuous beam or girder spans until completing main connections in adjacent spans; however, install sufficient bracing to maintain structural stability.  For erection bolts used to fasten cross frames, use not less than 5/8-inch (16 mm) diameter, and fully tighten bolts according to 513.20.

Erect end cross frames and end dams in a manner that ensures bearing parts remain in bearing contact.

Permanently fasten all intermediate cross frames before deck placement begins.

The webs of primary members shall be plumb before deck placement begins.

513.27  Shop Coating.  For steel surfaces specified to be coated according to Item 514, apply a prime coat in the shop.

513.28  Cleaning ASTM A 709/A 709M, Grade 50W (345W) Steel.  Before the new steel is shipped, solvent clean, where necessary, all surfaces of ASTM A 709/A 709M, and Grade 50W (345W) steel that are to be left unpainted to remove all traces of asphalt cement, oil, grease, diesel fuel deposits, chalk, paint marks, and other soluble contaminants according to SSPC-SP 1 Solvent Cleaning.  QCP #1 and QCP #2 shall apply according to Item 514.

Shop blast unpainted Grade 50W material to SSPC-SP 6, commercial blast.  QCP #3 shall apply according to Item 514.

After placing superstructure concrete, clean, where necessary, the exterior surface and bottom flanges of all fascia beams or girders that are to be left unpainted to remove all traces of asphalt cement, oil, grease, diesel fuel or petroleum deposits, concrete, and other contaminants.

Do not use acid for cleaning.

513.29  Method of Measurement.  The Department will measure Structural Steel Members on a lump sum basis or by the number of pounds (kilograms).

If payment is per pound (kilograms), submit weight computations to the Office of Materials Management based upon the accepted shop drawings.  Deduct waste material, removed by burning, cutting, machining, holes, etc., but include groove weld bevels.  Include the weight of all permanent fasteners, shop fillet welds, other metals and preformed bearing pads.  Exclude the weight of paint or galvanized coatings.  Exclude thickness or weight of members exceeding the plan requirements (due to overweight or other cause), unless authorized by the Department.  As an option, measure and record the weight of structural members before painting in the presence of the inspector.  Use the following unit weights for computations.

lb/ft³

(kg/m³)

Steel, cast steel, and deposited weld metal

490

(7850)

Cast iron

450

(7210)

Phosphor or leaded bronze

550

(8810)

Lead

710

(11370)

Preformed bearing pads

710

(11370)

The Department will measure Welded Stud Shear Connectors by the number of each installed and accepted.

513.30  Basis of Payment.  If the fabricator’s proposed methods of assembly with numerically controlled drilling or punching fail to produce specified results and the Office of Materials Management directs the Contractor to perform work, as according to 513.19 and 513.24, the Department will not pay for this work.

For steel surfaces specified to be coated according to Item 514, the cost of applying a prime coat in the shop is incidental to the bid for structural steel.

The Department will not pay for repairing or replacing members damaged by improper handling, storing, transportation, or erection.

The Department will pay for the accepted quantities at the contract prices as follows:

Item           Unit                                Description

513             Lump Sum                      Structural Steel Members, Level UF

513             Lump Sum                      Structural Steel Members, Level 1

513             Lump Sum                      Structural Steel Members, Level 2

513             Lump Sum                      Structural Steel Members, Level 3

513             Lump Sum                      Structural Steel Members, Level 4

513             Lump Sum                      Structural Steel Members, Level 5

513             Lump Sum                      Structural Steel Members, Level 6

513             Pound (Kilogram)           Structural Steel Members, Level UF

513             Pound (Kilogram)           Structural Steel Members, Level 1

513             Pound (Kilogram)           Structural Steel Members, Level 2

513             Pound (Kilogram)           Structural Steel Members, Level 3

513             Pound (Kilogram)           Structural Steel Members, Level 4

513             Pound (Kilogram)           Structural Steel Members, Level 5

513             Pound (Kilogram)           Structural Steel Members, Level 6

513             Each                                Welded Stud Shear Connectors

ITEM 514 PAINTING OF STRUCTURAL STEEL

514.01  Description

514.02  Materials

514.03  Superintendent

514.04  Quality Control

514.05  Testing Equipment

514.06  Work Limitations

514.07  Protection of Persons and Property

514.08  Pollution Control

514.09  Safety Requirements and Precautions

514.10  Inspection Access

514.11  Job Site Visual Standards

514.12  Quality Control Point Photographic Verification and Documentation

514.13  Surface Preparation

514.14  Washing Shop Primer

514.15  Handling

514.16  Mixing and Thinning

514.17  Coating Application

514.18  Removing Fins, Tears, or Slivers

514.19  Caulking

514.20  Dry Film Thickness

514.21  Final Inspection

514.22  Repair Procedures

514.23  Method of Measurement

514.24  Basis of Payment

514.01  Description.  This work consists of cleaning and painting all steel surfaces.

514.02  Materials.  On existing steel, apply a three-coat paint system consisting of an organic zinc prime coat, an epoxy intermediate coat, and a urethane finish coat. The coating system shall conform to 708.02.

On new steel, apply a three-coat paint system consisting of an inorganic zinc prime coat, an epoxy intermediate coat, and a urethane finish coat. The prime coat shall conform to 708.01, and the intermediate and finish coats shall conform to 708.02. Supply the intermediate and finish coats from the same manufacturer.  The Contractor is responsible for ensuring the compatibility of the intermediate and finish coats with the prime coat.

For caulking, use a single pack moisture cured polyurethane based material, which will not shrink or sag, capable of filling voids greater than 1/8 inch (3mm) and up to 1 inch (25 mm) wide. Only material that is listed on the OMM Qualified Product List website may be used.

514.03  Superintendent. In addition to the requirements of 105.06, the Superintendent must successfully complete a Bridge Painting pre-qualification course and training offered by the Department. The course must have been completed within the past four years and an individual course certificate must have been received by the Superintendent. Present certificate to the Engineer prior to commencing work. No work is permitted unless the Superintendent provides a valid course certificate.

514.04  Quality Control. Quality control consists of designating quality control specialists to control the quality of work in each phase established by Quality Control Points (QCPs). Control quality by inspection, tests, and cooperation with inspection and testing performed by the Engineer and inspector.

A.      Quality Control Specialist. Identify the individuals dedicated to performing duties as the painting quality control specialists before starting work in the field. Provide a quality control specialist for each structure, but one quality control specialist must be provided for every three structures for which work is progressing concurrently on this contract.

Each quality control specialist must be either a NACE (National Association of Corrosion Engineers)certified coating inspector or a SSPC (The Society for Protective Coatings, SSPC) protective coating specialist or formally trained or retrained by a NACE certified coating inspector or a SSPC protective coating specialist. The training shall be adequate to ensure that the quality control specialist is able to use all the testing equipment and understands the requirements of this specification. Provide a copy of the NACE or SSPC certification or a copy of the trainer’s NACE or SSPC certification and a letter or certificate signed and dated by the trainer to the Office of Construction Administration. Ensure that the NACE or SSPC certification is current or retrain the quality control specialist every five years in accordance with the above requirements.

The quality control specialist must successfully complete a Bridge Painting prequalification course offered by the Department. The training course must have been completed within the past four years and an individual course certificate must have been received by the quality control specialist.

Select only a quality control specialist who is approved by the Department. The Office of Construction Administration will publish a list of approved Quality Control Specialists. Present all required certificates, letters of certification, and valid identification to the Engineer prior to commencing work.

The quality control specialist will be immediately removed from their duties as the quality control specialist and disqualified from future duties as the quality control specialist if any quality control failure occurs. A quality control failure is defined as any of the following:

1.      The dry film thickness has been approved by the quality control specialist and it is later found that over 20 percent of the spot measurements of any one member of a structure, such as a cross frame, web, flange, stiffener, or other parts of the structure are either under the minimum or over the maximum spot thickness.

2.      The dry film thickness has been approved by the quality control specialist and it is later found that the thicknesses of any area of a structure as described in 514.20 are either under the minimum or over the maximum specification thickness.

3.      Two separate occurrences when the surface preparation has been approved by the quality control specialist of any one member type, such as the cross frames, webs, flanges, stiffeners, or other parts of the structure and it is later found that the surfaces of those members were either not properly profiled or not properly cleaned as required by the Contract Documents. Occurrences are determined per structure.

4.      Two separate occurrences of the quality control specialist performing production duties not allowed by the Contract Documents. Occurrences are determined per structure.

5.      Two separate occurrences when the quality control specialist fails to perform any one of the duties assigned to the quality control specialist in the Contract Documents. Occurrences are determined per structure.

Suspend work if the quality control specialist is not available or has been removed. The Engineer or Inspector will immediately provide written notification to the Office of Construction Administration of any quality control failure identified above. Resume work when a quality control specialist, qualified and approved as provided in 514.04, is available.

For work in the fabrication shop, each fabricator shall identify one or more full-time individuals who shall perform the duties of the painting quality control specialist.

The quality control specialist may not be used to perform production duties including supervision, blasting, painting, waste disposal, mixing, operating or repairing equipment, or other tasks not associated with duties of the quality control specialist while the Contractor is performing work toward the completion of a Quality Control Point.

Ensure that each quality control specialist is trained and equipped with Material Safety Data Sheets (MSDS), product data sheets, tools, and equipment necessary to provide quality control on all aspects of the work. Each quality control specialist shall have a thorough understanding of the plans for the work, including any pertinent addenda, change order, or other contract documents, and these Specifications. Duties each quality control specialist shall perform include:

1.      Inspect equipment and abrasive at specified intervals.

2.      Approve the work and provide documentation that the work has been approved immediately before each QCP.

3.      Inspect the work with the Engineer or Inspector at each QCP.

4.      Verify the Contractor or fabricator performed work according to the Contract Documents.

5.      Cooperate with the inspection and testing performed by the Engineer and inspector.

6.      Document test results and compare test results with the Engineer’s and inspector’s test results.

7.      Notify Superintendent of nonconforming work.

8.      Stop work when test equipment is not available and when necessary to ensure the work is performed according to the Contract.

The fabricator’s quality control specialists shall provide the Engineer with a letter that includes specified information or check point data documenting acceptance of the work and consisting of the following:

1.      Checks on the abrasive to ensure that it has not been contaminated with oil.

2.      The profile of the blasted surface.

3.      The air and steel temperature and dew point before blast cleaning and painting and at 4-hour intervals during the blasting and painting operation.

4.      Readings of the actual dry film thickness.

5.      The lot and stock number of the paint and the date of manufacture.

6.      Documentation that the paint mixer is functioning properly, that each spray operator has demonstrated the ability to paint, and that all spray equipment is used according to the manufacturer’s recommendation.

B. Quality Control Points (QCP). QCPs are points in time when one phase of the work is complete and approved by the quality control specialist and ready for inspection by the Engineer or the inspector before commencing the next phase of the work. At a QCP, the quality control specialist shall provide quality control tests bearing his signature to the Engineer or Inspector. The Contractor or fabricator shall provide the Engineer and inspectors access to inspect all affected surfaces. If inspection identifies a deficiency, correct the deficiency according to the Contract Documents before starting the next phase of work. Discovery of defective work or material after a Quality Control Point is past or failure of the final product before final acceptance, shall not, in any way, prevent the Department from rejecting the final product or obligate the Department to final acceptance. Final acceptance will be determined according to 514.21, Final Inspection.

Quality Control Points

Purpose

New

Steel

Existing

Steel

1. Solvent Cleaning

Remove asphalt cement, oil, grease, etc.

Yes

Yes

2. Grinding Flange Edges

Remove sharp corners

Yes

Yes

3. Abrasive Blasting

Blast surfaces to receive paint

Yes

Yes

4. Containment/ Waste Disposal

Contain, collect, & dispose of abrasive blasting debris

No

Yes

5. Prime Coat Application

Check surface cleanliness, apply prime coat, check coating thickness

Yes

Yes

6. Remove Fins, Tears, & Slivers

Remove surface defects and slivers

Yes

Yes

7. Washing of Shop Primer

Remove all water soluble materials (salt, dirt, etc.)

Yes

No

8. Intermediate Coat Application

Check surface cleanliness, apply intermediate coat, check coating thickness

Yes

Yes

9. Caulking

Caulk areas not sealed by the intermediate coat

Yes

Yes

10. Finish Coat Application

Check surface cleanliness, apply intermediate coat, check coating thickness

Yes

Yes

11. Final Review

Acceptance and check total system thickness

Yes

Yes

Provide signed documentation of inspection, testing, conditions and material information to the Engineer on the following ODOT forms, or forms with the equivalent information.

Dry FilmThickness Readings for QCP#5 Prime, #8 Intermediate,

& #10 Finish Coats…………. …. ……………. …. ……………. …. …..CA-S-2

QCS Inspection Documentation Sign Off for QCP’s…………. …. ……..CA-S-7

QCS & Visual Standards Information for QCP#3 Abrasive Blasting Test Section……………. …. ……………. …. ……………. …. ………..CA-S-11

QCP#1 Solvent Cleaning & QCP#2 Grinding Flange Edges……….CA-S-12

QCP#3 Abrasive Blasting……………………………………………………………...CA-S-13

QCP#4 Disposal of Hazardous/Non-Hazardous Waste……………………………………. …. …………….……CA-S-14

QCP#5 Prime Coat Application…………………………………………………………..CA-S-15

QCP#6 Grinding Fins, Tears and Slivers & QCP #9 Caulking……………………………. …. ……………. …. …………...CA-S-16

QCP#8 Intermediate & QCP#10 Finish Coat Application …. ……………CA-S-17

514.05  Testing Equipment. For the project duration, provide the Engineer or inspectors with the test equipment listed below for the type of work at each work site with ongoing work. With the exception of the recording thermometer, the fabricator shall provide its quality control specialists with the test equipment listed below.. The Contractor and fabricator shall maintain all testing equipment in good working order, and provide documentation or certification of calibration from the manufacturer.

A.      Film and a camera with the following features:

1.      Uses self developing color print film.

2.      Lens with auto focus system.

3.      Focuses from 2 feet (0.6 m) to infinity.

4.      Built-in fill flash.

Or provide a digital camera with the following features:

1.      5.0 Megapixel or greater resolution.

2.      Minimum 3× Optical zoom lens capability with automatic focus.

3.      Minimum 512MB Memory capability.

4.      Built-in flash.

5.      Photograph printer with docking capability compatible with the camera including supplies necessary to print. (i.e. Ink Cartridges, Photograph quality paper, and other consumables required for operation and photograph printing.)

B.      One Spring micrometer and extra-coarse replica tape on the project at all times.

C.      One SSPC-PA2 Type 2 (electronic) non-destructive coating thickness gage, with a set of calibration thickness foils, (shims),   and two sets of National Institute of Standards & Technology calibration plates. The first set of calibration plates shall be 1.5 to 8 mils (38 to 200 μm), Model No. 1362b, and the second set shall be 10 to 25 mils (250 to 625 μm) , Model No. 1363b.

D.      One Sling Psychrometer including Psychrometric tables, (or comparable electronic or digital equipment for the measurement of dew point, accurate within 2 °F (1 °C) and within one percent relative humidity).

E.      Two steel surface thermometers accurate within 2 °F (1 °C).

F.      Flashlight 2-D cell.

G.      SSPC Visual Standard for Abrasive Blast Cleaned Steel (SSPC-VIS 1).

H.     One recording thermometer capable of recording the date, time, and temperature over a period of at least 12 hours.

514.06  Work Limitations. Apply the prime coat to new structural steel inside permanent buildings at the fabricator’s facility. If inside permanent buildings, the fabricator may perform year-round abrasive blasting and painting. Perform abrasive blasting and painting in the field from April 1 to October 31. The Department will not issue a time extension due to adverse weather during the month of April. The plans or other Contract Documents may require additional work limitations for specific bridges or projects.

A.      Temperature. Except for inorganic zinc, apply paint when the steel, air, and paint temperature is 50 °F (10 °C) or higher and expected to remain higher than 50 °F (10 °C) for the cure times listed below. Apply inorganic zinc when the steel, air, and paint is 40 °F (4 °C) or higher. Cure inorganic zinc according to the minimum curing time and temperatures specified in the paint manufacture’s printed instructions.

50 °F

(10 °C)

60 °F

(16 °C)

70 °F

(21 °C)

Primer (Organic Zinc)

4 hrs

3 hrs

2 hrs

Intermediate

6 hrs

5 hrs

4 hrs

Finish

8 hrs

6 hrs

4 hrs

Monitor the temperatures listed above for cure times using the recording thermometer. The Contractor may use a heated enclosure or building. Supply heat continuously and uniformly to maintain the required minimum curing temperature within the enclosure or building until the coating has cured.

If combustion type heating units are used, vent the units away from the enclosure or building and do not allow exhaust fumes to enter the enclosure or building. Do not use open combustion in the enclosure or building.

The fabricator may use radiant heat when painting new structural steel inside permanent shop buildings. Locate radiant heaters at least 10 feet (3 m) above all surfaces to be painted. Vent exhaust fumes to prevent fumes from contacting surfaces to be painted.

B.      Moisture.  Do not apply paint:

1.      If the steel surface temperature is less than 5 °F (3 °C) above the dew point.

2.      If the steel surface is wet, damp, frosted, or ice-coated.

3.      If the relative humidity is greater than 85 percent.

4.      During periods of rain, fog, or mist unless the above moisture criteria is met.

If steel was abrasive blasted when the temperature of the steel was less than 5 °F (3 °C) above the dew point, reblast the steel when the steel temperature is at least 5 °F (3 °C) above the dew point.

514.07  Protection of Persons and Property. Collect, remove, and dispose of all rubbish, buckets, rags, or other discarded materials and leave the job site in a clean condition.

Except for deck bottoms and backwalls which have not been sealed or are not to have a sealer applied, protect all portions of the structure, that are not to be painted from damage or disfigurement by splashes, spatters, and smirches of paint.

If the Contractor causes any damage or injury to public or private property, the Contractor shall restore the property, to a condition similar or equal to the condition existing before the damage or injury.

514.08  Pollution Control.  Comply with pollution control laws, rules, or regulations of Federal, State, or local agencies and requirements of this specification.

514.09  Safety Requirements and Precautions. Comply with the applicable safety requirements of the Ohio Industrial Commission and OSHA.

Provide Material Safety Data Sheets (MSDS) at the preconstruction meeting for all paints, thinners, and abrasives used on this project. Do not begin work until submitting the MSDS to the Engineer.

514.10  Inspection Access and Lighting. In addition to the requirements of 105.10, furnish, erect, and move scaffolding and other appropriate equipment to allow the inspector and the Engineer the opportunity to closely observe all affected surfaces during all phases of the work and for at least 10 workdays after completely painting each structure to allow for the Final Inspection according to 514.21. Provide artificial lighting as necessary to supplement natural light with a minimum of 30 foot candles (325 LUX) at the surface of the steel for inspection, cleaning, and painting. Prevent glare that interferes with traffic, workers and inspection.Submit to the Engineer for information, complete details of the inspection access that complies with the applicable safety requirements of The Ohio Industrial Commission and OSHA. The details shall be reviewed, signed, stamped and dated by an Ohio registered Professional Engineer certifying that they meet these requirements. Maintain the in-place inspection access equipment employed during original painting activities or provide alternate inspection equipment such as platform lifts, bucket trucks, snooper trucks, or equivalent as approved by the Engineer. If scaffolding, or any hanger attached to the scaffolding, is supported by horizontal wire ropes, or if scaffolding is directly under the surface to be painted, comply with the following requirements:

A.      If scaffolding is suspended 43 inches (1092 mm) or more below the surface to be painted, place two guardrails on all sides of the scaffolding. Place one guardrail at 42 inches (1067 mm) above the scaffolding and the other guardrail at 20 inches (508 mm) above the scaffolding.

B.      If scaffolding is suspended at least 21 inches (533 mm) but less than 43 inches (1092 mm) below the surface to be painted, place one guardrail on all sides of the scaffolding at 20 inches (508 mm) above the scaffolding.

C.      If 514.10.A and 514.10.B do not apply, place two guardrails on all sides of scaffolding. Place one guardrail at 42 inches (1067 mm) above the scaffolding and the other guardrail at 20 inches (508 mm) above scaffolding.

D.      Provide scaffolding at least 24 inches (610 mm) wide if guardrail is used and 28 inches (711 mm) wide if guardrail is not used and scaffolding is suspended less than 21 inches (533 mm) below the surface to be painted. If using two or more parallel scaffolding to achieve the proper width, rigidly attach the scaffolding together to prevent differential movement.

E.      Construct guardrail as a substantial barrier, securely fastened in place and free from protruding objects such as nails, screws, and bolts. Provide a properly located opening in the guardrail to allow the Engineer and inspector access onto the scaffolding.

F.      Construct guardrails and uprights of metal pipe, steel angles, or wood. If using pipe railing, provide pipe with a nominal diameter of at least 1 1/2 inches (38 mm). If using steel angle railing, provide 2 ´ 2 ´ 3/8-inch (50 ´ 50 ´ 9 mm) steel angles or other metal shapes of equal or greater strength. If using wood railing, provide 2 ´ 4-inch (50 ´ 100 mm) nominal stock. Space uprights no more than 8 feet (2.4 m) on center. If using wood uprights, provide 2 ´ 4-inch (50 ´ 100 mm) nominal stock.

G.      If the surface to be inspected is more than 15 feet (4.57 m) above the ground or water, and the scaffolding is supported from the structure being painted, provide a safety harness (not a safety belt) and lifeline for the Engineer and inspector. The lifeline shall not allow a fall greater than 6 feet (1.8 m). Provide a method to attach the lifeline to the structure that is independent of the scaffolding, cables, and brackets supporting the scaffolding.

H.     If scaffolding is more than 2.5 feet (762 mm) above the ground, provide an access ladder and equipment to attach the ladder onto the scaffolding capable of supporting 250 pounds (113 kg) with a safety factor of at least four. uniformly space rungs, steps, cleats, and treads no more than 12 inches (305 mm) on center. Extend at least one side rail at least 36 inches (914 mm) above the landing near the top of the ladder.

I.       If the distance from the ladder to the access point on the scaffolding exceeds 12 inches (305 mm), provide an additional landing that is capable of supporting a minimum of 1000 pounds (454 kg) and at least 24 inches (610 mm) wide and 24 inches (610 mm) long. Size and shape the landing so that the distance from the landing to the point where the scaffolding is accessed does not exceed 12 inches (305 mm). Firmly attach the landing to the ladder; however, do not use the ladder to support the landing.

J.       In addition to the scaffolding requirements above, comply with all Federal, State, and local laws, ordinances, regulations, orders, and decrees.

K.      Furnish all necessary traffic control to allow inspection during and after all    phases of the project.

514.11  Job Site Visual Standards. Before starting abrasive blasting, establish job site visual standards by preparing a test section, subsequent test sections, and by using photographs of approved test sections. Use job site visual standards and SSPC-VIS 1 standard for blasting. The Contractor or fabricator shall prepare an approximately 20 to 30-square foot (2 to 3 m²) test section from a representative area on the first structure to be painted. After the Engineer or Inspector and the Contractor or fabricator agree the test area was blast cleaned to the requirements of the Contract Documents, photograph the test section and check the steel surface for the proper profile. After the Engineer or Inspector approves the test section and the job site visual standards are documented by photographs and replica tape, the Contractor or fabricator may start abrasive blasting. The quality control specialists and Engineer or Inspector will use the job site visual standards (photographs), the Plan, Specification and requirements to determine acceptance of blast cleaning procedures. In all cases of dispute, the SSPC-VIS 1 standard shall govern. If the Contractor, Engineer, Inspector, or fabricator believe the initial test section does not establish the proper visual standard for a different structure another test section on the different structure may be performed.

514.12  Quality Control Point Photographic Verification and Documentation. The Engineer or Inspector will take a sufficient number of photographs to document the condition of the work at Quality Control Points 3, 4 and 11.

514.13  Surface Preparation.

A.      Solvent Cleaning (QCP #1). Solvent clean by methods described in SSPC-SP 1, areas containing oil, grease, asphalt cement, diesel fuel deposits,  other petroleum products and contaminants.

B.      Grinding Flange Edges (QCP #2). Before abrasive blasting, round all exposed flange edges of all beams and girders to a radius of 1/8 ±1/16 inch (3 ±1.5 mm). This work has no weather and temperature restrictions.

C.      Abrasive Blasting (QCP #3). Do not abrasive blast areas that contain asphalt cement, oil, grease, or diesel fuel deposits. Before abrasive blasting, completely remove all dirt, sand, bird nests, bird droppings, and other debris from the scuppers, bulb angles, and pier and abutment seats.

Abrasive blast all steel to be painted according to SSPC-SP 10 and as shown on the pictorial surface preparation standards for painting steel surfaces shown in SSPC-VIS 1. Maintain steel in a blast cleaned condition until it has received a prime coat of paint. The Contractor may commercial blast clean the back side of end cross frame assemblies that are 3 inches (75 mm) or closer to backwalls according to SSPC-SP 6.

Cover and protect galvanized and metalized steel (including corrugated steel bridge flooring), adjacent concrete already or specified to be coated or sealed, and other surfaces not intended to be painted, from damage caused by blasting and painting operations. Repair adjacent coatings damaged during the blasting operation. Backwalls and bottoms of decks not sealed nor specified to be sealed do not need to be covered and protected.

For field blasting use a recyclable steel grit, or a recyclable natural mineral, low dusting abrasive. Do not use silica sands, mineral slags, and other types of non-metallic abrasives that contain more than 0.5 percent free silica, by weight, have a chlorides salts content more than 25 ppm, and contain any organic material. For shop blasting use an abrasive that produces an angular profile. All abrasives shall provide a profile from 1.5 to 3.5 mils (40 to 90 μm) as determined by replica tape according to ASTM D 4417, Method C. Adjust the abrasive size, blast hose nozzle pressure or other means in order to provide the 1.5 to 3.5 mil profile. Clean the abrasive of paint chips, rust, mill scale, and other foreign material after each use and before each reuse. Use equipment specifically designed for cleaning the abrasive.

Check abrasives used at the job site or fabrication shop for oil contamination at the beginning of each shift and at 4-hour intervals. Also check each load of abrasive delivered to the job site or fabrication shop for oil contamination before use.  Check for oil by placing a small sample of abrasives and tap water into a jar. Reject the abrasive if an oil film is detected on the water surface.

To ensure that the compressed air is not contaminated, the quality control specialists shall blow air from the nozzle for 30 seconds onto a white cloth or blotter held in a rigid frame. If the cloth or blotter retains oil or other contaminants, suspend abrasive blasting until retests verify the problem was corrected. Perform this test at the start of each shift and at 4-hour intervals.

The Contractor may simultaneously abrasive blast and paint the same bridge provided the abrasive blasting debris and dust does not contact freshly painted surfaces and does not contaminate paint during the curing period. For shop blasting, the fabricator may simultaneously abrasive blast and paint if the two operations are separated by distance or containment that prevents paint contamination.

For surface preparation of new structural steel in the fabricator’s shop, the quality control specialist shall take replica tape readings as follows:

1.      For an automated blasting process, test the greater of 20 percent of the main members or one member per shift. These tests shall consist of taking five random readings per member.

2.      For a manual blasting process, test each main member. The test of a main member consists of taking five readings at random locations.

3.      For both an automated and manual blasting process, test 15 percent of all secondary members. The test of a secondary member consists of taking one random reading.

Remove abrasives and residue from all surfaces to be painted. Keep all structural steel that was blast cleaned in the field or the fabricator’s shop dust free. Apply a prime coat to steel that was blast cleaned in the field within 12 hours of the beginning of the abrasive blasting operation. Apply a prime coat to structural steel that was blast cleaned in the fabricator’s shop within 24 hours of the beginning of the abrasive blasting operation. If a prime coat is not applied within the times stated above, reblast the steel before applying the prime coat. Remove all dust or abrasives from adjacent work and from the finish coat.

Provide the Engineer and Inspector with field wash facilities and an adequate supply of running potable water, soap, and towels for washing face and hands during the surface preparation operation. Properly contain, test, and dispose of the wastewater. Locate a wash facility at each bridge site and in an area that will not be contaminated by the blasting debris.

D. Containment/Waste Disposal (QCP #4). Waste material generated by abrasive blasting operations in the field is a solid waste and may be a hazardous waste. Contain, collect, store, evaluate, and properly dispose of the waste material. Comply with all Federal, State, and local environmental protection laws, regulations, and ordinances including, but not limited to, air quality, waste containment, and waste removal. The Contractor is advised that various governmental bodies are involved with solid waste and hazardous waste disposal and the Contractor is responsible for complying with laws enforced by the various governmental bodies.

To prevent contamination of the pavement or soil, park all equipment on ground covers free of cuts, tears, and holes.

Clean equipment of spent abrasives or debris before bringing equipment to the project, moving equipment from one bridge site to another, and removing equipment from the project. Store debris cleaned from equipment with the debris from the structure that generated the debris.

Erect an enclosure to completely surround (around, under and over the top on truss type bridges) the blasting operations. The Contractor may use the ground as the bottom of the enclosure if the ground is completely covered with plastic or tarps.

Construct the enclosure of flexible materials such as tarpaulins (specifically designed for blasting containments), or construct the enclosure of rigid materials such as plywood. Maintain all materials free of tears, cuts, and holes. Overlap all seams a minimum of 6 inches (150 mm) and fasten the seams together at 12-inch (300 mm) centers or in a manner that ensures a seal that does not allow openings between the edges of the containment material. Extend the vertical sides of the enclosure completely up to the bottom of the deck on a steel beam bridge and use bulkheads between beams to enclose the blasting area.

Collect all debris from blasting operations, equipment, or filters, and all debris that fell to the ground. Store the debris in steel containers with lids that are locked at the end of each workday. The storage location shall be at the bridge site unless, the Engineer and Contractor agree on an alternate storage location. Test and evaluate the debris for disposal. The location of centralized cleaning stations for recyclable steel shall also be agreed by the Engineer and the Contractor.

Obtain the services of a testing laboratory to obtain directly from the project site and evaluate a composite representative sample of the abrasive blasting debris for each bridge site. The person taking the sample must be an employee of the testing laboratory.

Take composite sample in the presence of the Engineer or Inspector, comply with the requirements of U.S. EPA Publication SW 846 and take individual samples from all containers that are on the site at the time of the sampling. Blend individual samples of equal size together to comprise one composite sample. Take one individual sample from each drum and four randomly spaced individual samples from each container other than drums.

Take individual samples and place into clean glass or plastic containers.

Prepare a chain of custody record (Chain of Custody) for all composite samples. The Chain of Custody must include the name of the person taking the sample, the name of the testing laboratory for which the person works, the date and time the sample was taken, the bridge sampled, the Township and Municipality where the bridge is located, and the signatures and dates of all persons in possession of the sample in the Chain of Custody.

Sample the abrasive blasting debris within the first week of production blasting at each bridge. Cease all blasting and painting operations on the bridge from which waste was generated, if sampling is not performed within the first week of production blasting.

Test composite samples for lead, chromium, cadmium and arsenic according to the U.S. EPA Publication SW 846 Method 1311 (TCLP). Provide the Chain of Custody and test results to the District Regulated Waste Engineer (DRWE) immediately after the test results are available. If the DRWE determines the blasting debris is hazardous, as defined below, provide the Engineer with the names of the hauler and treatment facility. Perform all sampling and testing required by the hauler, treatment facility, or disposal facility.

The existing paint removed from bridges may contain lead, chromium, cadmium or arsenic. The Contractor is responsible for taking the proper safety precautions to ensure workers in this environment are properly protected.

1.      Hazardous Waste. The blasting debris is hazardous if lead, chromium, cadmium or arsenic exceed any of the regulatory concentration limits shown below:

SW 846 Analyte

Regulatory Concentration Limit

Lead

5.0 mg/l

Chromium

5.0 mg/l

Arsenic

5.0 mg/l

Cadmium

1.0 mg/l

Label all the containers of hazardous blasting debris “HAZARDOUS”. Secure the storage location by surrounding the site with a 5 foot (1.5 m) high chain link fence fabric supported by traffic sign drive posts 10 feet (3 m) apart. Drive the traffic signposts into the ground at least 2 feet (0.6 m) deep. Secure the fencing with padlocks at the end of each day. Post hazardous waste warning signs at obvious locations on the fenced enclosure.

The Office of Construction Administration will obtain a generator number assigned to the State. After the Office of Construction Administration obtains the generator number, arrange for the hauling, treating, and disposing of the hazardous waste. Use a firm licensed by EPA to haul and dispose of the hazardous waste. This firm is also responsible for providing the completed Uniform Hazardous Waste Manifest (EPA Form 8700-22, or current version).

In every case, properly dispose of all hazardous waste within 60 days after it is generated. If hazardous waste is not properly disposed of within 60 days, the Department will consider the Contactor in breach of its Contract and the Department will take the following actions:

a.      Immediately suspend all abrasive blasting and painting of structural steel on the Project until hazardous waste is properly disposed.

b.      Cease processing all pay estimates.

c.      Forward a breach of contract notification to the Contractor’s Surety.

The Contractor is responsible for fines or liens assessed by any governmental agency that has jurisdiction over the disposal of this hazardous waste material.

Decontaminate or dispose of all collection and containment equipment according to EPA guidelines.

The Contractor shall inform the Department when all hazardous waste has been removed from the Project so the EPA Site ID Number (Hazardous Waste Generator Number) can be deactivated.

2.      Non-Hazardous Solid Waste.  For all waste that is determined to be a Non-Hazardous Solid Waste by the DRWE, the Contractor is required to:

a.      Before disposing of any material, provide the Engineer with documentation that the disposal facility is licensed by the EPA to accept non-hazardous solid waste.

b. Haul and dispose of the waste to the documented, non-hazardous solid waste facility.

c. Obtain from the disposal facility and provide the Engineer with a receipt that documents disposal of waste material at the licensed disposal facility.

d. Properly dispose of all waste within 60 days after it is generated.

514.14  Washing Shop Primer (QCP #7). Wash shop primed structural steel after it is erected and the concrete deck is placed and within 30 days of applying the intermediate coat.

Wash the steel with potable water. Use equipment capable of delivering the water at a nozzle pressure of at least 1000 pounds per square inch (7 MPa) and at a rate of not less than 4 gallons (15 L) per minute. The Contractor shall provide the Engineer with equipment specifications that verify both the delivery pressure and rate. Provide gauges on the equipment to verify the pressure during operation. Hold the nozzle a maximum of 12 inches (300 mm) from the surface being washed. The surface is clean when clear rinse water runs off the structure. After rinsing the surface, inspect for remaining dirt and rewash dirty areas until clean.

514.15  Handling. Deliver all paint and thinner in original unopened containers with labels intact. The Engineer or Inspector will accept containers with minor damage provided the container is not punctured. Thinner containers shall be a maximum of 5 gallons (19 L). Before use, provide the Engineer with shipping invoices for all painting materials used on the Project.

Supply containers of paint and thinner with labels clearly marked by the manufacturer to show paint identification, component, color, lot number, stock number, date of manufacture, and information and warnings as may be required by Federal and State laws.

Store paint at the temperature recommended by the manufacturer and in a storage facility that prevents theft. Provide thermometers capable of monitoring the maximum high and low temperatures inside the storage facility.

Before opening paint or thinner containers, check the labels to ensure the proper container is opened and the paint has not been stored beyond its shelf life. Do not use paint that exceeded its shelf life. Do not open containers of paint and thinner until required for use and then open the oldest paint of each kind first. Solvent used for cleaning equipment is exempt from the above requirements.

Do not use paint that has livered, gelled, or otherwise deteriorated during storage. Properly dispose of unused paint and paint containers.

514.16  Mixing and Thinning. Thoroughly mix all ingredients immediately before use with a high shear mixer (such as a Jiffy Mixer). Do not mix paint using paddle mixers, paint shakers, or an air stream bubbling under the paint surface. After mixing, carefully examine the paint for uniformity and to ensure that no unmixed pigments remain on the bottom of the container. Before use, strain the paint through strainers that remove skins or undesirable matter but not pigment.

Except for primer, mix paint as necessary during application to maintain a uniform composition. Continuously mix primer using an automated agitation system. Do not use hand-held mixers for primer paints.

Do not add thinner to the paint without the Engineer’s or Inspector’s approval, and only add thinner if necessary for proper application as recommended by the manufacturer’s printed instructions. In the Engineer’s or Inspector’s presence, slowly add the amount of thinner recommended and supplied by the manufacturer to the paint during the mixing process. Do not mix other additives into the paint.

Add catalysts, curing agents, or hardeners that are in separate packages to the base paint only after thoroughly mixing the base paint. With constant agitation, slowly pour the proper volume of catalyst into the required volume of base. Do not pour off liquid that has separated from the pigment before mixing. Use the mixture within the pot life specified by the manufacturer and dispose of unused portions at the end of each workday.

514.17  Coating Application

A.      General. Paint all structural steel, scuppers, expansion joints except top surface, steel railing, exposed steel piling, drain troughs, and other areas as shown on the plans. Paint galvanized or metalized surfaces if shown on the plans. Unless otherwise shown on the plans or specified below, apply paint to provide the specified coating thickness by brush and spray methods. If brush and spray are not practical to paint places of difficult access, the Contractor may use daubers, small diameter rollers, or sheepskins.

Use daubers, small diameter rollers, or sheepskins to paint the following areas:

1.      Where cross-frame angles are located within 2 inches (50 mm) of the bottom flange.

2.      Where end cross frames are within 6 inches (150 mm) of the backwall.

3.      Where there is less than 6 inches (150 mm) between the bottom of the bottom flange and the beam seat.

B.      Application Approval. The Engineer or Inspector may inspect the initial application of the prime, intermediate, and final coats. If the Engineer or Inspector discovers defects, adjust the method of application to eliminate the defects then continue applying the coat.

C.      Additional Information Pertaining to Shop Applied Primer. Apply a prime coat to all structural steel surfaces by brush or spray methods, including insides of holes, behind stiffener clips and contact surfaces of connection, and splice material that is to be fastened with bolts in the shop or field. Apply a mist coating from 0.5 to 1.5 mils (12.5 to 37.5 μm) on surfaces that are to be imbedded in concrete and on surfaces within 2 inches (50 mm) of field welds other than those attaching intermediate or end cross frames to beams or girders. Apply one coat of primer to pins, pin holes, and contact surfaces of bearing assemblies, except do not paint those containing self-lubricating bronze inserts. Once the prime coat is dry, apply erection marks, using a thinned paint of a type and color that is completely concealed by, and compatible, with the second coat.

Do not handle or remove structural steel coated with inorganic zinc primers from the shop until the paint has cured as specified by the paint manufacturer’s printed instructions.

Reduce the thickness of thick films of inorganic zinc primer by screening, sanding, or sweep blasting. If the primer paint cured longer than 24 hours, apply a re-coating of primer paint according to the paint manufacturer’s printed instructions. Abrasive blast and re-apply the primer to the affected area if “mud cracking” occurs. If “checking” occurs, abrasive blast and reapply the primer or remove the “checking” by screening and evaluate the area by adhesion testing.

D.      Surface Cleanliness. All surfaces to be painted shall be free of dust, dirt, grease, oil, moisture, overspray, and other contaminants. If the surface is degraded or contaminated, restore the surface before applying paint. In order to prevent or minimize degradation or contamination of cleaned surfaces in the field, the prime coat of paint shall be applied within 12 hours of the beginning of the abrasive blasting operation as required in surface preparation above, for steel which is cleaned and painted in the shop, the prime coat of paint shall be applied within 24 hours of the beginning of the blasting operation.

Schedule cleaning and painting when dust or other contaminants will not fall on wet, newly painted surfaces. Protect surfaces that do not receive paint or have already been painted from the effects of cleaning and painting operations. Before applying the next coat, remove overspray and bird droppings with a stiff bristle brush, wire screen, or a water wash with sufficient pressure to remove overspray and bird droppings without damaging the paint. Before applying the next coat, remove all abrasives and residue from painted surfaces with a vacuum system equipped with a brush type cleaning tool.

Remove all visible abrasives on the finish coat that came from adjacent work.

E.      Brush Application. Apply the paint to produce a smooth coat. For field painting, to ensure coverage, apply wet stripe coats using brushes, daubers, small diameter rollers or sheepskins to all edges, outside corners, crevices, welds, rivets, bolts, nuts and washers in addition to the spray application of each individual coating Apply additional paint as necessary to produce the required coating thickness.

F.      Spray Application (General). Apply paint using spray application as follows:

Keep spray equipment clean so that dirt, dried paint, solvents, and other foreign materials are not deposited in the paint film. Remove solvent left in the equipment before using the equipment.

Apply paint in a uniform layer with overlapping at the edges of the spray pattern. Paint the border of the spray pattern first, followed by painting the interior of the spray pattern. Complete painting a spray pattern before moving to the next spray pattern area. Within a spray pattern area, hold the gun perpendicular to the surface and at a distance that will ensure a wet layer of paint is deposited on the surface. Release the trigger of the gun at the end of each stroke. Each spray operator shall demonstrate to the Engineer or inspector the ability to apply the paint as specified before the operator sprays paint.

If mud cracking occurs, the affected area shall be cleaned to bare metal in accordance with surface preparation above and repainted. Fill all gaps and crevices 1/8 inch (3 mm) or less with primer.

Use spray equipment recommended by the paint manufacturer and suitable for use with the specified paint. Provide adequately sized traps or separators to remove oil and condensed water from the air. Periodically drain the traps during operations. To ensure that the traps or separators are working properly, test by blowing air from the spray gun for 30 seconds onto a white cloth or blotter held in a rigid frame. The Engineer or Inspector will verify the test results by inspecting the white cloth or blotter. If the cloth or blotter retains oil, water, or other contaminants, suspend painting until retests verify the problem was corrected. Perform this test at the start of each shift and at 4-hour intervals. This is not required for an airless sprayer.

Do not use spray application unless the operation is totally enclosed as required for abrasive blasting, to prevent overspray damage to the ground, public and private property, vegetation, streams, lakes, and other surfaces not to be painted.

G.     Prime, Intermediate, and Finish Coat Application (QCP #5, #8, and #10). Apply paint as a continuous film of uniform thickness, free of all defects such as holidays, pin holes, mud cracking, checking, drips, runs, and sags. The Contractor is responsible for applying the manufacturer’s paint as necessary to satisfy the above requirement.  Repaint all thin spots or areas missed before the next coat of paint is applied.

Ensure that each coat of paint is properly cured before applying the next coat. Comply with the manufacturer’s written instructions for the time interval between coats and apply the next coat when an additional coat will not cause detrimental film irregularities, such as lifting, wrinkling, or loss of adhesion of the undercoat. Do not exceed the following time intervals. If the prime coat is organic zinc, the maximum time between the prime and intermediate coats is 30 days. There is no maximum time between the prime and intermediate coats for an inorganic zinc primer. The maximum time interval between intermediate and finish coats is 13 days. These maximum recoat times include adverse weather days and the Engineer will not extend the times. If the next coating is not applied within the times stated above, remove the coatings and re-blast the steel according to SSPC-SP 10.

Stencil the Completion Date (month and year) of the finish coat and the letters of the applied paint system on the steel in 4 inch (100 mm) letters with black urethane paint. The appropriate letters for the paint systems are as follows:

System Comprised of

Letters

Inorganic zinc prime coat, epoxy intermediate coat, and urethane finish coat

IZEU

Organic zinc prime coat, epoxy intermediate coat, and urethane finish coat

OZEU

Apply the date and paint system at four locations near the end of each outside beam on the outside web visible from the road or as directed by the Engineer.

514.18  Removing Fins, Tears, or Slivers (QCP #6). Use a grinder to remove all fins, tears, slivers, or any other burred or sharp edges that become evident after applying the prime coat. Retexture ground surfaces to produce a profile from 1.5 to 3.5 mils (40 to 90 μm) and reprime ground surfaces before applying the intermediate coat. The Contractor may begin removing fins, tears, and slivers after blasting and before priming. Temperature and weather restrictions do not apply to removing fins, tears, and slivers, but do to applying the prime coat.

514.19  Caulking (QCP #9). After the intermediate coat cures and before applying the finish coat, caulk gaps or crevices greater than 1/8 inch (3 mm). Allow for the cure of the caulk, per the Manufacturer’s recommendations prior to the application of the finish coat.

514.20  Dry Film Thickness (QCP #9). After the intermediate coat cures and before applying the finish coat, caulk gaps or crevices greater than 1/8 inch (3 mm). Allow for the cure of the caulk, per the Manufacturer’s recommendations prior to the application of the finish coat.

Measure paint thickness at separate, evenly spaced, spot measurement locations over each 100-square feet (9 m²) of area of structural steel. Locate five spot measurements on each of the following locations: top flanges; bottom flanges; webs; cross bracing; stiffeners; etc. At each spot location, take three gage readings of either the substrate or the paint. Move the probe 1 to 3 inches (25 to 75 mm) for each new gage reading. Discard an unusually high or low gage reading that is not consistently repeated. The spot thickness measurement is the average of the three gage readings.

The average of five spot measurements for each location in the 100-square foot (9 m²) area shall not be less than the specified thickness. No single spot measurement area shall be less than 80 percent of the specified minimum thickness nor greater than 150 percent of the maximum specified thickness when organic zinc is applied and 120 percent of the maximum specified thickness when inorganic zinc is applied. Any one of three readings which are averaged to produce each spot measurement, may under run or overrun by a greater amount. Take five spot measurements per location for each 100-square foot (9 m²) area as follows:

A.      For all shop painted steel, regardless of size, randomly select and then measure one 100-square foot (9 m2) area within each 300 square foot (27 m²) unit of surface area that is painted.

B.      For structures not exceeding 300 square feet (27 m²) in area, measure each 100-square foot (9 m²) area.

C.      For structures not exceeding 1000 square feet (90 m²) in area, randomly select and then measure three 100-square foot (9 m²) areas.

D.      For structures exceeding 1000 square feet (90 m²) in area, measure the first 1000 square feet (90 m²) as stated in section C and for each additional 1000 square feet (90 m²), or increment thereof, randomly select and then measure one 100-square foot (9 m²) area.

E.      If the dry film thickness for any 100-square foot (9 m²) area (sections C and D) is not in compliance with the requirements of this subsection, then measure each 100-square foot (9 m²) area.

F.      Measure other areas or revise the number of spot measurements as shown on the plans.

Each coat of paint shall have the following thickness measured above the peaks:

Min.

Spec.

Thickness

Max.

Spec.

Thickness

Min.

Spot

Thickness

Max. Spot

Thickness

(Inorganic Zn)

Max. Spot

Thickness

(Organic Zn)

Prime

3.0 mils

(75 µm)

5.0 mils

(125 µm)

2.4 mils

(60 µm)

6.0 mils

(150 µm)

7.5 mils

(188 µm)

Intermediate

5.0 mils

(125 µm)

7.0 mils

(175 µm)

4.0 mils

(100 µm)

10.5 mils

(263 µm)

10.5 mils

(263 µm)

Subtotal

8.0 mils

(200 µm)

12.0 mils

(300 µm)

6.4 mils

(160 µm)

16.5 mils

(413 µm)

18.0 mils

(450 µm)

Finish

2.0 mils

(50 µm)

4.0 mils

(100 µm)

1.6 mils

(40 µm)

6.0 mils

(150 µm)

6.0 mils

(150 µm)

Total

10.0 mils

(250 µm)

16.0 mils

(400 µm)

8.0 mils

(200 µm)

22.5 mils

(563 µm)

24.0 mils

(600 µm)

Remove paint with a film thickness greater than the maximum specified thickness unless:

A.      The paint does not exhibit defects such as runs, sags, bubbles, or mud cracking, etc.

B.      The manufacturer provides a written statement to the Engineer that the excessive thickness is not detrimental.

For any spot or average of five spots at any location of a 100-square foot (9 m²) area that exceeds the maximum spot thickness, either remove and replace the coating according to 514.22 or prove to the Office of Construction Administration that the excess thickness will not be detrimental to the coating system. In order to prove to the Office of Construction Administration that the excess thickness will not be detrimental to the coating system, the Contractor must provide the Office of Construction Administration with the following information.

Certified test data proving that the excessive thickness will adequately bond to the steel when subjected to thermal expansion and contraction. The thermal expansion and contraction test shall take place over five cycles of a temperature range from -20 to 120 °F (-49 to 49 °C). After the thermal contraction and expansion cycles have taken place, the tested system shall be subjected to pull off tests and the results compared to the results of pull off tests that have been performed on a paint system with the proper thicknesses.

Perform the adhesion tests according to ASTM D 4541 Type IV. Document the preparation methods for the panels, including profile and level of cleanliness. Document the application methods, conditions and if any thinner, (percentage), was used. Test the panels according to the following:

1.      Lightly sand the coating surface and aluminum dolly, and apply a quick set adhesive. Document the type of adhesive.

2.      Allow adhesive to cure overnight.

3.      Scribe the coating and adhesive around the dolly before testing.

4.      Make a minimum of 4 trials to failure, and  report the 4 trials. Reject trial if fracture occurs at the primer-substrate interface or pressure at failure is less than 400 pounds per square inch (2.8 MPa).

a. Describe the test specimen as substrate A, upon which successive coating layers B, C, D, etc. have been applied including the adhesive Y which secures the dolly Z to the topcoat.

b. Designate cohesive failures by the layers within which they occur as B, C, etc., and the percent of each.

c. Designate adhesive failures by the interfaces at which they occur as A/B, B/C, C/D, etc, and the percent of each.

In addition to the certified test results, the Contractor shall provide the Office of Construction Administration a written statement from the paint manufacturer stating that the excessive thickness is not detrimental.

If the Office of Construction Administration does not approve the excessive coating thicknesses or the Contractor elects not to provide the required written statement from the paint manufacturer and the certified test results when required, the Contractor shall remove and replace the coating. The removal and replacement of the coating shall be done as specified in 514.22.

514.21  Final Inspection

A.      The Engineer will select locations for coating removal for inspection of surface preparation and dry film thickness. For all structures in which the supporting members are rolled beams or girders, remove a minimum of one location per 150 linear feet (46 m) of beam line for webs and flanges and 5 percent of all cross frame assemblies and other secondary structural members shall be selected for destructive testing. For all other bridge types with structural steel, remove one location for every 1,200 square feet (108 m²) of steel surface for destructive testing. Do not perform destructive testing on areas that have been painted with an inorganic zinc prime coat.

B.      At the selected areas, the Engineer will perform total dry film thickness testing using a type 2 magnetic gage. If the dry film thickness for that spot does not meet the requirements of 514.18, additional measurements will be taken to determine the extent of the deficient coatings.

C.      At the selected areas, where an organic zinc prime coat has been applied, remove at least 9 square inches (58 cm²) of the new coatings by methods that will not damage the surface of the steel.  Approved removal methods are scraping, sanding, or the use of solvents.   Do not use power tools. Perform removal while in the presence of the Engineer. The Engineer will document and photograph the selected areas after removal of the new coatings. If work is found not to be in conformance with the specifications and pertinent contract documents, additional locations may be selected for testing.

D.      Make repairs of areas where the coatings were removed and other areas that were determined to be deficient. Make repairs according to 514.22. If the final destructive testing according to 514.21.C, reveals greater than 15 percent of the areas inspected are not in complete conformance with the specifications and pertinent contract documents, the Department will require that surface preparation and painting of the structural steel be completely redone to meet the requirements of the Contract Documents at no additional cost to the Department.

E.      Final Acceptance shall be based upon the results of the surface preparation observations and dry film thickness measurements obtained from the final inspection. Final Acceptance will also take into consideration acceptable progressive project documentation and progressive field measurements in determining the final acceptability of the Bridge Paint System.

Inspection access to the test locations to perform the required final inspection measurements shall conform to the requirements of 514.10.

514.22  Repair Procedures. Remove paint and correct defects or damaged areas, including areas damaged by welding, and in areas that do not comply with the requirements of this specification. Correct defects and damaged areas using the same paint as originally applied except the Engineer may approve using organic zinc to repair inorganic zinc in the field. Retexture the steel to a near white condition and a profile between 1.5 to 3.5 mils (40 to 90 μm). Measure the profile immediately before applying the prime coat to ensure the profile is not destroyed during the feathering procedure.  See 514.13.C.

Feather the existing paint to expose a minimum of 1/2 inch (13 mm) of each coat.

During the reapplication of the paint, apply paint as follows:

A.      Apply the prime coat only to the surface of the bare steel and the existing prime coat exposed by feathering. Do not apply the prime coat to the adjacent intermediate coat.

B.      Apply the intermediate coat only to the new prime coat and the existing intermediate coat exposed by feathering. Do not apply the intermediate coat to the adjacent finish coat.

C.      Apply the finish coat only to the new intermediate coat and the existing finish coat that was feathered or lightly sanded. Do not apply the finish coat beyond areas that were feathered or lightly sanded.

At the perimeter of the repair area, apply the prime and intermediate coats using a brush. Apply the finish coat using either brush or spray.

The Contractor may need to apply several applications to obtain the proper thickness for each coat.

During the application of the prime coat, the paint shall be continuously mixed.

Perform all surface preparation and painting according to this specification. Instead of abrasive blasting, the Engineer may allow alternate methods of preparing the surface.

Blend repair areas with the adjacent coating and provide a finished surface in the patched areas that is smooth and has an even profile with the adjacent surface.

Submit, in writing, the method of correcting areas with runs to the Office of Construction Administration for approval.

514.23  Method of Measurement. The Department will measure Surface Preparation of Existing Structural Steel and Field Painting of Existing Structural Steel Prime Coat by the number of square feet (square meters) of structural steel painted or on a lump sum basis. The Department will measure Field Painting Structural Steel, Intermediate Coat and Field.  Painting Structural Steel, Finish Coat by the number of square feet (square meters) or pounds (kilograms) of structural steel painted, or on a lump sum basis.

The Department will determine the number of pounds (kilograms) of new structural steel painted by the accepted pay weight of the new structural steel.

For steel beam and steel girder bridges, the Department will determine the surface area by taking a nominal measurement of the beams (i.e., two times the beam depth plus three times the flange width). In addition to this nominal measurement, the Department will add a percentage to account for incidentals such as cross frames, bearing assemblies, stiffeners, expansion joints, scuppers, etc. It is not necessary for the Engineer or Inspector to field measure every detail of the bridge to verify quantities. If there is a quantity dispute, exact field measurements of all painted surfaces and calculations will govern over the above percentage to account for incidentals.

For extremely complex bridges, such as trusses, the Department will pay for painting on a lump sum basis.

The Department will measure grinding fins, tears, slivers on existing structural steel by the number of man hours expended by the workers actually doing the grinding and will include the time when the workers are performing grinding and repairing prime coat and not limited to only the actual grinding duration (i.e., the Department will include all hours of the workers when assigned to grinding regardless of actual grinding time). The Department will not measure grinding fins, tears, and slivers on new steel but will consider it incidental to unit price for the new steel.

514.24  Basis of Payment. The Department will pay for accepted quantities at the Contract prices as follows:

The Department may consider paint as eligible for payment for material on-hand as specified in 109.10, however, only paint that the Contractor can prove to the Engineer will be used during the construction season is eligible for payment. The Contractor shall provide the Engineer calculations indicating the total square feet (square meter) of steel to be painted during the construction season. The Contractor shall also provide calculations showing the total number of gallons (liters) required.

If the Contractor causes damage or injury to public or private property, the Department will not pay for restoring the property to its original condition.

The Department will not pay for repairing adjacent coatings damaged during the blasting operation.

The Department will not pay for removing and replacing an area of coating because a spot or maximum average thickness exceeds the maximum spot thickness.

The Department will not pay for additional testing required by any hauler, treatment facility, disposal facility or landfill.

The Department will pay for caulking under Field Painting Structural Steel, Intermediate Coat.

The Department will pay for final inspection access, test area preparation and test area repair at each selected area under Final Inspection Repair. The Department will not pay for accessing, inspecting, and repairing areas that are not found to be in conformance with the specifications and pertinent contract documents.

All other requirements of this specification are considered incidental to the work.

Item           Unit                                Description

514             Square Foot                     Surface Preparation of
                       (Square Meter)                Existing Structural Steel
                       Lump Sum

514             Square Foot                     Field Painting of Existing
                       (Square Meter)                Structural Steel, Prime Coat
                       Lump Sum                     

514             Square Foot                     Field Painting Structural
                       (Square Meter)                Steel, Intermediate Coat
                       Lump Sum, Pound
                       (Kilogram)

514             Square Foot                     Field Painting Structural
                       (Square Meter)             Steel, Finish Coat
                       Lump Sum, Pound
                       (Kilogram)

514             Man Hour                       Grinding Fins, Tears, Slivers
                                                               on Existing Structural Steel

514             Each                                Final Inspection Repair

ITEM 515  PRESTRESSED CONCRETE BRIDGE MEMBERS

515.01  Description

515.02  Fabricator Approval Procedure

515.03  Levels of Fabricator Qualification

515.04  General

515.05  Fabricator Documentation Responsibility

515.06  Shop Drawings

515.07  Pre-Fabrication Meeting

515.08  Materials

515.09  Materials Approval

515.10  Casting Beds

515.11  Weather Conditions During Production

515.12  Equipment

515.13  Inspection Facilities

515.14  Construction Methods

515.15  Concrete

515.16  Release of Prestressing Strands

515.17  Fabrication tolerances

515.18  Prestressed Member Acceptance and Repair

515.19  Handling, Storage, Transportation, and Erection

515.20  Safety Requirements

515.21  Method of Measurement

515.22  Basis of Payment

515.01  Description.   This work consists of preparing shop drawings, furnishing and manufacturing prestressed concrete bridge members, testing, fabricator performed quality control, documentation, shop coating, and handling, transporting, storing, and erecting prestressed concrete bridge members. Prepare shop drawings and erect prestressed concrete bridge members, according to Item 501 and the additional requirements specified below. Shop coating shall conform to Item 512.

515.02  Fabricator Approval Procedure.  Select fabricators that are pre-qualified and evaluated by the Office of Materials Management (OMM) according to Supplement 1079 and listed by the Department before the Contract letting Date.

515.03  Levels of Fabricator Qualification.  There are three levels of fabricator qualification.  The Laboratory will classify each fabricator at the highest level of fabrication it is qualified to perform.

Level

Description of Capabilities

1

Straight strand prestressed box beam members

2

Straight strand prestressed I-beam members

3

Draped strand prestressed I-beam members

515.04  General.  Produce all members according to Item 511, except as otherwise specified herein.

515.05  Fabricator Documentation Responsibility.  The fabricator shall keep and maintain records for each project bid line number concerning:

A.      Fabricator plant approval.

B.      Shop drawing approval.

C.      Material test reports.

D.      Welding qualifications.

E.      Quality Control Plan (QCP) according to Supplement 1079.

The fabricator shall provide access to the above records for audit, inspection, and copying.  Provide a copy of the complete records at the completion and final shipment of the work.  The Fabricator shall retain all documentation for at least 5 years from the date of final shipment from the fabrication shop.

The fabricator shall document all Quality Control (QC) activities to verify the fabrication conforms to the specification requirements.  QC activities include material quality checks, dimensional checks, weld inspections, strand tensioning procedures, release procedures, post-pour inspections, concrete strengths at release of strand and final strength of concrete before shipment, cleaning operations, coating applications, final QC inspections, repairs and all other QC procedures required to provide a prestress concrete member conforming to the specifications.

Supplement 1079 defines the quality control plan evaluation process and quality control plan enhancement process

The Department will perform a quality assurance (QA) evaluation of the fabricator’s quality control performance using forms in Supplement 1079 and will include both validation of the fabricator’s actual records of inspection and Department inspection.

515.06  Shop Drawings.  Provide shop drawings conforming to 501.04 and the following requirements.

Include all details, dimensions, dimensional tolerances, size of materials, lifting devices, inserts, reinforcing steel supports, fabricator incorporated reinforcing, piece mark diagrams for field connection and erection of any steel and all prestress members, and all other information necessary for the complete fabrication and erection of the prestressed members. Show all items that will be incorporated into each prestressed member.

Provide the detensioning procedure and pattern conforming to 515.16.

515.07  Pre-Fabrication Meeting.  At least 3 days after the Department receives shop drawings, conduct a pre-fabrication meeting at the fabricator’s facilities, or another location agreed to by all parties. 

As part of the pre-fabrication meeting request, provide a initial fabrication schedule for the prestressed beam project including:

A.      Start date for fabrication of the project

B.      Expected phasing of fabrication, if any

C.      Number of workdays for the project and length of work day

D.      Quality control final inspection date

The fabricator’s production manager, quality control specialists (QCS) for the project, the Department’s inspector, and the Contractor, or its designated representative, shall attend the meeting.  The meeting is to review fabrication issues, including information on shop drawings, previous QC/QA inspection issues, QC and Quality Assurance inspection hold points, unique and special fabrication items, and special processes.  The QCS will conduct the meeting and record and distribute meeting minutes that document all issues discusses.  Begin fabrication when all meeting issues have been resolved. 

Office of Material Management may waive the pre-fabrication meeting if accepted by the Fabricator and the Contractor.  If Contractor submitted shop drawings do not comply with the requirements of 515.06, no pre-fabrication meeting can be scheduled or waived.

515.08  Materials.  Furnish materials conforming to:

Reinforcing steel........................................................... 509

Concrete................................................................... 515.15

Portland cement.................................... 701.01 thru 701.09

Aggregate *............................................................. 703.02

Air-entraining admixture.......................................... 705.10

Chemical admixtures for concrete............................ 705.12

Prestressing steel..................................................... 711.27

Transverse tie rods................................................... 711.01

Welded wire reinforcement………………………..709.12

*   For fine aggregate, use natural sand for members without a separate wearing course.  Modify coarse aggregate as follows:

     Do not allow more than 0.4 percent deleterious materials.

     For gradation, use No. 6, 67, 68, 7, 78 or 8 size coarse aggregate.

515.09  Materials Approval.  The fabricator shall control, test, and validate material requirements for all materials either incorporated into the prestressed fabricated item or supplied under Item 515 as component parts to the fabricated items.  The fabricator shall provide S 1079 documentation to the inspector at the time of final inspection.

The Department will not sample materials at the fabricator’s shop for Department approval. The Department will randomly sample materials to verify the fabricator’s performance.

515.10  Casting Beds.  Use steel or concrete casting beds set above grade to ensure the beds remain above the accumulation of water resulting from production and curing operations. Design beds and abutments capable of safely resisting all forces applied to them without appreciable movement or deflection.  These forces include compression and eccentric forces due to end-jacking operations, forces at hold down points when draped strands are used, and downward forces due to the dead weight of the members.

515.11  Weather Conditions During Production.  Make temperature change adjustments to initial strand tensioning according to PCI Quality Control Manual 116.

A.      Cold Weather.  Conform to the requirements of this subsection if the ambient air temperature is below 50 °F (10 °C).  Heat mixing water, aggregates, or both as necessary to produce a concrete temperatures from 50 to 70 °F (10 to 21 °C) when placed.  Do not allow water heated above 150 °F (66 °C) to directly contact the cement.  Do not place concrete against forms, reinforcing steel, prestressing strand, or other hardware materials with a temperatures below 32 °F (0 °C).

Do not place concrete when the ambient temperature with sustained wind chill factor at the point of concrete placement is below 0 °F (-18 °C). 

B.      Hot Weather.  If the ambient temperature is above 90 °F (32 °C) cool the mixing water, aggregates, or both, as necessary to produce a concrete temperature from 70 to 90 °F (21 to 32 °C).  Do not place concrete against forms, mild reinforcing steel, prestressing strand, or other hardware materials with a temperature greater than 120 °F (49 °C). 

Water fog spray forms, mild reinforcing steel and strand  just prior to placing the concrete.  Cover beams immediately after casting to prevent surface drying. 

Do not place concrete when the ambient temperature at the point of concrete placement is above 100 °F (38 °C).

C.      Inclement Weather.  If a rainfall event begins after placement of concrete in the forms has begun, provide cover and complete only the beam that had concrete in it when the rain began.  Provide immediate cover over previously poured concrete, not yet cured.  Resumption of concrete placement is permitted after the rainfall stops.

515.12  Equipment.   Provide hydraulic jacks of sufficient capacity and stroke to tension strands.  Use either single or multiple strand tensioning.  Provide tensioning jacks equipped with automatic cutoff valves and equipped with  6 inch (150 mm) minimum diameter gages that provide readings at 500-pound (2 kN) increments.  Calibrate gages for the jacks with which they are to be used.  Have a graph or table showing the calibration available for the inspector.  Calibrate jacks according to a method acceptable to the Laboratory at least every 6 months or as required by the Director.  Maintain calibration documentation as part of the project’s QC inspection records.

Design the jacking system to ensure uniform stress in all strands.  If simultaneously tensioning multiple strands, use approved types of dynamometers to equalize the initial stress on all strands before applying the full tensioning load with the master jack Provide dynamometers with sufficient capacity to ensure that the desired readings are in the middle to upper range.

515.13  Inspection Facilities.  The fabricator shall provide the inspector office accommodations conforming to the following requirements:

A.      Minimum floor area of 120 square feet (11 m²).

B.      Minimum ceiling height of 7 feet (2.1 m).

C.      Adequate working and storage facilities, work space, lighting, electrical outlets, lockable files or cabinets and ventilation.

D.      Heat capable of maintaining a temperature of not less than 68 °F (20 °C).

E.      Telephone with direct access to an outside trunk line for the inspector’s exclusive use.

F.      A set of keys for the lockable files or cabinets in the office.

515.14  Construction Methods.  Use metal forms capable of producing members within the tolerances shown on the plans.  Forms made of material other than metal may be used for bulkheads and voids.  Ensure that the surfaces of the forms in contact with the concrete are smooth and the joints between panels are tight.  The soffit form shall have a plane surface at right angles to the vertical axis of the members and have the two bottom edges beveled 3/4 inch (19 mm) with a triangular strip built into the forms.  Increase the length of the forms for elastic shortening and normal concrete shrinkage, and design the forms to accommodate this movement.

Provide water-resistant formwork for box beam voids  constructed of a material that resists breakage and deformation during placement of concrete.  Provide form material that does not excessively increase the dead load of the beams.

Prevent the release agent from contacting the prestressing strands or reinforcing steel.

Install and assemble reinforcing steel according to the approved shop drawings.  If authorized, weld reinforcing cages using welders qualified to AWS D1.4.  Do not weld epoxy coated or galvanized reinforcing steel unless approved by  Office of Material Management.  Repair all coating areas damaged by welding according to the coating manufacturer’s instructions.  Reject reinforcing steel with a loss of cross-section of reinforcing caused by welding. 

Provide a protective covering for the prestressed steel from the elements until the strand is pulled into the bed.  Accurately place strands in the positions shown on the shop drawings.  Do not use strands with kinks, bends, nicks, broken wires, scale, loose rust, or other defects.  The fabricator may use slightly rusted reinforcing steel provided the rust is not sufficient to cause visible pits.  Before placing the concrete, carefully clean the strands of all dirt, grease, oil, or other foreign matters.  Do not splice strands within a member.

Tension strands uniformly to the stress indicated on the shop drawings.  If multiple stands are stressed simultaneously, use dynamometers to equalize the initial stress on all strands before applying full tension load with master jack.  Measure the required stress in the strands using the calibrated jacking equipment gages, and check the measured stress by the elongation of the strands.  If the stress from the gages and the measured elongation are not within a 5 percent tolerance of the design, stop stressing the strands and determine the reason for the differences.  The quality control specialist shall keep a record of the jacking forces and elongations of all strands. Secure the strands by suitable anchorage devices capable of developing at least 85 percent of the ultimate strength of the strands.  The anchorage shall not allow the strand to slip after the tensioning operation.

If using draped strands, the loss of stress due to friction shall not exceed 5 percent.  Tension the strands at both ends.  The quality control specialist shall measure the loss due to friction by a procedure approved by the Office of Material Management.  Place hold-down points within 3 inches (90 mm) of the locations shown on shop drawings and within 12 inches (0.3 m) of the locations shown on the plans.

Unless otherwise shown in the plans, do not install inserts or holes in the beam web within a distance of 1.5 times the beam height from the end of the beam.

515.15  Concrete.  The fabricator shall provide concrete mix designs to Office of Material Management. The submittal will include:

A.      Test data showing the mix achieves the required 28-day strength when cured by methods used for member fabrication. The strength of the concrete for the mix design approval and during production is determined using sets of two, 6 × 12-inch cylinders or three, 4 × 8-inch cylinders.

B.      W/c ratio (maximum = 0.40)

C.      A design and maximum slump

D.      Test data showing the mix design achieves 2000 coulombs or less @ 90 days when tested according to AASHTO T277. Use samples for the test that were mixed without corrosion inhibitors and that were cured with the same methods that will be used to produce the prestressed concrete bridge members. Do not apply additional cure to samples that have reached the required design strength. 

Changes in proportioning, cement, pozzolans or aggregate will require retesting and resubmittal.  Office of Materials Management may waive the retests.  Provide the waiver request in writing and include all information for the new mix design and a comparison to the previously tested and approved mix design(s).

Deliver concrete according to Item 499except that 499.03 and 499.04 does not apply. The plastic air content of the concrete before placement shall be 6 ± 2 percent.  If the Departmentquestions the concrete’s placed air content, obtain cores from the prestressed member and have hardened air testing performed by an independent testing lab acceptable to the Department.  Beams with hardened air contents below 4 percent will be rejected.  Add an approved corrosion inhibiting admixture at the approved dosage and document the dosage that has been incorporated into each batch of concrete.

Maintain the mix design slump during production.  Segregation of the mix is not acceptable.  Do not exceed the maximum water-cement ratio during concrete production.  When using admixtures to increase the slump, use Type F or G as described in 705.12.  Do not use calcium chloride or admixtures containing calcium chloride.

For beams containing up to 20 yards of concrete each, make at least two cylinders from both the first and last loads placed on each casting bed, each day. If producing more than 200 feet (60 m) of beam on the same bed, make at least two additional cylinders for each additional interval of 100 feet (30 m) or part thereof.  In general, produce the additional cylinders from a load placed in the middle of the additional member length.  The QCS shall determine the exact location for these samples.

For beams containing between 20 and 35 yards of concrete, make at least one set of two cylinders per beam.  For beams containing more than 35 yards of concrete, make at least two sets of two cylinders per beam.

Determine strength, for both strand release and final shipping, by testing a group of cylinders, which consists of one cylinder from every sample location.  Each group of cylinders shall have an average strength of what is specified in the shop drawings, and no individual cylinder shall have less than 95 percent of the specified strength. 

The inspector may require additional cylinders from locations were the concrete does not conform to mix design or placement requirements.  Include these additional cylinders in the group of cylinders for determining release and final strength.

The fabricator may place concrete in the bottom flange of a box beam before placing the interior forms and reinforcement for the upper portion of the member, provided continuous concrete placement is not interrupted for more than 45 minutes.

Screed the top surfaces of non-composite members and finish the surface with a burlap drag or other means to provide a uniform surface with a gritty texture suitable for waterproofing.

Screed the top surface of composite members and finish the surface with a wire broom, in a transverse direction and penetrating the finished surface approximately 1/4 inch (6 mm) + 1/16 inch (1.5 mm) – 1/8 inch (3 mm).

Immediately after final concrete placement and surface finishing, protect the concrete surface with a suitable enclosure until application of live steam or radiant heat.  Assure the enclosure’s ambient temperature is at least 50 °F (10 °C).  Assure the plastic concrete’s temperature before initial set doesn’t rise more than 10 °F (5 °C) per hour.  Limit the total rise before initial set to less than 40 °F (22 °C) and the maximum temperature to 100 °F (38 °C).  Record the times and concrete temperatures before initial set.

For curing with low-pressure steam, do not apply live steam directly onto the concrete forms if it causes localized high temperatures.

For accelerated curing with radiant heat, apply radiant heat using pipes circulating steam, hot oil, or hot water, or using electric heating elements.  Minimize moisture loss by covering all exposed concrete surfaces with plastic sheeting, 705.06, or by applying a liquid membrane curing compound, 705.07, to all exposed concrete surfaces.  Before bonding field-cast concrete or other materials in the finished structure, remove the curing compound from the shear faces of composite members and other surfaces.

Start initial application of the steam or heat 2 to 4 hours after final concrete placement.  If using retarders, start applying the steam or heat 4 to 6 hours after final concrete placement.  If determining the time of initial set according to ASTM C 403, these time limits do not apply.  Record and report the actual time of concrete placement of the last load, placement of enclosure and initial set time.

Apply live steam or radiant heat so the ambient temperature within the curing enclosure does not gain more than 40 °F (22 °C) per hour until reaching the curing temperature.  Do not exceed 160 °F (71 °C).  Only use a maximum temperature of 180 °F (82 °C) if the fabricator documents to the Department that delayed ettringite or alkali silica reaction is not at issue.  Maintain the maximum curing temperature until the concrete has reached the required release strength.  De-tension the strands immediately upon completing the accelerated curing. Keep a record of the time the application of heat began, and curing temperatures throughout the entire curing process.

Neatly fill cavities in the exposed surface of beams with nonshrink grout.  Clean the concrete, and apply and cure the grout according to the manufacturer’s published recommendations.  Reject beams with honeycombing that impairs the member’s performance.

515.16  Release of Prestressing Strands.  Do not release prestressed strands until the concrete reaches a minimum strength of 4000 pounds per square inch (28.0 MPa), or plan defined release strength.  Determine strength of concrete by testing cylinders produced according to AASHTO T 23 and cured in the same method as the member.  Test cylinders in the fabricator’s laboratory.  Assure all tested cylinders obtain the required strength of 4000 pounds per square inch (28.0 MPa) or the plan defined release strength.  Provide the Department the ability to witness the cylinder testing by notifying the inspector before testing.

Before releasing prestressed strands, loosen or remove forms and hold-downs and all other attachments restricting either horizontal or vertical movement of prestressed members.  Release the strands immediately upon completing accelerated curing.  Heat release and burn the strands simultaneously between each beam and at all exposed points between anchorages, and follow an approved pre-determined pattern, to equalize the forces being transferred to the various areas of the cross-section of the member.  Submit any alternative strand release plans during the prefabrication meeting to OMM for approval. For heat release, use a low-oxygen flame to uniformly heat at least a 4 inch (100 mm) long section of strand before completely cutting the strand.

515.17  Fabrication Tolerances.  Construct all members to conform to the following tolerances.

BEAM DIMENSIONAL TOLERANCES

Description

Box Beam

I Beam

Length of beam

±1/8" per 10 ft (1 mm/m)

max ±3/4" (19 mm)

±1/8" per 10 ft (1 mm/m)

max ±1" (25 mm)

Depth of beam

±1/4" (6 mm)

-1/4" (6 mm)

+1/2" (13 mm)

Depth of I beam flange including fillets

N/A

±1/4" (6 mm)

Flange Width

±1/4" (6 mm)

-1/4" (6 mm)

+3/8" (10 mm)

Flange Thickness excluding fillets

   a) Top

-0

+1/2" (13 mm)

±1/4" (6 mm)

   b) Bottom

-1/8" (3 mm)

+1/2" (13 mm)

±1/4" (6 mm)

Width Web

N/A

-1/4" (6 mm)

+3/8" (10 mm)

Width beam walls

-1/4" (6 mm)

+3/8" (10 mm)

N/A

Width of Void

±1/2" (13 mm)

N/A

Height of Void

±1/2" (13 mm)

N/A

Box Beam Diaphragm spacing

±2" (50 mm)

N/A

Deviation from True Vertical

±1/8" (3 mm)

1/8" per ft (8 mm per m)

Deviation from Skew Angle

±1/2" (13 mm)

±1/2" (13 mm)

Beam Accessory Tolerances

Description

Box Beam

I Beam

Position of railing anchors

±1/4" (6 mm)

N/A

Position of lifting devices

±6" (150 mm)

±6" (150 mm)

Positions of anchor dowels and tie rods, inserts

±1/2" (13 mm)

±1/2" (13 mm)

Deviation from skew angle

±1/2" (13 mm)

±1/2" (13 mm)

Beam Strand Tolerances

Description

Box Beam

I Beam

Strand tendon position

±1/4" (6 mm)

±1/4" (6 mm)

Strand CG position

±1/4" (6 mm)

±1/4" (6 mm)

Reinforcing Steel Tolerances

Description

Box Beam

I Beam

Clear cover

-0

+1/4" (6 mm)

-0

+1/4" (6 mm)

Splice lengths

-1 1/2" (38 mm)

-1 1/2" (38 mm)

Stirrup spacing in anchorage zone

±1/4" (6 mm)

±1/4" (6 mm)

Stirrup spacing outside anchorage zone

±1" (25 mm)

±1" (25 mm)

Stirrup extension above top flange

-1/2" (13 mm)

+1/4" (6 mm)

-3/4" (19 mm)

+1/4" (6 mm)

Beam Sweep and Camber Tolerances

Description

Box Beam

I Beam

Horizontal Sweep

±1/8" per 10 ft (1 mm/m)

max ±3/4" (19 mm)

±1/8" per 10 ft (1 mm/m)

max ±1" (25 mm)

Max Gap between beam

1" (25 mm)

N/A

Deviation from Design camber (DC) [1]

±1/8" per 10 ft (1 mm/m)

max ±1/2" (13 mm)

±1/8" per 10 ft (1 mm/m)

For member lengths ≤ 80 ft

max ±1/2" (13 mm)

For member lengths > 80 ft

max ±1" (25 mm)

Variation in camber between beams in same span

max 1/2" (13 mm)

N/A

[1]  Design camber (DC)

      For DC [0 to 30 days] = [Dcp - Dcr] × [beam age / 30] + Dcr

      For DC [> 30 days] = [Dltc - Dcp] × [(beam age - 30) / 690] + Dcp

Where:

      Dcr    = Design plan camber at release (0 days)

      Dcp   = Design plan camber at paving (30 days old)

      Dltc   = Design plan long term camber (720 days old)

515.18  Prestressed Member Acceptance and repair.  Throughout the fabrication process reject all prestressed members not meeting specification requirements.

For all rejected members provide the Department with a complete description of the rejection, and unless waived by the Director, an Ohio registered professional engineer’s written evaluation of the criticalness of the rejection and the professional engineer’s proposed repair method that will repair the rejected member to an acceptable condition. The Department will determine the acceptability of the member and the repair procedure.  If acceptable, the fabricator will only make repairs witnessed by the Department’s inspector unless waived by Director. 

Use the Precast/Prestress Concrete Institute’s Manual for the evaluation and repair of Precast, Prestressed Concrete Bridge Products MNL-137-06 as a general guide.

515.19  Handling Storage, Transportation, and Erection.  Handle, store, transport, and erect the members in an upright position.  The direction of support reactions during storage and transportation shall be the same as the member will experience in its in-service position.  Do not ship prestressed members until the concrete obtains its 28-day design strength and the inspector’s approval.

Provide at least 30 inches (762 mm) horizontally between each beam for inspection.  Provide at least 8 inches (200 mm) of vertical clearance from the bottom.  Use storage support locations as close as practical to the in-service support locations.  During storage, provide unyielding horizontal supports and bracing capable of maintaining the members in a vertical position. 

Transportation support locations shall be the sole responsibility of the fabricator with respect to member stresses and safe delivery to the job site. Obtain the Director’s written approval to transport the members in a position other than vertical., 

Provide lifting devices capable of withstanding the required loads to lift and erect the members.  During erection, accurately place the prestressed beams on their bearings to ensure a uniform load on all bearings.  When shifting a member, lift the member up completely off of its bearings.  Temporarily brace the first I-beam erected to its substructure support units in the vertical position before releasing the beam from the crane.  Tie each subsequent I- beam to the previously braced beam(s).  Provide bracing after erection adequate to prevent sliding, tipping, or other movement that may result from high winds, creeping down the grade, or other causes, until placement of the diaphragms.  Within any one day erect and brace at least 2 adjacent members in any one span before suspending operations for the day.

Place box beams to ensure a correct fit of the keyways and to ensure proper grouting of the keyways.  After placing the beams and installing tie devices, fill the longitudinal keyways using non shrink keyway grouts, 705.22, approved by OMM.  Mix, install, and cure the grout according to the manufacturer’s published recommendations to obtain a design compressive strength of 5000 pounds per square inch (34.5 MPa).

Do not allow vehicular load on an individual prestressed concrete box beam until the grout in the keyway obtains the specified design strength of 5000 pounds per square inch (34.5 MPa).

At the Director’s discretion, repair or replace members damaged by improper handling, storage, transportation, or erection.

515.20  Safety Requirements.  Provide effective safety measures to prevent injuries to personnel due to breakage of strands or failure of anchorage devices during the tensioning operations.  Provide adequate protection and assure the OMM inspector can perform inspection of beams and manufacturing processes.  The Department inspector will report any inadequate safety precautions to the plant QCS and to OMM if fabricator remedial action is not taken.  OMM inspectors will follow safety rules established by the fabricator, at a minimum.  Where fabricator safety rules interfere with the inspectors duties, the process should be altered to allow the inspections to be performed while maintaining the required level of safety.

515.21  Method of Measurement.  The Department will measure Prestressed Concrete Bridge Members by the number of members.

The Department will measure the intermediate diaphragms by the number of each placed.

515.22  Basis of Payment.  Payment for prestressed concrete beams include all inserts, sleeves, fittings, reinforcing steel fully or partially encased in the members, and all transverse tie rods necessary to complete this work.

The Department will pay for concrete diaphragms, steel diaphragms, and bearing plates or pads, or other expansion materials, as separate items.

The Department will not pay for repaired or replaced members damaged by improper handling, storing, transporting, or erecting.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

515             Each                                Prestressed Concrete Non- Composite Box
                                                               Beam Bridge Members, Level 1         

515             Each                                Prestressed Concrete Composite Box
                                                               Beam Bridge Members, Level 1         

515             Each                                Straight Strand Prestressed Concrete Bridge 
                                                               I-Beam Members, Level 2                  

515             Each                                Draped Strand Prestressed Concrete Bridge 
                                                               I-Beam Members, Level 3                  

515             Each                                Intermediate Diaphragms

ITEM 516  EXPANSION AND CONTRACTION JOINTS JOINT SEALERS AND BEARING DEVICES

516.01  Description

516.02  Fabrication

516.03  Coating

516.04  Materials

516.05  Expansion and Contraction Joints

516.06  Joint Sealers

516.07  Bearing Devices

516.08  Method of Measurement

516.09  Basis of Payment

516.01  Description.  This work consists of fabricating, assembling, constructing, coating, and installing expansion and contraction joints, vertical extension of structural expansion joints, joint sealers, or bearing devices of the type and size specified.

516.02  Fabrication.  Fabricate metal joint armor and metal bearings according to Items 513.  Select a fabricator that is at least pre-qualified at level SF.  The Department will base final acceptance of fabricated members on the Engineer’s approval that the fabricated items that can be successfully incorporated into the structures.  Submit mill test reports for structural steel, steel castings, bronze, and sheet lead certified according to 501.06.

516.03  Coating.  Coat exposed steel bearings according to Items 513 and 514 that are to be attached to structural steel.  Galvanize bearings according to 711.02 that are to be attached to concrete beams.

Coat metal parts of expansion joints with metalized 100 percent zinc wire.  Prepare the surface to be coated and apply coating as required by The Society of Protective Coatings SSPC-CS-23.00(1).  Apply coating to a minimum thickness of 6 mils.

Repair metalized coatings damaged during fabrication by removal of the damaged coating and reapplication as specified above.  Repair metalized or galvanized coatings damaged during shipping, construction, or field welding according to 711.02.

516.04  Materials.  Furnish materials conforming to:

Structural steel.............................................................. 513

Bearing bolts and anchor rods................................. 711.10

Painting......................................................................... 514

Joint sealer, hot applied............................................ 705.04

Preformed elastomeric compression stager.............. 705.11

Neoprene Sheeting................................................... 705.13

Steel castings........................................................... 711.07

Sheet copper............................................................ 711.15

Bronze........................................... 711.16, 711.17, 711.18

Sheet lead................................................................. 711.19

Preformed bearing pads........................................... 711.21

Elastomeric bearings................................................ 711.23

Preformed fillers...................................................... 705.03

Swedged anchor bolts or bars*................................ 711.10

*   Fabricated by deforming a minimum of 20 percent of the embedded bolt surface with deformations whose radial dimensions are 15 to 20 percent of the bar diameter.

516.05  Expansion and Contraction Joints.  Ensure that expansion joints are completely open for the dimension specified for their full length.  Remove stones, forms, or other materials that interfere with expansion.

Finish the surface adjacent to preformed expansion joints to a smooth, uniform surface.  Use methods that do not interfere with the free compression of the joint material to anchor the expansion joint materials.  The joint material shall neatly fill the space, and have a uniform thickness for the full extent of the joint.

For Integral and Semi-Integral Abutment Expansion Joint Seals, install a 3 foot wide neoprene sheet for waterproofing of the backside of the joint between the integral backwall and the bridge seat at locations shown in the plans. Secure the neoprene sheeting to the concrete with 1 1/4 inch by #10 gage (length × shank diameter) galvanized button head spikes through a 1 inch outside diameter, #10 gage galvanized washer. Maximum fastener spacing is 9 inches. Use of other similar galvanized devices, which will not damage either the neoprene or the concrete, will be subject to the approval of the Engineer.

Center the neoprene strips on all joints. For horizontal joints, secure the horizontal neoprene strip by using a single line of fasteners, starting at approximatel 6 inches from the top of the neoprene strip. For the vertical joints secure the vertical neoprene strip by using a single vertical line of fasteners, starting at approximately 6 inches from the vertical edge of the neoprene strip nearest to the centerline of roadway.

For vertical joints, install two additional fasteners at 6 inches, center to center, across the top of the neoprene strip on the same side of the vertical joint as the single vertical row of fasteners is located. The vertical neoprene strips shall completely overlap the horizontal strips. Lap lengths of the horizontal strips that are not vulcanized or adhesive bonded, shall be at least 1 foot in length, or 6 inches in length if the lap is vulcanized or adhesive bonded. No laps are acceptable in vertically installed neoprene strips. The neoprene sheeting shall be 3/32 inch thick general purpose, heavy-duty neoprene sheet with nylon fabric reinforcement.

516.06  Joint Sealers.  Before applying joint sealer to the surface, clean the concrete of foreign matter, curing compounds, oil, grease, dirt, free water, and laitance and clean steel by sand blasting.

Apply joint sealer with a minimum depth of 1 inch (25 mm) at its thinnest section.  Fill joints to within 1/4 inch (6 mm) of the roadway surface.

Separate joint sealer from contact with asphalt concrete using a barrier of foil or other material that is impervious to the joint sealer.

As required to prevent bonding of the joint sealer with a joint surface, place a suitable bond breaker barrier before applying the joint sealer.

Remove joint sealer that did not bond to the joint face as intended within 24 hours after placing.  Clean the joint by sandblasting and reseal the joint.

Mix and place joint sealer according to the manufacturer’s instructions.  Provide the Engineer with a copy of the manufacturer’s instructions.

Protect joint sealer with an impervious masking tape during the application of concrete protective coatings containing mineral spirits.

516.07  Bearing Devices.  For sliding plates, lubricate the sliding surfaces with flake graphite, and superimpose plates on each other with their edges flush.

Accurately set, level and align elastomeric bearings, bearing plates and bolsters. Set bearing plates and bolsters on 1/8-inch (3 mm) thick sheet lead conforming to 711.19.

Set bearing plates or bolsters on bridge seat areas that are flat and smoothly finished.  If the bridge seat area is high or uneven, use a bushhammer or grinder followed by thin film of portland cement mortar or paste to fill the pitted surface to bring the seat area to the proper elevation and provide a level, even surface.  If the bridge seat area is low, use steel plate shims of the same bearing area as the bearing plates and bolsters to bring the seat area to the proper elevation.

Set elastomeric bearing pads directly on the concrete surface. If the beams seats are sealed with an epoxy or non-epoxy sealer prior to setting the bearings, do not apply sealer to the concrete surfaces under the proposed bearing locations. If these locations are sealed, remove the sealer to the satisfaction of the Engineer before setting the bearings. Perform this removal at no expense to the Department.

Position rockers, elastomeric bearings, and rollers so that, when the completed bridge is at 60 °F (16 °C), the rockers and elastomeric bearings are vertical and the rollers are centered on the base. If the steel is erected at an ambient temperature higher than 80 °F or lower than 40 ºF and the bearing shear deflection exceeds 1/6 of the bearing height at 60 ºF ± 10 ºF, raise the beams or girders to allow the elastomeric bearings to return to their undeformed shape at 60 ºF ± 10 ºF.

Set anchor bolts for bearing devices that are clear of the beam or girder flanges, in the concrete after erecting the main structural steel, except as specified below for bearing devices at abutments.  Place reinforcing steel in the bridge seat to not interfere with the drilling of anchor holes.  Accurately set anchor bolts in the holes and embed the anchor bolts in cement mortar.  Until the anchors’ are installed, prevent water from entering and or freezing in the anchor bolt holes.

If structural steel interferes with the setting of the anchor bolts, set the anchor bolts before erecting the steel.  The Contractor may determine the location of the bolts by using a template and form holes or embed the bolts when placing concrete or, drilling holes in the hardened concrete.

Install anchor bolts to project at least 1/4 inch (6mm) beyond the nut when tightened.  Damage or burr the threads on the projecting end of the bolt after the nut is tightened.  The bolt threads shall not extend to the planes of the contact surfaces between the connected parts.  Include the length of two additional threads to the specified thread length of the bolt to allow for thread runout.  Washers no thicker than 1/4 inch (6mm) are permitted under the nut.

Permanently fasten bearing devices to the abutments, steel beams, or girders after backfilling the abutments to within 2 feet (0.6 m) of the top of the bridge seat.

Where the load plate of an elastomeric bearing is to be connected to the structure by welding, control the welding so that the plate temperature at the elastomer bonded surface does not exceed 300 °F as determined by use of pyrometric sticks or other temperature monitoring devices.

516.08  Method of Measurement.  The Department will measure the specified items by the number of each, square feet (square meters), pounds (kilograms), or feet (meters) horizontally along the joint centerline and between the outer limits of the fabricated joint.

For deck resurfacing, the Department will measure Structural Steel Expansion Joints extending vertically by the actual horizontal length of joint.

516.09  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

516             Foot or Pound                 Structural Steel Expansion
                       (Meter or Kilogram)        Joints

516             Foot (Meter)                    Structural Expansion Joints
                                                               Including Elastomeric ___ Seals

516             Foot (Meter)                    Elastomeric Compression
                                                               Seals for Structural Steel Joints, ___ Width

516             Foot (Meter)                    Folder Copper Strip ___

516             Foot (Meter)                    Vertical Extension of
                                                               Structural Expansion Joints

516             Square Foot                     ___ Preformed Expansion
                       (Square Meter)                Joint Filler

516             Foot (Meter)                    Joint Sealer

516             Each, Foot,                      Bearing Devices
                       Square Foot, Pound
                       (Meter, Square Meter,
                       Kilogram)

516             Each, Square Foot           ___ inch (___ mm)
                       (Square Meter)                Elastomeric Bearing Pad

516             Each                                Elastomeric Bearing with

                                                               Internal Laminates Only

516             Each                                ___ ´ ___ ´ ___ Elastomeric Bearing
                                                               with Internal Laminates and
                                                               Load Plate ___ ´ ___ ´ ___

516             Square Foot                     1/8-inch (3 mm) Preformed
                       (Square Meter)                Bearing Pads

ITEM 517  RAILINGS

517.01  Description

517.02  Fabrication

517.03  Materials

517.04  Construction Methods, General

517.05  Steel and Iron Railings

517.06  Aluminum Railings

517.07  Method of Measurement

517.08  Basis of Payment

517.01  Description.  This work consists of furnishing, constructing, coating, and erecting the type of railing specified.  This work also consists of providing and galvanizing structural posts, anchors, and connections.

517.02  Fabrication.  Fabricate railing according to Items 513.  Select a fabricator that is at least prequalified at level SF.  The Department will base final acceptance of fabricated members on the Engineer’s approval that the fabricated items that can be successfully incorporated into the structures.  Submit mill test reports for structural steel, steel castings, bronze, and sheet lead certified according to 501.06.

517.03  Materials.  Furnish materials conforming to:

Concrete, Class QC 2........................................... 499, 511

Reinforcing steel................................................... 509, 709

Structural steel.............................................................. 513

Preformed fillers

.... (sponge rubber or PVC)........................ 705.03, 711.28

Steel tubing.............................................................. 707.10

Paint.............................................................................. 708

Metal deep beam rail................................................ 710.06

Ductile iron casings................................................. 711.13

Aluminum................................................................ 711.20

Timber..................................................................... 711.26

Stainless steel fasteners............................................ 730.10

Pipe.......................................................................... 748.06

Submit mill test reports for structural steel and aluminum according to 501.06.

517.04  Construction Methods, General.  Construct railings as shown on the plans.  Install posts for metal railings normal to the grade line.  Install the tops of railings parallel to the grade line.

Remove or release shoring or falsework supporting the superstructure before placing railing that has no expansion joints or that is on the concrete parapet.

517.05  Steel and Iron Railings.  Unless specified to paint according to Item 514, galvanize all parts of steel and iron railings.

Erect metal deep beam rail elements according to Item 606.

517.06  Aluminum Railings.  Use alloy conforming to 711.20 for aluminum railings.

Give the extreme outer surfaces of cast railing posts a 40-grit finish.  The Contractor is not required to provide a special finish for other portions of railings.  Do not scratch, dent, or cause other damage to railings that may affect the durability or appearance of the railing.

Use galvanized steel anchor bolts and hexagon nuts conforming to 711.02.  Coat the entire projecting portion of anchor bolts and fill the space between the bolts and post base with an aluminum-impregnated caulking compound.

Where aluminum contacts concrete or stone masonry, thoroughly coat the contact surfaces with an aluminum-impregnated caulking compound or with a heavy asphalt material paint pigmented with aluminum powder or paste thereby providing an aluminum appearance.  Where aluminum or aluminum shims contacts different metal, thoroughly coat the contact surface with an aluminum-impregnated caulking compound or place a synthetic rubber impregnated fabric gasket between the metals.

Weld only where shown on the plans using inert gas shielded metal-arc or tungsten-arc method without flux, or by other approved methods.

517.07  Method of Measurement.  The Department will measure Railing by the number of feet (meters) of railing including end posts.  If deep beam guardrail is used, the Department will measure the length of railing between the first posts off the bridge excluding the first posts off the bridge.  If hand rails or tubular backup rails are used, the Department will not measure any portions extending beyond the first posts off the bridge.  If twin steel tube bridge railing is used, the Department will measure the length of the railing between the second post off the bridge including the second post.

517.08  Basis of Payment.  The cost of hand rails or tubular backup rails extending beyond the measured limits are included for payment in the unit price bid for the measured length.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

517             Foot (Meter)                    Railing (___)

ITEM 518  DRAINAGE OF STRUCTURES

518.01  Description

518.02  Fabrication

518.03  Materials

518.04  General

518.05  Porous Backfill

518.06  Pipe

518.07  Scuppers

518.08  Excavation

518.09  Method of Measurement

518.10  Basis of Payment

518.01  Description.  This work consists of constructing drainage systems.

518.02  Fabrication.  Fabricate scuppers according to Item 513.  Select a fabricator that is at least pre-qualified at level SF.  The Department will base final acceptance of all fabricated members on the Engineer’s approval that the fabricated items can be successfully incorporated into the structures.  Submit mill test reports for structural steel, steel castings, bronze, and sheet lead certified according to 501.06.

518.03  Materials.  Furnish materials conforming to:

Scuppers, structural steel and cast steel......................... 513

Metal pipe..................................................................... 707

Plastic pipe.................................................. 707.33, 707.45

Other metals.................................................................. 711

Filter fabric, Type A................................................ 712.09

Furnish pipe specials of a grade at least as high as the type of pipe specified.

Furnish porous backfill consisting of gravel, stone, or air-cooled blast furnace slag, with a NO. 57 size gradation according to Table 703.01-1.  The sodium sulfate soundness loss shall not exceed 15 percent.

Furnish ACBF slag conforming to Supplement 1027.

518.04  General.  As shown on the plans, connect all parts to new or existing sewers or other outlets.

When installing to superstructure, take into account the deflection of spans under full dead load.

518.05  Porous Backfill.  Place porous backfill as shown on the plans.  When not shown on the plans, place backfill at least  2 feet (0.6m)  thick behind the full length of abutments, wing walls, and retaining walls.  Measure the thickness of porous backfill normal to the abutment or wall face.  The Contractor may leave undisturbed rock or shale within 18 inches (0.5 m) of the abutment or wall.  Place 2 ft³ (0.23 m³) of bagged No. 3 aggregate at each weep hole to retain the porous backfill.  Place the porous backfill for the full width of the trench and extend it to the bottom of the approach slab or base, as shown in the plans.  .

518.06  Pipe.  For drain pipe leading down from the superstructure, use either galvanized steel pipe, 748.06; or plastic pipe, 707.45.  Provide specials, elbows, tees, wyes, and other fittings essential for a complete and satisfactory installation of the same material and quality as the pipe.  Construct watertight joints of adequate strength.  In steel pipe, weld joints or use clamp-type couplings having a ring gasket.  In plastic pipe, make joints according to the applicable ASTM standard.  Securely fasten the pipe to the structure with hanger or clamp assemblies that are galvanized according to 711.02.

Place subsurface pipeas shown in the plans..  If the plans require drainage pipe in the porous backfill, provide plastic pipe conforming to 707.33.

For corrugated metal pipe, perforated specials are not required and the Contractor may make bends with adjustable elbows conforming to the thickness requirements of the pipe specifications.

518.07  Scuppers.  Construct secure and watertight connections, including the connections to adjacent concrete.  Provide castings, true to form and dimension.  Weld the joints of structural steel scuppers.  Galvanize scuppers according to 711.02.

518.08  Excavation.  Excavate all material encountered to the dimensions necessary to provide ample space at least to install pipe or other drainage facility behind abutments and for outlets.

518.09  Method of Measurement.  The Department will measure Porous Backfill and Porous Backfill with Filter Fabric by the number of cubic yards (cubic meters) or lump sum.  The Department will measure pipe specials by the same method as the pipe.  If pipe is by the foot (meter), the Department will measure the pipe along its centerline.

518.10  Basis of Payment.  The cost to backfill, if not separately itemized in the Contract, and excavation is incidental to the drainage facility that necessitates them.

The Department will include bagged aggregate with porous backfill for payment.          

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

518             Cubic Yard                      Porous Backfill
                       (Cubic Meter) or
                       Lump Sum

518             Cubic Yard                      Porous Backfill with Filter Fabric
                       (Cubic Meter) or            
                       Lump Sum

518             Foot (Meter)                    ___ inch (___ mm) ___ Pipe,

                                                               Including Specials               

518             Each                                Scuppers, Including Supports
518             Pound or Foot                 Trough Horizontal Conductors
                       (Kilogram or Meter)       

518             Pound or Foot                 Pipe Horizontal Conductors
                       (Kilogram or Meter)

518             Foot (Meter)                    ___ inch (___ mm) Pipe
                                                               Downspout Including Specials

ITEM 519  PATCHING CONCRETE STRUCTURES

519.01  Description

519.02  Materials

519.03  Removal of Disintegrated Concrete

519.04  Preparation of Surface

519.05  Placing of Reinforcing Steel

519.06  Placing, Finishing, and Curing of Concrete

519.07  Method of Measurement

519.08  Basis of Payment

519.01  Description.  This work consists of removing all loose and disintegrated concrete; preparing the surface; furnishing and placing reinforcing steel including welded steel wire fabric, dowels, and expansion bolts; placing forms; and placing concrete patches, including curing of same.

519.02  Materials.  Furnish materials conforming to:

Concrete, Class QC 2 *........................................ 499, 511

Dowels...................................... 709.01, 709.03, or 709.05

Reinforcing steel........................................................... 509

Welded steel wire fabric.......................... 709.10 or 709.12

*   For aggregate for superstructure, conform to 703.02 and use No. 57 or 8 size.

519.03  Removal of Disintegrated Concrete.  Remove all loose and disintegrated concrete from the areas to be repaired in such a manner and to such an extent as to expose a sound concrete surface.  Provide patches at least 4 inches (100 mm) deep, except on top horizontal surfaces, provide patches at least 3 inches (75 mm) deep.  Remove sound concrete (beneath the disintegrated concrete) for a depth of not less than 1/4 inch (6 mm) and not more than 1 inch (25 mm), provided that the above minimum depth of patch is maintained.  Make square or, preferably, slightly undercut shoulders having a depth of not less than the specified minimum depth of the patch at the edges of all patches.

Only use pneumatic or hand tools that give results satisfactory to the Engineer in the removal of the disintegrated concrete and in preparing and shaping the areas to be patched.

If working around reinforcing steel, avoid damaging or debonding any reinforcing steel, that is un-corroded and completely embedded in sound concrete.  Ensure there is no shattering of the concrete, beyond the area to be patched. If the area around the reinforcing steel is either embedded in unsound concrete or the reinforcing steel is exposed during removal, continue to remove the concrete around the reinforcing steel to completely expose the reinforcing and provide at least a 1 inch (25 mm) clearance around the reinforcing.  The 1 inch (25 mm) clearance may be reduced to 1/2 inch (13 mm) if the patching concrete uses No. 8 coarse aggregate.

Adequately support reinforcement that is loose, and tie it back into place.  Replace reinforcement damaged during removing concrete.

519.04  Preparation of Surface.  After removing all disintegrated and loose concrete, properly shape the area to be patched, and install dowels or expansion bolts as necessary to hold the wire fabric to be used in the patch.  Thoroughly clean the surface of the area to be patched and all exposed reinforcing steel of all dirt, dust, or other foreign materials with water, air under pressure, or any other method that produces satisfactory results.  Thoroughly drench the surface with clean water.  Before placing the concrete, allow the surface to dry to a damp condition.

519.05  Placing of Reinforcing Steel.  The Department will not require reinforcement for patches on top horizontal surfaces.  Reinforce patches on other surfaces with welded steel wire fabric either 2 ´ 2 inch (50 ´ 50 mm) using wire size number W 0.9, or 3 ´ 3 inch (75 ´ 75 mm) using wire size number W 1.4.  Cover the entire area of the patch with the fabric, and place and hold the fabric approximately 1 inch (25 mm) from the completed exposed surface of the patch.  Securely fasten the fabric to the reinforcing steel in the original structure exposed in removing the disintegrated concrete.  If no reinforcing steel is exposed or it is not practical to fasten the fabric to exposed steel, install dowels or expansion bolts at a distance not to exceed 18-inch (0.5 m) centers in both directions, and fasten the fabric to these dowels or bolts.

519.06  Placing, Finishing, and Curing of Concrete.  Place and finish Class QC 2concrete according to Items 499 and 511.

Remove the forms within 24 hours after placing the concrete, and finish all exposed surfaces by rubbing to match the surrounding concrete.  Apply membrane curing according to 511.17, Method B, immediately after rubbing the surfaces.

After curing and before final acceptance, sound all patched areas.  Remove and replace all unsound or visibly cracked areas.

519.07  Method of Measurement.  The Department will measure Patching Concrete Structures by the number of square feet (square meters) of the exposed surfaces of all completed patches, irrespective of the depth or thickness of the patch.  If a patch includes corners or edges of members such as beams, curbs, and columns, the Department will measure all of the exposed surfaces.  If a patch extends completely through a member of a slab, the Department will measure both exposed surfaces.

519.08  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

The Department will not pay for replacing reinforcement damaged during concrete removal.

The Department will not pay for removing and replacing of patched areas that are unsound or visibly cracked.

Item           Unit                                Description

519             Square Foot                     Patching Concrete Structures
                       (Square Meter)

ITEM 520  PNEUMATICALLY PLACED MORTAR

520.01  Description

520.02  Materials

520.03  Removal of Concrete

520.04  Reinforcement

520.05  Preparation of Repair Area

520.06  Mixing

520.07  Proportions

520.08  Pressures

520.09  Preconstruction Testing

520.10  Placing

520.11  Inspection and Testing

520.12  Method of Measurement

520.13  Basis of Payment

520.01  Description.  This work consists of repairing the surface of concrete structures using pneumatically placed mortar where the depth of repair generally is less than 6 inches (150 mm).

520.02  Materials.  Furnish materials conforming to:

Reinforcing steel........................................................... 509

Portland cement ................ 701.01 through 701.05, 701.09

Fine aggregate............................................. 703.02, 703.03

Welded steel wire fabric.......................... 709.10 or 709.12

Use water free from sewage, oil, acid, strong alkalis, vegetable matter, clay, and loam.  Potable water is satisfactory for use in mortar.

520.03  Removal of Concrete.  In areas to be repaired, remove all loose, soft, honeycombed, and disintegrated concrete, plus a 1/4-inch (6 mm) depth of sound concrete.  Remove additional concrete as necessary to permit the placement of the minimum specified mortar thickness of not less than 1 1/2 inches (38 mm), except on top horizontal surfaces where it shall not be less than 3/4 inch (19 mm).  Perform all work in such a manner as not to damage or shatter the concrete that is to remain in place.  Make square or, preferably, slightly undercut shoulders at the edge of all repair areas.

Encase reinforcing bars exposed after concrete removal, as required above, with pneumatically placed mortar.  If these bars are less than 1 inch (25 mm) from the proposed finished surface of mortar, drive them back, if practical, into recesses cut in the masonry to obtain that coverage.  If this is impractical because of large concentrations of reinforcing bars, provide the minimum specified mortar coverage by modifying the finish surface as the Engineer approves.

If the bond between the concrete and a primary reinforcing bar has been destroyed, or if more than one-half of the periphery of a bar has been exposed, remove the adjacent concrete to a depth that will provide a minimum 3/4-inch (19 mm) clearance around the bar, except where other reinforcing bars make this clearance impractical.  Adequately support reinforcing that has become loose, and tie it back into place.  Replace reinforcement that is damaged during construction operations.

Only use pneumatic or hand tools that give results satisfactory to the Engineer in the removal of concrete and in preparing and shaping the areas to be repaired.

If working around reinforcing steel, avoid loosening the steel, or shattering the concrete around it, beyond the repair area.

520.04  Reinforcement.  If pneumatically placed mortar is specified to repair areas of unsatisfactory concrete, or for surface coverage of exposed reinforcing steel, place wire fabric in all areas where the thickness of the mortar patch is 1 1/2 inches (38 mm) or more.  For areas where the thickness of the mortar patch exceeds 4 inches (100 mm), use a single layer of wire fabric to reinforce each 4-inch (100 mm) thickness of patch or fractional part thereof.  Use fabric that is either 2 ´ 2 inches (50 ´ 50 mm) using wire size number W 0.9, or 3 ´ 3 inches (75 ´ 75 mm) using wire size number W 1.4.  Place all fabric parallel to the proposed finished surface.  Completely encase each layer of fabric in mortar that has taken its initial set before the succeeding layer of fabric is applied.  Ensure that fabric supported adjacent to the prepared masonry surface is no closer than 1/2 inch (13 mm) to that surface.  Overlap adjacent sheets of fabric by 6 inches (150 mm), and securely tie them together.  Carefully pre-bend fabric before installation to fit around corners and into re-entrant angles.  Never spring fabric into place.

Place all steel items, including reinforcing bars and wire fabric, no closer than 1 inch (25 mm) to the proposed finished surface of mortar.

Support wire fabric with anchor bolts except where existing reinforcing steel in the repair area is considered by the Engineer to be satisfactory for this purpose.  Construct anchors of 1/4-inch (6 mm) minimum diameter expansion hook bolts, and ensure that each bolt has sufficient engagement in sound masonry.  For repairs that are generally 4 inches (100 mm) thick or less, space anchors no more than 12 inches (0.3 m) and 18 inches (0.5 m), center-to-center, on overhead and vertical surfaces, respectively, and 36 inches (1.0 m), center-to-center, on top horizontal surfaces.  For repairs that exceed 4 inches (100 mm) in thickness, ensure that the anchor bolts are capable of supporting three times the weight of suspended mortar and two times the weight of mortar on vertical surfaces.  Use at least three anchors for each patch.

If specified, thoroughly clean reinforcing exposed in the original structure, or exposed after removals as required above, and restore any appreciable reduction in steel area as directed.

520.05  Preparation of Repair Area.  After removing all unsatisfactory concrete, properly shaping the sound concrete surface, placing dowels and expansion hook bolts, and restoring steel area as directed, and within 24 hours before placing the mortar, blast clean all surfaces to which the mortar is to bond, including exposed reinforcing steel, existing concrete, and the work face of any previously placed mortar, to remove all spalls, laitance, and contaminants detrimental to the achievement of an adequate bond.  The Contractor may blast clean these surfaces using high-pressure water blasting with or without abrasives in the water, abrasive blasting with containment, or vacuum abrasive blasting.  If a bonding compound is not specified, drench the prepared masonry surface with water and keep the prepared surface wet during the 2 hours preceding the placement of the mortar.  Ensure that all surfaces are damp, but without free water, while placing mortar.  The Engineer will approve the preparation and condition of all surfaces immediately before the application of the mortar.

520.06  Mixing.  Thoroughly dry mix the materials in a batch mixer.  Before placing the mixture in the hopper of the cement gun, remove all materials and lumps over 1/4 inch (6 mm) in size by screening.

Apply the screened sand and cement to the masonry surface within 1 hour after being combined.

520.07  Proportions.  Ensure that the mixture as placed in the hopper has a ratio of one volume of portland cement to three volumes of sand.

520.08  Pressures.  Use at least 35 pounds per square inch (240 kPa) pneumatic pressure at the cement gun in placing the mixed material.  If more than 100 feet (30 m) of hose or a greater lift than 25 feet (7.5 m) is used, increase the pressure proportionately.  Maintain the water at a uniform pressure of not less than 25 pounds per square inch (170 kPa) above the pressure of the air on the gage at the cement gun.

520.09  Preconstruction Testing.  Before the start of placing any mortar, perform a preconstruction test to verify the operation of the equipment, to confirm the application crew’s capability, and to ensure the pneumatically placed mortar will be of acceptable quality.

Fabricate the test panel by gunning mortar onto the plywood bottom of an open box 4-foot (1.2 m) square and 4 inches (100 mm) deep.  Install reinforcement in the test panel that matches the largest size and tightest spacing found for the reinforcement in the bridge.  Mount the box vertically and apply the mortar using the same personnel, equipment, and procedures that will be used on the project, until the box is full.  Adjust the mixing water to provide mortar of the proper consistency, but do not exceed a total water content, including the free moisture in the aggregate and water added at the nozzle, of 4.5 gallons (17 L) per sack of cement (94 pounds = 42.6 kg).

Take three cores from the test panel, and test them for compressive strength at an independent testing laboratory.  Ensure that the strength at 28 days is a minimum of 4200 pounds per square inch (29.5 MPa) or at a minimum compressive strength of 3200 pounds per square inch (22.5 MPa) at 7 days.

After taking the cores, break the test panel and allow the Engineer to carefully examine the interior portions.  Ensure that they are substantially free of hollow areas and sand pockets, and ensure that the mortar is well bonded to the reinforcement.

Have each crew proposed to perform this work fabricate a satisfactory panel before allowing that crew to apply mortar to the structure.

520.10  Placing.  Place the premixed dry cement and sand by pneumatic equipment with the proper amount of water applied in the mixing nozzle for the correct placement consistency.  Apply the mortar as dry as practical to prevent shrinkage cracking.  Use shooting strips to ensure square corners, straight lines, and a plane surface of mortar, except as otherwise permitted by the plans or approved by the Engineer.  Place shooting strips so as to keep the trapping of rebound at a minimum.  At the end of each day’s work, or similar stopping periods requiring construction joints, slope the mortar off to a thin edge.  In shooting all surfaces, ensure that the stream of flowing material from the nozzle impinges as nearly as possible at right angles to the surface being covered, and hold the nozzle 2 to 4 feet (0.6 to 1.2 m) from the working surface.

Apply a sufficient number of mortar coats to obtain the required thickness.  Finish mortar repairs flush with the original masonry surface, except as noted for areas of exposed reinforcing steel.  On vertical and overhead surfaces, do not apply any coat thicker than 1 inch (25 mm), except as the Engineer approves, and place each coat so that it will neither sag nor decrease the bond of the preceding coat.  If a successive coat is applied on mortar that has set for more than 2 hours, clean and dampen the mortar surface as required in 520.05 for the prepared masonry surface.  Remove deposits of rebound from previous shooting, whether loose or cemented.

After mortar has been placed to the desired thickness, cut off all high spots with a sharp trowel, or screed them to a true plane as determined by shooting strips or by the original masonry surface, or as directed.  If using screeds, apply them lightly to all surfaces so as not to disturb the mortar for an appreciable depth, and work them in an upward direction when applied on vertical surfaces.  Unless otherwise directed, give the finished mortar surface a flash coat about 1/8 inch (3 mm) thick.  Take special care to obtain a sightly appearance on all exposed surfaces.

Cover the pneumatically placed mortar patches with burlap or cotton mats, and keep them wet for 7 days after placing.  If it is not practical to use mats, keep the surface wet by sprinkling for the same length of time.  If the Engineer determines that the above curing procedures are impractical because of the inaccessibility of isolated repair areas, the Contractor may cure the final mortar surface according to 511.17, Method B.  Do not place pneumatically placed mortar when the air temperature is below 50 °F (10 °C) or against a surface in which there remains any frost.  Protect all mortar against cold weather according to 511.15.

520.11  Inspection and Testing.  After curing and before final acceptance, sound all patched areas.  Remove and replace all unsound or cracked areas. In addition to sounding all patches, the Department will base acceptance of the pneumatically placed mortar on 4-inch (100 mm) diameter cores taken from patched areas and tested for compressive strength. The Engineer will determine the location of the cores, with one core being taken for each 200 square feet (20 m²) of pneumatically placed mortar.  Drill the cores completely through the patched area and into the underlying sound concrete at least 1/2 inches.  Ensure that the depth of the cores is at least 4 inches.  The Engineer will visually inspect the cores at the site for hollow areas, sand pockets, and voids around reinforcing steel.  Test the cores at an independent laboratory for compressive strength.  The required minimum average compressive strength is 3000 pounds per square inch (21 MPa) at 7 days, with no single core test less than 2600 pounds per square inch (18 Mpa).

The Engineer will waive coring on small quantities or overhead patches if it is determined by sounding and visual inspection that the patches are sound.    

Remove, replace, re-inspect, and re-test all defective patches, as determined by sounding, visible cracks, or unacceptable cores.       

Fill core holes with concrete according to 519.

520.12  Method of Measurement.  The Department will measure Pneumatically Placed Mortar by the number of square feet (square meters) as determined under Method A, unless Method B or another method is specified.

A.      Method A.  The Department will measure the actual area of exposed surfaces of all completed, tested, and approved patches, irrespective of depth or thickness of the patch.  If a patch includes corners or edges of such members as beams, columns, or curbs, the Department will include all of the exposed surfaces; or if a patch extends completely through a member or a slab, the Department will include both exposed surfaces.

B.      Method B.  For unreinforced mortar repairs, the Department will measure the actual area of exposed surfaces of all completed, tested, and approved patches, irrespective of depth or thickness of patch.  If a patch includes corners, or edges of such members as beams, columns, or curbs, the Department will include all of the exposed surfaces.  For fabric reinforced mortar repairs, the Department will measure the actual surface area of fabric, complete and in place.  The Department will consider fabric laps and layers of fabric closer than 2 1/2 inches (65 mm), center-to-center of layer, as a single layer in area measurements.  The Contractor and the Engineer will agree on the measured area of wire fabric before said fabric is encased in mortar, otherwise the Department will obtain the area of the patch for pay purposes as described for unreinforced mortar repairs.

The Contractor is responsible for all test panels, coring repair of core holes, independent laboratory testing of the cores, and replacement of rejected areas and shall include them under Pneumatically Placed Mortar.

520.13  Basis of Payment.  The Department will not pay for additional reinforcement to replace that damaged by the Contractor’s operations.

The Department will not pay for removing, replacing, and re-inspecting of defective patched mortar as determined by sounding, visible cracks, or unacceptable cores.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

520             Square Foot                     Pneumatically Placed Mortar
                       (Square Meter)

ITEM 522  STRUCTURAL PLATE CORRUGATED METAL STRUCTURES ON FOOTINGS

522.01  Description

522.02  Materials

522.03  General

522.04  Method of Measurement

522.05  Basis of Payment

522.01  Description.  This work consists of furnishing structural plate corrugated metal structures of specified dimensions, including metal bearing angles or channels as required, and erecting same on concrete footings.

522.02  Materials.  Furnish plates and bolts conforming to 707.03 or 707.23.  Furnish steel bearing angles or channels conforming to 707.03 or 711.01.  Furnish aluminum bearing angles or channels conforming to 707.23.

522.03  General.  Properly support the metal bearing angle or channel in the position shown on the plans before placing footing concrete.

Erect the plates according to the manufacturer’s assembly instructions.  Hold the unsupported edges of all plates in position using temporary props.  Progressively install a sufficient number of bolts to hold the plates in position.  Do not tighten bolts until tightening will not interfere with the adjustment and matching of additional sections.  If using drift pins or pry bars, take care to prevent chipping or injury to the galvanized coating.  Tighten the bolts to a final minimum torque of 100 foot-pounds (140 Nm).

Within the limits of backfill, field coat the exterior of the 707.03 conduit above the limits of the bedding.  The coating material and application shall conform to AASHTO M 243M.  Thoroughly seal around all plate seams and bolts.  Allow asphalt mastic material to dry for 48 hours and tar base material to dry for 28 hours before placing the conduit backfill.

Backfill according to the requirements for 611.

522.04  Method of Measurement.  The Department will measure the actual number of feet (meters) of the corrugated metal structure, installed in place.  The Department will determine the length by taking the average of the two side measurements, end to end, at the point of bearing.

Excavation will be paid for under Item 203 or 503 as shown on the plans.

Concrete footings will be paid for as a separate pay item.

522.05  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

522             Foot (Meter)                    ___' ___" (___ mm) Structural Plate
                                                               Corrugated Metal Structure,
                                                               ___-inch (___ mm)

ITEM 523  DYNAMIC LOAD TEST

523.01  Description

523.02  General

523.03  Equipment

523.04  Test Report

523.05  Basis of Payment

523.01  Description.  This work consists of establishing a driving criteria for all the piles of a specified shape, cross-section, and ultimate bearing capacity or as specified on the plans to be installed in the structure.  This shall be accomplished by applying dynamic loads with a pile hammer during driving of production piles to determine driving requirements.  Apply the dynamic load to the piles using a pile hammer that is operating at its normal operating level.  Perform restrike tests when specified in the plans

523.02  General.   Perform dynamic tests on a minimum of two piles. Perform signal matching analysis of the dynamic test data on at least one of the two test piles. Perform the test according to ASTM D 4945 to determine driving requirements to achieve the required ultimate bearing values for the piles to be installed in the structure.

Perform restrike tests after piles have been driven and a minimum time specified in the plans has elapsed. When performing a restrike, warm the hammer before restriking the pile by applying at least 20 blows to another pile. Each restrike consists of performing dynamic testing on two piles and performing a signal matching analysis on one of the two piles tested.

Use the hammer selected for driving the test piles to drive all piles represented by the test piles.  If the Contractor subsequently finds it necessary to use a different hammer or multiple hammers to drive piles represented by dynamic load testing, or if the hammer performance varies subsequent to the dynamic test, complete additional tests at no additional cost to the Department.

523.03  Equipment.  Supply all required dynamic testing equipment necessary to run the test set forth in ASTM D 4945.  Supply personnel with an Advanced Master, or Expert Level Certification in High Strain Dynamic Pile Testing (HSDPT) from either Foundation QA or the Pile Driving Contractors Association (PDCA) to operate this equipment..  Supply the Engineer a copy of the certificate showing that personnel operating dynamic testing equipment are currently certified.  Supply all personnel and equipment needed to strike the test piles with the pile hammer.

523.04  Test Report.   Perform the dynamic test and signal matching analysis and immediately provide the Engineer driving criteria for any piles to be driven within the next 48 hours. Within 48 hours after performing the dynamic pile test or restrike tests, supply the Engineer with a written report confirming driving requirements for piles represented by the test. Include in the report, the required blow count for:

A.      The different strokes of the ram at 6-inch (150 mm) intervals within the expected range of operation as determined by a wave equation analysis, when open ended diesel hammers and drop hammers are used.

B.      The selected bounce pressures when closed end diesel hammers are used.

C.      The operating air pressure and stroke when an air operated hammer is used.

D.      The selected output energy or stroke when a hydraulic hammer is used.

Also include in the report a minimum depth of penetration if applicable.

Submit an electronic version of the report and data files from the testing and analysis to the Office of Geotechnical Engineering and the Office of Construction Administration.

523.05  Basis of Payment.  The Department will pay for dynamic load testing after being provided the written test at the contract price as follows:

Item           Unit                                Description

523             Each                                Dynamic Load Testing

523             Each                                Restrike

ITEM 524  DRILLED SHAFTS

524.01  Description

524.02  Materials

524.03  Contractor’s Installation Plan

524.04  Hole Excavation

524.05  Friction Type Drilled Shafts

524.06  Casings

524.07  Slurry

524.08  Excavation Inspection

524.09  Reinforcing Steel for Drilled Shafts

524.10  Concrete for Drilled Shafts

524.11  Free Fall Concrete Placement

524.12  Tremie

524.13  Pumped Concrete

524.14  Construction Tolerances

524.15  Inspection Records

524.16  Method of Measurement

524.17  Basis of Payment

524.01  Description.  This work consists of furnishing and installing drilled shafts.  The lengths of the drilled shafts shown on the plans are estimated from available subsurface information.  Furnish the proposed drilled shafts according to plan requirements, with the understanding that the actual length required is based on conditions encountered during construction and may differ from the estimated length shown on the plans.

524.02  Materials.  Furnish material conforming to:

Concrete, Class QC 2................................................... 511

Epoxy coated reinforcing steel ..................................... 509

524.03  Contractor’s Installation Plan.  Submit, for the Engineer’s acceptance, a written installation plan of procedures to follow when excavating the hole, placing the concrete, and monitoring the concrete placement.  Submit the installation plan at least 14 Calendar Days before constructing the drilled shafts.  Include the following information:

A.      Details of the sequence proposed for the overall drilled shaft construction operation.

B.      Procedures for maintaining correct horizontal and vertical alignment of the excavation.

C.      Procedure and the proposed equipment required to deal with the possible presence of and subsequent removal of underground obstructions within the hole excavations.

D.      If using a casing, method to advance the casing.

E.      If using a temporary casing, details of the methods to extract the temporary casing and to maintain the concrete slump to keep concrete workable by adding admixtures such as retarders or superplasticizers.

F.      If using slurry, details of the methods to mix, circulate, and de-sand the slurry.  For polymer slurry, submit the manufacturer’s recommendations for use of the slurry.

G.      Details of methods to clean the shaft excavation.

H.     Details of reinforcement placement including support and centralization methods.

I.       Details of concrete placement including proposed operational procedures for free fall, tremie, or pumping methods.

J.       A list of proposed equipment to be used such as cranes, drills, augers, bailing buckets, final cleaning equipment, de-sanding equipment, slurry pumps, tremies, concrete pumps, casings, etc.

Acceptance of the installation plan will not relieve the Contractor of the responsibility for obtaining the required results.

524.04  Hole Excavation.  Take precautions to prevent damaging existing structures and utilities.  Precautions include, but are not limited to, selecting construction methods and procedures that will prevent excessive caving of the shaft excavation, and monitoring and controlling the vibrations from the driving of casing or sheeting or drilling of the shaft.

When encountered, remove objects such as large boulders.  Do not blast unless shown on the plans or authorized in writing by the Engineer.

Unless otherwise shown on the plans, where drilled shafts are to be installed in conjunction with embankment placement, construct shafts after the placement of the fill and completion of any specified settlement periods.

Excavate for the shafts to the dimensions and elevations shown on the plans.  Use methods and equipment suitable for the intended purpose and materials encountered.  Use either the dry method, wet method, temporary casing method, or permanent casing method as necessary to produce sound, durable concrete foundation shafts free of defects.  When a particular method of construction is required on the plans, that method shall be used.  If no particular method is specified for use, select and use a method based on site conditions.

If the excavation operation is stopped, protect the shaft cavity by installing a safety cover.  The Contractor is responsible for the safety of the shaft excavation, surrounding soil, and the stability of the sidewalls.  If necessary to ensure such safety and stability, use a temporary casing, slurry, or other methods accepted by the Engineer.  Unless cased to the full depth, do not leave excavations unfilled overnight.

Use appropriate means, such as a cleanout bucket or air lift, to clean the bottom of the excavation of all shafts.  Promptly notify the Engineer when unexpected obstructions are encountered.

A.      Dry Construction Method.  Use the dry construction method only at sites where the groundwater table and site conditions are suitable to allow construction of the shaft in a relatively dry excavation, and where the sides and bottom of the shaft remain stable without any caving, sloughing, or swelling and may be visually inspected before placing the concrete.  The dry method consists of excavating the drilled shaft hole, removing accumulated water, and loose material from the excavation, and placing the shaft concrete in a relatively dry excavation.  The rate of flow of water into the hole should not be more than 12 inches (300 mm) within a 1-hour period.  Do not place the initial concrete if there is more than 3 inches (75 mm) of water in the bottom of the hole.

B.      Wet Construction Method.  Use the wet construction method at sites where a dry excavation cannot be maintained for placement of the shaft concrete.  The wet method consists of using water or slurry to contain seepage and groundwater movement and placing concrete using a tremie or concrete pump.  Additionally, use this method to maintain stability of the hole perimeter while advancing the excavation to its final depth, placing the reinforcing cage, and placing the shaft concrete.  This method also consists of de-sanding and cleaning the slurry.  For drilled shafts that are not socketed into the bedrock and during drilling operations, maintain a water or slurry fluid elevation inside the shaft excavation higher than the static water table.  Unless demonstrated to the Engineer’s satisfaction that the surface casing is not required, provide temporary surface casings to aid shaft alignment and position and to prevent sloughing of the top of the shaft excavation.  Extend surface casings from the ground surface to a point in the shaft excavation where sloughing of the surrounding soil does not occur.

C.      Temporary Casing Construction Method.  Use the temporary casing construction method when the stability of the excavated hole and/or the effects of groundwater must be controlled.  Remove temporary casings while the concrete remains workable.  As the casing is being withdrawn, maintain a 5-foot (1.5 m) minimum head of fresh concrete in the casing so that all the fluid trapped behind the casing is displaced upward without contaminating the shaft concrete.  As necessary, increase the required minimum concrete head to counteract groundwater head inside the casing.  Extract casing at a slow, uniform rate with the pull in line with the shaft axis. Rotate, tap, push down, or vibrate the casing when necessary to extract it. Rotate the casing as little as possible to avoid deforming the reinforcing steel cage.

D.      Permanent Casing Construction Method.  The permanent casing construction method generally consists of driving or drilling a casing to a specified depth before excavation begins.  If full penetration of the casing to the specified depth cannot be attained, the Contractor may either excavate material within the embedded portion of the casing or excavate a pilot hole ahead of the casing until the casing reaches the desired penetration.  Make the pilot hole no larger than one-half the diameter of the shaft and center the hole in the shaft.  Do not over ream to the outside diameter of the casing unless specifically shown on the plans.

Ensure that the casing is continuous between the elevations shown on the plans.  Unless otherwise shown on the plans, do not use temporary casing instead of or in addition to the permanent casing.

After installing the casing and excavating the shaft, place the reinforcing steel, then place the shaft concrete.  After filling the permanent casing with concrete, pressure grout voids between the shaft excavation and the casing with cement grout.  Submit the method of pressure grouting the voids to the Engineer for approval.  Pressure grouting is required to ensure contact (bearing) between the casing and any surrounding soil layer that is used for lateral support.

524.05  Friction Type Drilled Shafts.  Friction type drilled shafts are defined as drilled shafts that do not bear on bedrock and obtain their ability to support load from a combination of end bearing on the soil and adhesion between soil and concrete along the length of the shaft.

For friction type drilled shafts, dry construction method may be used for cohesive soils only.  If using a casing for the construction of a friction type drilled shaft, remove the casing completely or partially as shown on the plans.  If enough water is entering the hole through the sides and bottom of the hole such that the supporting soils are being eroded, maintain a positive head of fluid in the excavation hole to ensure that water is not continuously flowing into the hole.

If the Engineer determines that the hole sidewall has softened due to excavation methods, swelled due to delays in concreting, or degraded because of slurry cake buildup, over ream the sidewall to sound material.  If the concrete is not placed the same day that the excavation is completed, protect the excavation with a temporary casing, and redrill the hole at least 6 inches (150 mm) larger in diameter, clean the excavation, and perform slurry test before concreting.

524.06  Casings.  Use smooth, watertight, steel casings of sufficient strength to withstand handling and driving stresses and the concrete and surrounding earth pressures.  Provide an outside diameter of the steel casing equal to or greater than the plan diameter of the shaft.  If the plan diameter of the bedrock socket is same as the drilled shaft above the bedrock and a steel casing is used, provide a diameter of the bedrock socket as shown on the plans.  Ensure that the diameter of the casing is large enough to allow the excavation of the bedrock socket.

Where drilled shafts are located in open water areas, extend the casing a minimum of 12 inches (300 mm) above the water to protect the shaft concrete from water action during placement and curing of the concrete.  Cut off the casing at the plan top of drilled shaft elevation after the concrete has cured.  If practical, install the casing in a manner that produces a positive seal at the bottom of the casing to prevent piping of water or entry of other material into the shaft excavation.

If it becomes necessary to remove a casing and substitute a longer or larger diameter casing through caving soils, stabilize the excavation with slurry or backfill before installing the new casing.  The Contractor may use other methods accepted by the Engineer to control the stability of the excavation and to protect the integrity of the foundation soils.

524.07  Slurry.  Slurry used in the drilling process shall be a mineral or polymer slurry.  The mineral slurry shall have both a mineral grain size that remains in suspension and sufficient viscosity and gel characteristics to transport excavated material to a suitable screening system.  Ensure that the percentage and specific gravity of the material used to make the suspension is sufficient to maintain the stability of the excavation and to allow proper concrete placement.  Maintain the level of the slurry at a height sufficient to prevent caving of the hole.

Thoroughly premix the mineral slurry with clean fresh water and allow adequate time for hydration before introduction into the shaft excavation.  Agitate, circulate, and adjust the properties of the slurry to prevent the slurry from “setting up” in the shaft excavation.

Perform control tests using suitable apparatus on the mineral slurry to determine density, viscosity, and pH.  Conform to the acceptable range of values for these physical properties as shown in Table 524.07-1.

TABLE 524.07-1  MINERAL SLURRY SPECIFICATIONS
Range of Values at 68 °F (20 °C)

Property

Test Method

Time of Slurry Introduction

Time of Concreting in Hole

Density

lb/ft³ (kg/m³)

Density Balance

64.3 to 69.1

(1030 to 1107)

64.3 to 75.0

(1030 to 1201)

Viscosity

s/qt (s/L)

Marsh Cone

28 to 45

(30 to 48)

28 to 45

(30 to 48)

pH

pH Paper or meter

8 to 11

8 to 11

If de-sanding is required, do not allow the sand content to exceed 4 percent by volume at any point in the shaft excavation as determined by the American Petroleum Institute sand content test.

Determine density, viscosity, and pH values before and during the shaft excavation to establish a consistent working pattern.

Before placing shaft concrete, use an approved slurry-sampling tool to take slurry samples from the bottom and at mid-height of the shaft.  Eliminate heavily contaminated slurry that has accumulated at the bottom of the shaft.  Ensure that the mineral slurry conforms to the requirements specified immediately before shaft concrete placement.

Only use polymer slurry after demonstrating to the Engineer that the stability of the hole perimeter can be maintained while advancing the excavation to its final depth by excavating a trial hole of the same diameter and depth as that of the production shafts.  Use the same polymer slurry in the trial hole as proposed for the production shafts.  If using different sizes of the shafts at the project, use the same size trial hole as that of the largest diameter shaft, except the depth of the trial hole need not be more than 40 feet (12 meters).  Only one trial hole per project is required.  Do not use the trial hole excavation for a production shaft.  After completing the trial hole excavation, fill the hole with sand.  The acceptance of the polymer slurry does not relieve the Contractor of responsibility to maintain the stability of the excavation.  Polymer slurry shall conform to the manufacturer’s requirements.

524.08  Excavation Inspection.  Provide equipment for checking the dimensions and alignment of each shaft excavation.  Determine the dimensions and alignment.  Measure the final shaft depth after final inspection.

Immediately before placing concrete, ensure that the bottom of the completed drilled shaft excavation is as clean as practical.  Remove drilling spoils that adhere to the vertical sides of the bedrock socket.

524.09  Reinforcing Steel for Drilled Shafts.  Place the reinforcing steel cage as a unit immediately after inspection of the excavation and before placing concrete.  If not placing the concrete immediately after installing the cage, the Contractor may have to remove the cage before placing the concrete to verify the integrity of the excavated area and to ensure loose material is removed from the bottom of the hole.

Tie and support the reinforcing steel so it remains within the required tolerances.  Securely tie spacers at quarter points around the cage perimeter and space at intervals not to exceed 5 feet (1.5 m) along the length of the cage.  If the size of the longitudinal reinforcing steel equals or exceeds 1-inch (25 mm) in diameter, the Contractor may increase the minimum spacing of the spacing devices to 10 feet (3 m).  Use spacers of adequate dimensions to ensure a minimum annular space between outside of cage and side of hole or casing of 3 inches (75 mm) for shaft diameters up to 4 feet (1.2 m) and 6 inches (150 mm) for shaft diameters larger than 4 feet (1.2 m).  The Contractor may use round plastic spacers.

Maintain the top of the reinforcing steel cage no more than 6 inches (150 mm) above and no more than 3 inches (75 mm) below the required position.  If the reinforcing steel cage is not maintained within tolerances, make acceptable corrections and do not construct additional shafts until the method of reinforcing steel cage support has been approved.

When approved by the Engineer, the Contractor need not provide the reinforcing steel for the extended length of the drilled shaft if it is determined in the field that the Contractor must drill the shaft deeper than the estimated length.

524.10  Concrete for Drilled Shafts.  For all drilled shafts, use Class QC 2 concrete according to Item 511 except as modified and supplemented as follows.  The required slump is 6 ± 1 inch (150 ± 25 mm).  Achieve the additional slump over 4 inches (100 mm) by using chemical admixtures conforming to 705.12, Type F or G.  The accepted JMF’s maximum water cementitious ratio shall not be exceeded.  If placing concrete under water, add 10 percent more cement to the concrete mix.  If placing concrete using a tremie, further increase the slump to 8 ± 1 inch (200 ± 25 mm), by using chemical admixtures.

For wet method construction, place concrete in one continuous operation from bottom to top of the shaft.  After the concrete has reached the top of the drilled shaft, continue pumping and remove all contaminated concrete until acceptable quality concrete is evident at the top of the shaft.  Do not vibrate concrete with a vibrator.  Carefully remove the casing so that the reinforcing steel cage is not deformed by the force of the downward flowing concrete.

Do not place concrete in any drilled shaft excavation without acceptance from the Engineer.  Inspect the drilled shaft excavation immediately before placing the concrete.  Provide a light powerful enough to thoroughly inspect the reinforcing steel cage, the sides, and the bottom of the drilled shaft.  The inspection for the wet construction method consists of only probing and measuring.

If the elevation of the top of the shaft is below ground at the time of concrete placement, use a casing to prevent caving of materials into fresh concrete.

524.11  Free Fall Concrete Placement.  The Contractor may place the concrete in a dry drilled shaft excavation using the free fall method provided the concrete falls to its final position through air without striking the sides of the hole, the reinforcing steel cage, or any other obstruction.  Use a centering drop chute, at least 3 feet (1 m) long with the free fall method.  Unless shown on the plans, there is no limit to the height of free fall.  If the concrete placement causes the shaft excavation to cave or slough or if the concrete strikes the rebar cage or sidewall, reduce the height of free fall or the rate of concrete flow into the excavation, or both.

If the Engineer determines that dewatering is not practical or placement by free fall method cannot be accomplished, place the concrete using a tremie or a concrete pump.

524.12  Tremie.  The Contractor may use a gravity tremie to place concrete placement instead of a concrete pump in either wet or dry holes.  For uncased wet holes, maintain the drilled shaft excavation full of slurry or water to such a depth that water does not flow into the shaft excavation at any time.  To place concrete, use tremies consisting of a tube of sufficient length, weight, and diameter to discharge concrete at the shaft base elevation.  If the tremie contains aluminum parts, do not allow these parts to contact the concrete.  Use tremies with an inside diameter of at least 10 inches (250 mm).  Ensure that the inside and outside surfaces of the tremie are clean and smooth to allow both flow of concrete and unimpeded withdrawal during concreting.  Use tremies with a wall thickness adequate to prevent crimping or sharp bends that restrict concrete placement.

For concrete placement, use water-tight tremies.  Do not begin underwater placement until the tremie is placed to the shaft bottom elevation.  Use valves, bottom plates, or plugs so concrete discharge can begin within one tremie diameter of the base.  Either remove plugs from the excavation or use plugs of an Engineer approved material that does not cause a defect in the shaft if not removed.  Construct the discharge end of the tremie to allow the free radial flow of concrete during placement operations.  Immerse the tremie discharge end at least 10 feet (3 m) in concrete at all times after starting the flow of concrete.

If the tremie line orifice is removed from the fluid concrete column during the concrete pour, and discharges concrete above the rising concrete level, consider the drilled shaft defective.

524.13  Pumped Concrete.  Pump concrete into either wet or dry holes.  For uncased wet holes, maintain the drilled shaft excavation full of slurry or water to such a depth that water does not flow into the shaft excavation at any time.  Use concrete pump pipe at least 4 inches (100 mm) in diameter and constructed with watertight joints.  Arrange the concrete pump equipment so no vibrations result that might damage fresh concrete.  Arrange pipes carrying concrete from the pump to the shaft with a minimum number of bends.  Anchor the pipe used to convey the concrete to the bottom of the drilled shaft excavation to the steel casing or another suitable stationary object to prevent the pipe from undulating during the initial placement of the concrete.  Do not begin placing concrete until the pump line orifice is at the shaft base elevation.

Do not use aluminum pipe as a conveyance for the concrete.  Pump an adequate quantity of grout, mortar, or concrete without coarse aggregate through the equipment ahead of the specification concrete to provide lubrication to the pumping system.  Do not place the concrete used for lubrication in the shaft.  The lubrication process will not be repeated as long as the pumping operations are continuous.  Operate the pump so a continuous stream of concrete without air pockets is produced.  To prevent the contamination of the concrete placed initially at the bottom of the shaft, seal the outlet end of the pumping pipe with a diaphragm or plug that is flushed out when the hydrostatic pressure from the column of concrete exceeds that of the water in the shaft.  Control the initial rate of concrete placement so not to lift or displace the cage of reinforcing steel.  Use a watertight conveying system, and leave the outlet end well below the top of the freshly placed concrete.  The preferred concrete placement procedure is to maintain the outlet end of the pumping system at approximately 10 feet (3 m) below the top of the fresh concrete.  When the concrete reaches the top of the drilled shaft column, remove all laitance.

If the concrete pump line orifice is removed from the fluid concrete column during the concrete pour, and discharges concrete above the rising concrete level, the drilled shaft shall be considered defective.

524.14  Construction Tolerances.  For shafts supporting single columns, position the drilled shaft within 3 inches (75 mm) of the plan location in the horizontal plane at the plan elevation for the top of the shaft.  For shafts supporting footings, position the center within 6 inches (150 mm) of the plan location.  Do not allow the vertical alignment of the shaft to vary from the required alignment by more than 1/4 inch per foot (21 mm/m) of depth.  Construct the supported elements at the plan location.  Perform all corrections required to construct the supported elements.

524.15  Inspection Records.  Provide all necessary equipment and labor needed to obtain measurements for completing the Inspection Records.  Obtain measurements before placing concrete.

524.16  Method of Measurement.  The Department will measure Drilled Shafts by the number of feet (meters), measured along the axis of the drilled shaft from the required bottom elevation of the shaft to the proposed top plan elevation.  The Department will not measure the length of reinforcing steel projecting from the drilled shaft into the pier column or the footing supported on Drilled Shafts as shown on the plans.  If the drilled shaft extends into the bedrock, The Department will divide the total length of each drilled shaft into two segments.  The length of the lower segment is the length of the bedrock socket, and the length of the upper segment is the length of the drilled shaft above the bedrock socket.

If a steel casing extending down to bedrock is used, the Department will measure the bedrock socket from the bottom of the casing to the bottom of the drilled bedrock excavation.  If the Engineer is assured that a portion of the metal casing is embedded in solid bedrock, and upon the Engineer’s concurrence, the Department may include the embedded distance as a part of the bedrock socket.

524.17  Basis of Payment.  Payment is full compensation for performing required excavation; furnishing and placing steel casings; furnishing and placing reinforcing steel and concrete by free fall, pumping, or tremie method; removing casings; casings left in place; supplying equipment and performing slurry testing; supplying and disposing of slurry; and disposing excess excavated material.

The Department will not pay for the cost of performing slurry tests before concreting.

The Department will not make separate payment for the trial holes.

The Department will not pay for corrections required to construct the supported elements.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

524             Foot (Meter)                    Drilled Shafts, ___" (___ mm) Diameter,
                                                               above Bedrock

524             Foot (Meter)                    Drilled Shafts, ___" (___ mm) Diameter,
                                                               into Bedrock

524             Foot (Meter)                    Drilled Shafts, ___" (___ mm) Diameter

ITEM 526 APPROACH SLABS

526.01  Description

526.02  Materials

526.03  Forming and Placing Reinforcing Steel

526.04  Placing and Sampling Concrete

526.05  Finishing and Curing

526.06  Side Curbs

526.07  Method of Measurement

526.08  Basis of Payment

526.01  Description.  This work consists of constructing reinforced portland cement concrete approach slabs for bridges on the completed and accepted subgrade or subbase.

526.02  Materials.  Furnish materials conforming to:

Concrete, Class QC 2*................................................. 499

Epoxy coated reinforcing steel.................... 509.02, 709.00

Preformed joint filler................................................ 705.03

Joint sealer............................................... 705.04 or 705.11

*   Use the same class of concrete used in the bridges superstructure that the approach slab is attached to unless otherwise shown in the plans.  If the super-structure concrete class for the bridge is not identified in the plans use Class QC 2.

526.03  Forming, Furnishing and Placing Reinforcing Steel.  Furnish true and straight steel or wooden side forms.  Securely brace and hold forms to the line and grade shown on the plans.  Do not allow forms to vary more than 1/8 inch (3 mm) from a 10-foot (3 m) straightedge.  Do not remove forms for a minimum of 36 hours.  Clean and oil forms after each use.

Furnish reinforcing steel and place it in the position shown on the standard construction drawing and firmly secure the steel during placing and setting of the concrete.  Tie reinforcing bars at all intersections, except tie reinforcing bars at alternate intersections where bar spacing is less than 1 foot (0.3 m) in any direction.

526.04  Placing and Sampling Concrete.   Immediately before placing concrete according to Item 511.07, thoroughly moisten the subgrade or subbase with water in the amount and manner directed by the Engineer. When the bridge superstructure and the approach slab require QC/QA, make at least one set of test cylinders for each 50 cubic yards (35 cubic meters) of concrete. Include the results of the cylinders into the LOT for the 511 superstructure item.

526.05  Finishing and Curing.  If the approach slab is to serve as a base for an asphalt concrete wearing course, finish and texture the approach slab according to Item 305.  If the approach slab is to serve as a wearing surface finish and test the surface according to 451.12 and diamond groove the surface according to 511.17. Cure approach slabs according to 511.14.A, deck superstructure concrete.

Open approach slabs to traffic according to Table 511.14-1A or Table 511.14B.

526.06  Side Curbs.  If concrete curb extends across the approach slab, construct side curbs of the dimensions required, and place the concrete curb at the same time as the approach slab.  Finish the curb according to Item 609.

526.07  Method of Measurement.  The Department will measure Reinforced Concrete Approach Slabs by the number of square yards (square meters) complete in place.

526.08  Basis of Payment.  The Department will calculate the final adjusted payment per 511 and Supplement 1127. The Department will pay for accepted quantities at the contract price as follows which includes all concrete, curbs, reinforcing steel, dowels, joints, and other materials:

Item           Unit                            Description

526             Square Yard            Reinforced Concrete Approach Slabs
                       (Square Meter)

526              Square Yard            Reinforced Concrete Approach Slabs with QC/QA

                                (Square Meter)

600 INCIDENTALS

ITEM 601 SLOPE AND CHANNEL PROTECTION

601.01  Description

601.02  Materials

601.03  General Construction

601.04  Riprap

601.05  Grouted Riprap or Rock

601.06  Crushed Aggregate Slope Protection

601.07  Concrete Slope Protection

601.08  Dumped Rock Fill

601.09  Rock Channel Protection

601.10  Detention Basin, Infiltration Basin, or Water Quantity Swale Aggregate

601.11  Paved Gutter

601.12  Tied Concrete Block Mat

601.13  Articulating Concrete Block Revetment System

601.14  Method of Measurement

601.15  Basis of Payment

601.01  Description.  This work consists of the excavation for and the construction of gutters, riprap, concrete, grouted items, tied concrete block mats, articulating concrete block revetment systems, crushed aggregate, or rock items for protecting slopes and channels.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

601.02  Materials.  Furnish materials conforming to:

Curing.............................................. 451 or 705.07 Type 1

Concrete, Class QC-Misc..................................... 499, 511

Water for grout........................................................ 499.02

Reinforcing steel...................................................... 509.02

Cement for grout........................................................... 701

Structural Backfill Type 3........................................ 703.11

Sand for grout.......................................................... 703.03

Rock and Aggregate Materials................................. 703.19

Brick and blocks........................................................... 704

Preformed expansion joint....................................... 705.03

Joint sealer............................................................... 705.04

Filter fabric, Type B................................................. 712.09

Provide steel filter fabric securing pins with washers for securing filter fabric.  Use a steel washer having an outside diameter not less than 1 1/2 inches (38 mm).  Use securing pins at least 18 inches (0.5 m) long and at least 3/16 inch (5 mm) in diameter that are pointed at one end and fabricated with a head to retain the steel washer.

Ensure tied concrete block mats and articulating concrete block revetment systems are held together by galvanized steel wire, HDPE mesh, stainless steel wire, or any material that has a service life of 75 years or more as approved by the Office of Hydraulic Engineering. 

601.03  General Construction.  Cure gutters, concrete slope protection, and grouted riprap according to Item 451, except apply all the membrane cures at the rate of not less than 1 gallon per 200 square feet (1 L/5 m²) of surface.

Mix and place all concrete according to Item 511.  Finish to produce a sandy texture.

601.04  Riprap.  Construct riprap according to one of the following four alternatives unless specifically itemized in the Contract.  The Contractor may elect to use a different alternative at each location on the project.

A.      Provide Flat Stones or Broken Concrete.  Ensure that individual pieces are roughly rectangular in cross-section with a minimum volume of 1/3 cubic foot (0.01 m³) and a minimum thickness of 3 inches (75 mm).  Place individual pieces by hand in courses and so that the pieces overlap the joints in the course below.  Place riprap with the flat surfaces roughly perpendicular to the slope and in contact with the courses immediately below and above.  Fill spaces between larger pieces with spalls that are rammed into place to present an even and tight surface, pleasing in appearance and varying not more than 3 inches (75 mm) from that shown on the plans.  When required by the plans, fill riprap with grout.  Compact the backing as riprap construction progresses.  Ensure that the thickness of the riprap, measured perpendicular to the slope, is not flatter than 9 inches (230 mm) and averages not flatter than 12 inches (0.3 m).

Approved manufacturers are on file with the office of Materials Management.  For approval, manufacturers will submit product information to the Office of Hydraulic Engineering.

B.      Provide Articulating Concrete Block Revetment System. Ensure articulating concrete block revetment conform to 712.1-3.  Install according to the manufacturer’s recommendations.

C.      Construct Concrete Riprap Using Cloth or Burlap Bags.  After soaking the bags with water, fill them with approximately 2/3 cubic foot (0.02 m³) of concrete and place the bags by hand to the limits on the plans.  Provide bags with approximate dimensions of 6 ´ 12 ´ 16 inches (150 ´ 300 ´ 400 mm).

Stack the bags on the slope to ensure a minimum of 1/3 cubic yard (0.3 m³) of concrete for each square yard (square meter) of riprap in place as measured along the slope.

Tie the open end of each bag and fold the tie under the bag.  Place each tie or fold so that it overlaps the joint in the lower layer.  After placing, pierce each bag in the lower layer to allow some concrete to flow out and bond with the top overlying layer.

Stretchers are bags placed with the long length parallel to the streambed flow.  Headers are bags placed with the long length perpendicular to the streambed flow.  A layer runs horizontally at approximately the same elevation perpendicular to the protected slope grade.

If the slope is 1.5:1 or steeper, make the bottom layer with two bags laid as stretchers.  Place the next overlying layer as a header.  Place the rest of the overlying upslope layers as stretchers.

If the slope is flatter than 1.5:1, make the bottom layer with two bags as stretchers.  Place all remaining layers as headers.

Push or drive No. 4 (No. 13M) reinforcing bars approximately 18 inches (0.5 m) long and spaced approximately 12 inches (0.3 m) apart through the top three layers.  When required by the plans, fill voids with grout.

D.      Construct a 6-inch (150 mm) Reinforced Concrete Slab.  Reinforce the slab approximately midway between the top and bottom of the slab with steel bars or fabricated reinforcement equivalent to No. 3 (No. 10M) round bars, spaced at 24-inch (0.6 m) centers in two directions, or wire fabric according to the standard construction drawing for pavement reinforcing.  The Contractor may use formed construction joints.  Extend reinforcement through all formed construction joints.  Include cutoff walls as shown on the plans in the unit price bid for reinforced concrete slab.

601.05  Grouted Riprap or Rock.  When specified, grout in place riprap cloth bags, riprap burlap bags, flat stones, precast blocks, broken concrete, rock, or tied concrete block mats.  Make the grout by mixing one part portland cement, three parts sand, and enough water to allow the grout to flow into the joints and cracks.

Prepare the grout in a mixing machine of an approved design and equipped with an accurate graduated regulating device for controlling the amount of water in each batch.  Accurately measure and proportion the quantities for each batch, and ensure that the quantities are exactly sufficient for one or more sacks of cement.

Immediately before applying grout, thoroughly wet all surfaces.  Place the grout, filling all the joints or voids.  Do not add water to the grout after it has been placed.

601.06  Crushed Aggregate Slope Protection.  Furnish material conforming to 703.19.  Place the material on the filter fabric so that the surface is flush with the embankment slopes.  Use a thickness of 12 inches (300 mm) unless a different thickness is specified.  Extend the aggregate from the face of the abutments down to the toe of the slope or to normal water elevation, and a minimum of 3 feet (1 m) beyond the outer edges of the superstructures or as shown on the plans.

601.07  Concrete Slope Protection.  Construct a concrete slab, 6 inches (150 mm) thick, extending over the embankment area under a bridge from the face of the abutment down to the toe of the slope and extending a minimum of 3 feet (1 m) beyond the outer edges of the superstructure or as shown on the plans.  Thicken the bottom 3 feet (1 m) of the concrete slab from 6 to 18 inches (150 to 460 mm) to provide resistance to sliding.

Where pier columns extend through the slab, place 1-inch (25 mm) preformed expansion joint material around the columns and for the full thickness of the slab.

Divide the surface into an equally spaced block grid pattern at approximately 4 to 5-foot (1.2 to 1.5 m) intervals.  Make the block grid pattern with one direction horizontally at a constant elevation or as directed by the Engineer, and the other direction parallel to the superstructure centerline, skewed, or as directed by the Engineer.  Saw or form the block grid pattern to make joints at a depth of not less than one-fourth the thickness of the slab and approximately 1/8 inch (3 mm) wide.

601.08  Dumped Rock Fill.  Furnish material conforming to 703.19.  Dump larger pieces at the outer face and smaller pieces in the inner surface of the protected area.  Ensure a reasonably smooth and continuous surface conforming to the slope lines shown on the plans.  Avoid concentration of fines and small pieces at any location in the completed dumped rock fill material.  When required by the plans fill all voids with grout.

601.09  Rock Channel Protection.   Furnish material conforming to 703.19.  When specified with a filter, provide a filter consisting of filter fabric or a 6-inch (150 mm) bed of aggregate conforming to 703.19.  When placing rock, exercise reasonable care to ensure that the finished surface of the protected channel conforms to the channel cross-sections shown on the plans.

If filter fabric is used, prepare the surface to receive the fabric to a relatively smooth surface, free of obstruction and debris.  With the long dimension parallel to the flow direction, loosely place the fabric without wrinkles and creases.  Where joints are necessary, provide a 12-inch (0.3 m) minimum overlap, with the upstream strip overlapping the downstream strip.  Place securing pins with washers at a minimum distance apart of 2 feet (0.6 m) along the joints and at a minimum distance apart of 5 feet (1.5 m) everywhere else.  When required by the plans fill all voids with grout.

601.10  Detention Basin or Infiltration Basin.  For detention basin or infiltration basin aggregate, furnish material conforming to Structural Backfill Type 3 at 6 inches (150 mm) thick. Use a filter consisting of filter fabric.  When placing aggregate, exercise reasonable care to ensure that the finished surface of the basin conforms to the details shown in the plans.

601.11  Paved Gutter.  Mix and place concrete paved gutters according to Items 499 and 511 and to the dimensions and shape shown on the plans or the standard construction drawing.

When gutter constructed under this item is to be tied to an existing concrete base, pavement, or other rigid structure, match the type and location of the joints in the gutter with those in the adjoining pavement.

When gutter constructed under this item is not tied to an existing concrete base, form impressed joints using a device or bar shaped to the gutter cross-section.  Make the impression before initial setting of the newly placed concrete.  Remove the device or bar as soon as the concrete is in such condition to retain its shape when the bar or device is removed.  Form an impressed joint that is 3/8 inch (10 mm) wide at the surface; 1/4 inch (6 mm) wide at the bottom; and a depth equal to one-third the thickness of the concrete.  Edge the joints to a radius not greater than 1/4 inch (6 mm).  Until the filler is placed, protect the joint from dirt or foreign matter.  Fill the impressed joints in such a manner to confine the material to the joint and in no way mar the surface.

Compact the subgrade for all paved gutters according to 204.03. When required by the plans fill all voids with grout.

Approved manufacturers are on file with the Laboratory.  For approval, manufacturers will submit product information to the Office of Hydraulic Engineering.

601.12  Tied Concrete Block Mat.  When specified, use Tied Concrete Block Mat Type ___ conforming to 712.12 as shown on the plans.  Place directly on the filter fabric. Install per the manufacturer’s recommendation. Tied Concrete Block Mats are approved by the Office of Hydraulic Engineering. Furnish products according to the Departments Qualified Products List (QPL).

601.13  Articulating Concrete Block Revetment System.  When specified, use Articulating Concrete Block Revetment System Type _ conforming to 712.13 as shown on the plans.  Install per the manufacturer’s recommendation. Articulating Concrete Block Revetment Systems are approved by the Office of Hydraulic Engineering. Furnish products according to the Departments Qualified Products List (QPL).

601.14  Method of Measurement.  The Department will measure Riprap, Articulating Concrete Block Revetment System, Crushed Aggregate Slope Protection, Concrete Slope Protection, and Tied Concrete Block Mats by the square yard (square meter) of the finished surface completed and accepted in place, with or without grout.

The Department will measure Dumped Rock Fill and Rock Channel Protection (with or without filter), by the cubic yard (cubic meter), completed and accepted in place according to the dimensions shown on the plans, excluding rock filter, with or without grout.  The Department may determine quantities by volume in the vehicle or by a job conversion weight of acceptable material delivered.

The Department will measure Paved Gutter by the foot (meter) completed and accepted in place.

601.15  Basis of Payment.  The Department will specify with grout in the pay item description when required.  When the pay item calls out Tied Concrete Block Mat or Articulating Concrete Block Revetment System, include filter fabric material and installation in the price.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

601             Square Yard                    Riprap
                       (Square Meter)

601             Square Yard                    Crushed Aggregate Slope Protection
                       (Square Meter)            

601             Square Yard                    Concrete Slope Protection
                       (Square Meter)

601             Square Yard                    Tied Concrete Block Mat, Type _ __

                       (Square Meter)

601             Cubic Yard                      Articulating Concrete Block Revetment
                       (Cubic Meter)              System, Type___

601             Cubic Yard                      Dumped Rock Fill, Type ___
                       (Cubic Meter)

601             Cubic Yard                      Rock Channel Protection,
                       (Cubic Meter)                  Type ___ with Filter

601             Cubic Yard                      Rock Channel Protection,
                       (Cubic Meter)                  Type ___ without Filter

601             Cubic Yard                      Rock Channel Protection,
                       (Cubic Meter)                  Type ___ with Aggregate Filter

601             Cubic Yard                      Detention Basin Aggregate
                       (Cubic Meter)

601             Cubic Yard                      Infiltration Basin Aggregate
                       (Cubic Meter)

601             Foot (Meter)                    Paved Gutter

ITEM 602  MASONRY

602.01  Description

602.02  Materials

602.03  Construction Requirements

602.04  Method of Measurement

602.05  Basis of Payment

602.01  Description.  This work consists of constructing headwalls, pipe cradles, collars, and other brick and masonry units of the types and sizes specified.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

602.02  Materials.  Furnish materials conforming to:

Backfill......................................................................... 203

Concrete, Class QC-Misc............................... 499 and 511

Water for grout and mortar...................................... 499.02

Reinforcing steel...................................................... 509.02

Cement for mortar.......................... 701.01 through 701.07

Sand for mortar........................................................ 703.03

Granular base ........... Granular material, Type B, 703.16.C

Brick and masonry units................ 704.01, 704.02, 704.03

Nonshrink mortar.................................................... 705.22

Lime for mortar........................................................ 712.04

602.03  Construction Requirements.  Construct the designated items as shown on the plans.

A.      Excavate to dimensions that provide ample room for construction.  Remove obstructions as necessary to perform this work.

Protect the sides of all excavations from caving by providing suitable sheeting, shoring, and bracing.  Use excavation methods that do not disturb the original material below the bottom of footers or below the additional 6 inches (150 mm) required for precast structures.

If the material found at the bottom of the headwall or below the additional 6 inches (150 mm) required for precast structures is not suitable for a foundation, excavate to further depth to provide a suitable foundation. Backfill the void left by the additional excavation with granular base.  The Department will pay for this additional work according to 109.05.

Backfilling shall follow completion of the work as closely as the construction will allow.  Backfill with granular base or soil. Place backfill in 6-inch (150 mm) loose lifts.

B.      Compaction requirements are according to Item 203 except for the following:

Four passes per lift with additional passes as required until 95 percent compaction is reached.  Use compaction equipment with a minimum total weight of, or minimum centrifugal force of, 1 ton (0.9 metric ton).  Supply the manufacturer’s specifications for this equipment to verify these requirements.

C.      Cast-in-place structures are headwalls, pipe cradles, collars, and other units. Construct cast-in-place structures according to the corresponding Standard Construction Drawing using methods specified in Items 499, 511, and 509.

D.      Precast structures are half height headwalls for conduits up to a maximum of 78 inches (1980 mm). These pre-approved precast structure drawings are on file in the Office Material Management. With the submission of the TE-24 from an approved manufacturer furnish stamped, approved from the Office of Hydraulic Engineering design drawing sheets.  Precast half-height headwalls for elliptical and pipe arch conduits may be constructed from templates of the actual conduit being supplied, up to a maximum 78 inch (1980 mm) (round equivalent) to the project to ensure the opening is OD plus one inch.  Submit drawings to the Office of Hydraulic Engineering for approval, on a project by project basis, of precast half-height headwalls for elliptical and pipe arch conduit.  Non-pre-approved drawings are required to be submitted to the Office of Hydraulic Engineering for approval. Allow 4 weeks for approval.  Failure to furnish the stamped, approved design drawing sheets will result in rejection of the precast structure.  The drawings will include the following:

1.      All manufacturers are pre-approved according to Supplement 1073.

2.      All reinforcing steel will be epoxy coated.

3.      All HW-2.1 SCD require wire insert details.

4.      Attachment detail for metal or plastic conduit conforming to SCD HW2.1.

5.      Non-corrosive lifting devices.

6.      Maximum opening is conduit outside diameter plus 1 inch (25 mm) for each conduit material type.

7.      All openings to be filled with nonshrink mortar including all lifting device voids.

8.      Changes in pre-approved drawings are the same as non pre-approved drawings.

9.      Detail how the 6 inch (150 mm) extension is treated if required.

10.    Fill the void between the precast half height headwall and the conduit by using nonshrink mortar.

11.    Apply marking, either stamped or painted, to the headwall to ensure each headwall size is matched to the proper conduit size and material type.

E.  Pre-cast structures for wing walls and headwalls for use with Items 706.05, 706.051,  706.052, and 706.053. The Contractor may provide precast wingwalls or headwalls in lieu of cast-in-place walls using the following criteria:

1.       Select fabricators that are prequalified and evaluated by the Office of materials Management (OMM) according to Supplement 1073 and listed by the Department before the Contract Letting Date.

2.       All reinforcing steel shall be epoxy coated.

3.       Wall anchorage dowels shall be epoxy coated as per 709.00 or galvanized as per 709.16.

4.       Galvanize all connection hardware per 711.02.

5.       Install dowels per 510 using non-shrink, non-metallic 705.20 epoxy grout. 

6.       Provide the entrained air requirements as per the applicable concrete specification.

7.       Provide Non-corrosive lifting devices.

8.       Fill all openings including all lifting hook voids with non-shrink mortar per 705.22.

9.       Provide shop drawings detailing precast concrete structural elements and calculations according to the AASHTO LRFD Bridge Design Specifications.

10.    Have an Ohio Registered Engineer prepare, sign, seal and date the shop drawings. Have a second Ohio Registered Engineer check, sign, seal and date the shop drawings. The preparer and checker shall be two different Engineers. Have all questions and comments addressed before submitting the shop drawings.

11.    Submit the shop drawings and calculations to the Engineer at least 7 days before construction begins. Department acceptance is not required. 

12.    The Contractor’s written acceptance letter shall document acceptance of the shop drawings including confirmation of field verification, as required, and descriptions of issues resolved between the Contractor, the fabricator, or the Department.

13.    By accepting these shop drawings, the Contractor represents to the Department that all dimensions and elevations of existing conditions shown on the plans have been field measured and verified, and that these shop drawings comply with all the materials requirements, construction requirements, contract requirements, and performance criteria.  The Contractor further represents that these drawings have been coordinated and verified with the details of the work to be performed by other fabricators and entities on the project.  The Department will not make any allowance for additional cost or delays to the Contractor for incorrect fabrication as a result of failure to coordinate or perform this acceptance.

14.    If the Department requests changes on these shop drawings, or the Contractor makes changes in addition to those expressly requested, ensure that the shop drawings are accepted as above with suitable revision marks to identify the changes.

15.    Shop Drawing General Requirements:

a.Provide a separate shop drawing for each culvert location.

b.Provide on 11” x 17” sheets in pdf  (portable document format).

c. Show:

                                                                 i.      All dimensions.

                                                                ii.      Inlet and outlet.

                                                              iii.      North arrow.

                                                              iv.      Roadway centerline stationing.

                                                               v.      All construction phases.

                                                              vi.      Precast piece labels

                                                            vii.      Holes for conduits, framed with diagonal reinforcing on both faces.

                                                           viii.      Reinforcing Lap lengths

                                                              ix.      Material strengths

                                                               x.      Weep holes locations

                                                              xi.      Lifting device locations.

d. Label:

                                                                 i.      Project Number

                                                                ii.      PID

                                                              iii.      County Route Section of the structure

                                                              iv.      Stream Name as show on plans

                                                               v.      Structure File Number or Culvert File Number as given on the plans

                                                              vi.      Fabrication facility where units are to be cast

F.      Masonry units structures are headwalls, pipe cradles, collars, and other units. Thoroughly wet masonry units before laying the mortar. Lay masonry units with full mortar joints. Take adequate precautions to prevent the mortar from freezing.  Do not set masonry units having a temperature of 40 °F (4 °C) or less with mortar until heated.  When required, heat to ensure that a temperature of 50 to 80 °F (10 to 27 °C) is obtained throughout the entire masonry units. Cure the exposed surfaces of the masonry units by covering with wet burlap for 48 hours or by applying curing membrane according to Item 511. Construct the masonry units structures according to the corresponding Standard Construction Drawing. Use one of the following mortars:

1.      One part Portland cement to two parts sand by volume.  The Contractor may add lime in an amount not to exceed 10 percent of the cement by weight

2.      One part masonry cement to two parts sand by volume.

602.04  Method of Measurement.  The Department will measure Brick Masonry, Block Masonry, and Concrete Masonry by the number of cubic yards (cubic meters) calculated from dimensions shown on the plans.

602.05  Basis of Payment.  When a precast structure is used, payment is based on the number of cubic yards (cubic meters) required for the cast in place item and is considered full compensation for construction of the precast structure.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

602             Cubic Yard                      Brick Masonry
                       (Cubic Meter)

602             Cubic Yard                      Block Masonry
                       (Cubic Meter)

602             Cubic Yard                      Concrete Masonry
                       (Cubic Meter)

ITEM 605  UNDERDRAINS

605.01  Description

605.02  Materials

605.03  Pipe Underdrains Construction

605.04  Construction Underdrains 

605.05  Prefabricated Edge Underdrains

605.06  Underdrain Outlets

605.07  Aggregate Drains

605.08  Method of Measurement

605.09  Basis of Payment

605.01  Description.  This work consists of constructing unclassified pipe underdrains, shallow pipe underdrains, deep pipe underdrains, base pipe underdrains, or rock cut underdrains with or without a filter fabric, construction underdrains, prefabricated edge underdrains and aggregate drains.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

605.02  Materials.

Concrete, Class QC-Misc............................... 499 and 511

Reinforcing steel...................................................... 509.02

Filter fabric, Type A................................................ 712.09

Backfill unclassified pipe underdrains, shallow pipe underdrains, deep pipe underdrains, base pipe underdrains, or rock cut underdrains with or without a filter fabric, construction underdrains and aggregate drains with granular material consisting of No. 8, 9, or 89 size air-cooled blast furnace slag, limestone, or gravel. Use granular material with a maximum sodium sulfate soundness loss of 15 percent.

Backfill prefabricated edge underdrains with granular material consisting of No. 8 size air-cooled blast furnace slag, limestone, or gravel. Use granular material with a maximum sodium sulfate soundness loss of 15 percent.

For 605.02.A through 605.02.B, use the pipe of the same size and kind listed in the Proposal.  If the kind of pipe is not specifically itemized in the Proposal, use types as listed below.

A.      Pipe for 605 Rock Cut Underdrains.

Corrugated polyethylene drainage tubing 

.... (perforated)......................................................... 707.31

Smooth-wall polyvinyl chloride underdrain

.... pipe……………………………………………707.41

Polyvinyl chloride corrugated

smooth interior pipe

.... (perforated according to 707.31)......................... 707.42

Polyvinyl chloride solid wall pipe

.... (perforated according to 707.31)......................... 707.45

B.      Pipe for 605 Unclassified Pipe Underdrains, Shallow Pipe Underdrains, Deep Pipe Underdrains, Base Pipe Underdrains

Perforated concrete pipe........................................... 706.06

Concrete drain tile, extra quality............................... 706.07

Perforated vitrified clay pipe.................................... 706.08

Clay drain tile, extra quality..................................... 706.09

Corrugated steel underdrains, Type III.................... 707.01

Corrugated polyethylene

.... drainage tubing, (perforated)............................... 707.31

Polyvinyl chloride plastic pipe................................. 707.41

Corrugated aluminum alloy pipe and

.... underdrains, Type III.......................................... 707.21

If the specified size of the underdrains a 6-inch (150 mm) shallow pipe underdrain or base pipe underdrain and the kind of pipe material is not specifically itemized, then the Contractor may use 4-inch (100 mm) 707.31 perforated corrugated polyethylene drainage tubing.

C.      Pipe for 605 Construction Underdrains

6 inch (150 mm) Corrugated polyethylene drainage

 ... tubing (perforated)............................................. 707.31

D.      Pipe for 605 Prefabricated Edge Underdrains.  Use pipe conforming to 712.10.

605.03  Pipe Underdrains Construction.  Construct underdrains as follows:

A.      Excavation.  Excavate trenches to such dimensions allowing ample room for construction.  Construct the trench width to at least 14 inches (350 mm) for 6-inch (150 mm) diameter underdrains, and to at least 10 inches (250 mm) for 4-inch (100 mm) diameter underdrains.  Excavate the trench walls as vertical as possible, and excavate bell holes to allow proper placing of the underdrain.  Remove obstructions encountered while excavating for the underdrains.

Excavate trenches measured vertically from the subgrade to the bottom of the trench at a depth of 18 inches (450 mm) for base pipe underdrains, 30 inches (760 mm) for shallow pipe underdrains, and 50 inches (1270 mm) for deep pipe underdrains unless otherwise specified in the plans.  Furnish a depth of 30 inches (760 mm) for construction underdrains unless otherwise specified in the plans.  Excavate trenches for unclassified pipe underdrains to the depth specified in the plans.

Excavate trenches to a depth of 6 inches (150 mm) below the rock, shale or coal depth required in 204.05 for Rock Cut underdrains unless otherwise specified in the plans.

If underdrains are to be placed within or beneath an embankment, construct the embankment to the elevation of the top of the subgrade before trenching for the underdrain.

If filter fabric is specified, line the underdrain trench with filter fabric.  Place the filter fabric to completely surround the granular material.  Overlap the filter fabric at the top of the trench.  Match the overlap to the trench width.  At other seams, overlap filter fabric a minimum of 12 inches (0.3 m).

B.      Laying  Underdrain.  Lay the underdrain true to line and grade with close fitting joints.  Place the underdrain in the center of the trench .  Use locking bands or smooth sleeve type couplers matching the underdrain material type to join 707.01, 707.31, 707.41, and 707.21.  When bell and spigot underdrain is used, lay it with the bell end facing up grade.  Set the underdrain on a solid bed shaped to fit the underdrain throughout its entire length.  Make all necessary connections with branches, wyes, tees, transitions, and bends that match the underdrain material type.  Close the upper ends of underdrains with suitable plugs.

Lay perforated underdrain so that the perforations are in the bottom half of the underdrain.

C.      Backfilling.  Inspect the underdrains before placing any granular material.  Place the granular material for the full width of the trench around the underdrain, and extend it to the bottom of the pavement or base as shown on the plans.  If underdrains are placed outside of the pavement or base area, extend the granular material to within 4 inches (100 mm) of the finished grade.  Fill the remaining depth of the trench with 203 embankment material.

D.      Protection.  Place the pavement over the underdrain trench within 90 days after placing the trench backfill.  If the trench remains open for longer than 90 days, remove and replace backfill contaminated by soil.

605.04  Construction Underdrains.  Construct construction underdrains as follows:

A.      Excavation.  Construct the trench width to at least 10 inches (250 mm) with a minimum of 2 inches (50 mm) on each side of the underdrain.  Excavate the bottom of the trench to allow proper placing of the underdrain.  Remove obstructions encountered while excavating for the underdrains.

B.      Trench Depth and Backfill.  Construct the trench depth to that shown on the plans or 30 inches (750 mm).  Backfill the trench with granular material for the full width of the trench and to the full height of the trench.

C.      Outlet.  Outlet the construction underdrains as possible into the ditch or drainage structures.  There is no change in pipe types for the outlet.

D.      Removal.  Construction underdrains are not to be removed at any time.  If the construction practice used requires the construction underdrains to be removed then install replacements as soon as possible.

605.05  Prefabricated Edge Underdrains.  Install the prefabricated edge underdrains against the outside wall of a 4-inch (100 mm) trench, and backfill the trench adjacent to the pavement with granular material.  Place the granular material in one or more lifts with a vibratory compactor run over the final lift to compact the granular material before placing the asphalt plug.  Place the first layer of the granular material simultaneously with the trenching operation to hold the edge underdrains flush against the trench wall.

Splice the prefabricated edge underdrains as required before placing in the trench, using material furnished by the manufacturer and according to the manufacturer’s directions.  Require the manufacturer to furnish all material required for the splices, and furnish any equipment required for splicing.  Construct splices to prevent separation of adjoining sections of the prefabricated edge underdrain panels.

605.06  Underdrain Outlets.  Construct pipe outlets concurrently with underdrains.  Provide all outlets on the slope with a precast reinforced concrete outlet according to Item 611 and a tied concrete block mat type 1 grouted according to 601.12.

Construct the underdrains outlets according to Item 611 using outlet fittings.  Require the manufacturer to supply outlet fittings that transition between the underdrains and the outlet pipe. Provide smooth-lined or corrugated outlet fittings. Have the underdrains and outlets on fractured slab projects, such as crack and seat, rubblized, or break and seat projects, in place and functional before fracturing the existing pavement.

Mark all underdrain outlets with a wooden lath prior to final seeding.  Clean all debris from the outlets after final seeding.

605.07  Aggregate Drains.  Construct the aggregate drains after the completion of granular pavement courses.

A.      Excavation.  Excavate trenches for aggregate drains to a minimum width of 12 inches (0.3 m) and to the depth shown on the plans.  Slope the bottom of the trench to drain and keep it free from loose particles of soil.  Excavate the trench to furnish a clean exposure of the granular pavement courses.

B       Placing and Backfilling.  Use granular material for the drains.  Place the aggregate to a minimum depth of 8 inches (200 mm) above the bottom of the trench.  The remaining depth of the trench backfill with suitable embankment material according to Item 203.

605.08  Method of Measurement.  The Department will measure Unclassified Pipe Underdrains, Shallow Pipe Underdrains, Deep Pipe Underdrains, Base Pipe Underdrains Construction Underdrains, Rock Cut Underdrains, and Prefabricated Edge Underdrains by the number of feet (meters) completed and accepted in place, measured from end to end of each run.

The Department will measure Aggregate Drains by the number of feet (meters) completed and accepted in place, measured along the bottom of the trench.

605.09  Basis of Payment.  The Department will pay for pipe outlets under 611.

The Department will pay for precast reinforced concrete outlets under 611 Precast Reinforced Concrete Outlet.

The Department will pay for tied concrete block mats type 1 grouted under 601 Tied Concrete Block Mat.

Rock Cut Underdrains are placed in rock and all required trenching in the rock is included under Rock Cut Underdrain.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

605             Foot (Meter)                    ____ " (____ mm) Unclassified Pipe
                                                               Underdrains

605             Foot (Meter)                    6" (150 mm) Construction Underdrains 

                                                               707.31

605             Foot (Meter)                    ____ " (____ mm) Shallow Pipe Underdrains

605             Foot (Meter)                    ____ " (____ mm) Deep Pipe Underdrains

605             Foot (Meter)                    ____ " (____ mm) Base Pipe Underdrains

605             Foot (Meter)                    Aggregate Drains

605             Foot (Meter)                    ____ " (____ mm) Rock Cut Underdrains

605             Foot (Meter)                    ____ " (____ mm) Prefabricated Edge
                                                               Underdrains

ITEM 606  GUARDRAIL

606.01  Description

606.02  Materials

606.03  Setting Posts

606.04  Erecting Rail Elements

606.05  Guardrail Rebuilt

606.06  Impact Attenuators

606.07  Method of Measurement

606.08  Basis of Payment

606.01  Description.  This work consists of constructing or reconstructing guardrail, guardrail posts, bridge terminal assemblies, end terminals, and impact attenuators, including the furnishing, assembling, and erecting of all component parts and materials.

Guardrail shall be deep beam rail Type MGS, 5, 5A, or 8.  Appurtenances shall include bridge terminal assemblies, end terminals, and impact attenuators.  Construction of the various types of guardrail include the furnishing, assembling, and erecting of all component parts and materials, complete in place, at the location shown on the plans or as directed, and according to the manufacturer’s recommendations where applicable.

606.02  Materials.  Furnish materials conforming to:

Concrete, Class QC Misc, QC 1, QC 2.......... 499 and 511

Reinforcing steel...................................................... 509.02

Deep beam rail and hardware................................... 710.06

Pressure treated guardrail posts

.... and blockouts...................................................... 710.14

Steel guardrail posts................................................. 710.15

Guardrail posts........................................................ 710.16

Galvanizing.............................................................. 711.02

Use galvanized steel posts, rails, bolts, fittings, and other accessories.

For guardrail, use deep beam rail Type MGS. 5, 5A, or 8.

606.03  Setting Posts.  Set or drive posts plumb in a manner that prevents battering or distorting of posts.  Trim posts that are set or driven more than 1-inch (25 mm) above grade.  Treat trimmed posts with a preservative material specified in 712.06.  Backfill post holes with acceptable material, placed in layers, and thoroughly compacted.

606.04  Erecting Rail Elements.  Erect standard design (single-faced) guardrail of the type shown on the plans.  Erect barrier design (double-faced) guardrail as shown on the plans.

Erect rail elements in a manner resulting in a smooth, continuous installation.  Use shop-curved rail on curves with radii from 5 to 70 feet (1.5 to 22.4 m).

Except where otherwise required, such as expansion joint bolts, draw bolts tight.  Tighten bolts through expansion joints as tight as possible without preventing the rail elements from sliding past one another longitudinally.  Provide bolts long enough to extend at least 1/4 inch (6 mm) beyond the nuts.

Do not use splice bolts that extend more than 1/2 inch (13 mm) beyond the nuts.  For double-faced guardrail, provide bolts that extend from 1/4 to 1 inch (6 to 25 mm) beyond the nuts.

Fabricate all metal in the shop.  Do not perform burning or welding in the field.  The Engineer may approve making holes in the field, but only for special details in exceptional cases.  The Engineer may approve field punching, cutting, and drilling if the Contractor demonstrates that its methods do not damage the surrounding metal.

Repair galvanized surfaces that have been abraded such that the base metal is exposed, including threaded portions of all fittings and fasteners, and cut ends of bolts as specified by ASTM A 780.

Erect guardrail so that the bolts at expansion joints are located at the centers of the slotted holes.  Splice the rail elements by lapping in the direction of traffic.  Ensure that the plates at each splice make contact throughout the area of the splice.

606.05  Guardrail Rebuilt.  As shown on the plans, rebuild existing guardrails.  Unless otherwise shown on the plans, rebuild units of the same type and spacing of members as the existing guardrail.

For re-erecting, obtain the rail element from specified salvage sources.  Furnish the following new materials: posts, blockouts, bolts, washers, and incidental hardware as necessary to complete the guardrail, except:  (1) existing steel posts and blockouts that are not damaged and have a good galvanized coating may be reused, and (2) reuse guardrail splice bolts that are undamaged and were not removed during salvage may be reused.

606.06  Impact Attenuators.  Before installing the attenuator, make all corresponding shop drawings from the manufacturer available for the Engineer’s inspection.  Include installation drawings and instructions with the shop drawings that completely describe the attenuator system.

Grade the top of each foundation at the same elevation as the adjacent travel lane and/or paved shoulder.

Adjust the location of the anchors to avoid pavement joints.

The Contractor shall use approved proprietary impact attenuator products as required which can be found on the Office of Roadway Engineering’s website.

606.07  Method of Measurement.  The Department will measure Guardrail, new or rebuilt, of the type specified by the number of feet (meters) from center-to-center of end posts, excluding anchor assemblies.  If, however, end connections are made to masonry or steel structures, the Department will measure to the center of the normal post bolt slot.  If rail element is used across a bridge, the Department will measure to the first post off the bridge.

The Department will measure Anchor Assembly of the type specified by the number each assembly furnished and erected complete.

The Department will measure Bridge Terminal Assembly of the type specified by the number of each assembly furnished and erected complete.

The Department will measure Impact Attenuator of the type specified by the number of each furnished and erected complete.

The Department will measure Guardrail Post of the kind specified by the number of each furnished and erected.

606.08  Basis of Payment.  The additional costs associated with furnishing and installing extra-length posts instead of standard-length guardrail posts are incidental to Guardrail Post, 8-foot (2.44 m) or Guardrail Post, 9-foot (2.75 m).

For the extra costs associated with furnishing and installing extra-length posts in lieu of standard-length guardrail posts, payment for 9-foot (2.75 m) guardrail posts is considered full compensation.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

606             Foot (Meter)                    Guardrail, Type ___

606             Foot (Meter)                    Guardrail, Barrier Design, Type ___

606             Foot (Meter)                    Guardrail, Rebuilt, Type ___

606             Each                                Anchor Assembly, Type ___

606             Each                                Anchor Assembly, Type ___, Barrier Design

606             Each                                Bridge Terminal Assembly, Type ___

606             Each                                Impact Attenuator, Type ___

606             Each                                Guardrail Post

606             Each                                Guardrail Post, 8-foot (2.44 m)

606             Each                                Guardrail Post, 9-foot (2.75 m)

ITEM 607  FENCE

607.01  Description

607.02  Materials

607.03  Clearing, Grading and Seeding

607.04  Post Assemblies

607.05  Horizontal Deflection

607.06  Line Posts

607.07  Fabric

607.08  Barbed Wire

607.09  Method of Measurement

607.10  Basis of Payment

607.01  Description.  This work consists of furnishing and erecting fence and gates of the types designated.  Construct fence in a manner that provides a rigid, taut fence closely conforming to the surface of the ground.

Fence is designated by the following types:

A.      Type 47 [47-inch (1195 mm)] woven wire fence fabric, steel line posts, and one strand of barbed wire.

B.      Type 47RA [47-inch (1195 mm)] woven wire fence fabric, wood line posts, and no barbed wire.

C.      Type CLT [60-inch (1525 mm)] chain-link fence fabric with tension wire.

607.02  Materials.  Furnish materials conforming to:

Concrete, QC Misc or QC 1 or QC 2............. 499 and 511

Reinforcing steel...................................................... 509.02

Barbed wire............................................................. 710.01

Woven steel wire fence ........................................... 710.02

Chain-link fence....................................................... 710.03

Fence posts, braces, and dimension lumber............. 710.11

Steel line posts and ties, Type 47 fence.................... 710.11

Expansion shield anchors, self drilling.................... 712.01

Seeding and Mulching.................................................. 659

607.03  Clearing, Grading and Seeding.  Perform clearing and grading as necessary to construct the fence to the required alignment, and provide a reasonably smooth ground profile at the fence line. Perform fenceline seeding and mulching according to Item 659 Seeding and Mulching on all areas disturbed by the clearing and grading for the fence within 8 months of the activity.  The Department will deduct the area paid for under Item 607 Fenceline Seedng and Mulching from Item 659 Seeding and Mulching quantities as described in the plan, if applicable.

607.04  Post Assemblies.  Securely brace end, corner, gate, and pull or intermediate anchor posts in position during the curing period of the concrete encasement.  The Engineer will not require forms for post encasement.

For Type 47 and Type CLT fence, ensure that the maximum spacing between intermediate anchor post assemblies, or between end post assemblies and intermediate anchor post assemblies, are 660 feet (200 m).

607.05  Horizontal Deflection.  At points of horizontal deflection, construct the fence as follows:

A.      Type 47 Fence.  If the fence changes alignment by more than 1 degree but not more than 4 degrees, install either steel line posts encased in concrete or wood posts without encasement at all horizontal deflection points.  If the change in alignment is more than 4 degrees and less than 30 degrees, build an intermediate anchor post assembly at the deflection point.  If the change in alignment is 30 degrees or more, build a corner post assembly at the deflection point.

B.      Type CLT Fence.  If the fence changes alignment by more than 1 degree but not more than 4 degrees, install line posts encased in concrete at all horizontal deflection points.  If the change in alignment exceeds 5 degrees, provide a post brace and truss rod in each fence panel adjacent to the post located at the angle point.  If the change in alignment exceeds 5 degrees, construct the footings for all post located at deflection points as specified for end posts.

607.06  Line Posts.  Set line posts according to the following:

A.      Type 47 Fence.  Space line posts at intervals not to exceed 12 feet (3.6 m).  Anchor line posts at the bottom of dips or depressions in the ground surface in concrete.  If channels or streams cross the fence line, construct crossings as shown on the plans.

On tangents, place line posts so that the fabric, when installed on the side toward the highway, is 2 feet (0.6 m) from the Right-of-Way line.  If adjacent to Right-of-Way lines with less than 5740 feet (1750 m) radius (in excess of 1 degree curvature), construct line posts on chords so that the fabric, when installed on the side toward the highway, is not less than 2 feet (0.6 m) or more than 8 feet (2.4 m) from the Right-of-Way line.

Locate posts at points of horizontal deflection so that the fence fabric will bear against the post.

B.      Type CLT Fence.  Protect the tops of driven line posts by drive caps or other method to prevent distortion of the exposed end.  Space line posts at not more than 10-foot (3 m) centers, and place them so that, when the wire is fastened on the side toward the highway, it is 1 foot (0.3 m) from the Right-of-Way line.

607.07  Fabric.  If setting posts in concrete, do not erect the fabric until after 5 days from the time of setting the posts when using regular concrete, or until after 3 days when using concrete with high early strength cement,

Stretch and securely fasten Type 47 fabric to line posts using galvanized ties.  At a minimum, use one tie each for the top and bottom horizontal wires and one tie for each alternate horizontal wire below the top horizontal wire.

Fasten chain-link fabric to the line posts using clips or bands spaced approximately 14 inches (0.4 m) apart, and to the top rail or top tension wire using bands or tie wires at approximately 24-inch (0.6 m) intervals or less.  Join successive rolls of fabric by weaving a single picket into the ends of the rolls to form a continuous mesh.

607.08  Barbed Wire.  If barbed wire is specified, stretch and fasten it in the same manner as woven wire fabric.

607.09  Method of Measurement.  The Department will measure Fence, Type ___ by the number of feet (meters), complete in place.  The Department will measure along the top of the fence from outside to outside of end posts, exclusive of gates and other openings.

The Department will count Gate, Type ___ by the number of complete units of the size and type specified.

The Department will measure Fenceline Seeding and Mulching by the number of feet (meters) of fence. The Department will measure along the top of the fence from outside to outside of end posts, exclusive of gates and other openings.

607.10  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Seeding and Mulching shall be paid under Item 607 Seeding and Mulching

Item           Unit                                Description

607             Foot (Meter)                    Fence, Type___

607             Each                                Gate, Type___

607             Foot (Meter)                    Fenceline Seeding and Mulching

ITEM 608  WALKS, CURB RAMPS, AND STEPS

608.01  Description

608.02  Materials

608.03  Concrete Walks

608.04  Asphalt Concrete Walks

608.05  Crushed Aggregate Walks

608.06  Concrete Steps

608.07  Curb Ramps

608.08  Method of Measurement

608.09  Basis of Payment

608.01  Description.  This work consists of constructing walks, curb ramps, and steps as per plans, specifications and standard drawings.

608.02  Materials.  Furnish materials conforming to:

Aggregate Base............................... 304.01 and 304.02

Asphalt concrete Type 1.......................................... 448

Concrete,
Class QC Misc or QC 1* ................................... 499
Reinforcing steel............................................ 509.02

Crushed aggregate meeting

..... grading requirements of................................ 703.10

Detectable Warning Devices.............................. 712.14

Expansion joint material.................................. 705.03

* Replacing Coarse aggregate in the concrete mixes with Recycled Concrete Aggregate conforming to Supplement 1117 is an option

608.03  Concrete Walks.  Construct concrete walks as follows:

A. Excavation.  Excavate to the required depth and to a width that allows installation and bracing of forms.  Shape and uniformly compact the subgrade to a surface conforming to the plans.

B. Forms.  Use either fixed forms or slip-form methods.  For fixed-form construction, use wooden or metal forms that extend the full depth of the concrete and that do not spring under the concrete pressure.  For slip-form construction, perform the work according to 609.04.C.

C. Placing and Finishing.  Immediately before placing concrete, thoroughly moisten the subgrade.  Deposit concrete in a single layer, strike it off with a template, and smooth it with a float to obtain a sandy texture.  Do not plaster the concrete.  Use a 1/4-inch (6 mm) radius edging tool to edge all outside edges and joints.  Divide the surface of the walks into equally spaced rectangular blocks at approximately 5-foot (1.5 m) intervals.  Saw or form transverse joints to a depth of not less than one-fourth the thickness of the slab and to a width of approximately 1/8 inch (3 mm).  Install 1/2-inch (13 mm) thick expansion joint filler between the walk and any fixed structure that extends the full depth of the walk.  Install 1-inch (25 mm) thick expansion joint filler between the walk and the back of curb that is on a 250-foot (75 m) or smaller radius, such as at street intersections.

D. Slope.  Construct the surface of the walk with a transverse slope rate of 0.02 and with the low side adjacent to the roadway.

E. Curing.  Cure concrete according to Item 451.

608.04  Asphalt Concrete Walks.  Construct asphalt concrete walks as follows:

A. Excavation and Forms.  Excavate and construct forms according to 608.03.A and 608.03.B.

B. Base.  Place and thoroughly compact aggregate base in layers not exceeding 4 inches (100 mm) in depth.

C. Asphalt Placement and Compaction.  Place asphalt concrete in one or more courses to provide the required depth when compacted using a hand roller or power roller of a type and weight acceptable to the Engineer.

608.05  Crushed Aggregate Walks.  Construct crushed aggregate walks as follows:

A.      Excavation.  Excavate according to 608.03.A.

B.      Forms.  Construct forms of wood or metal of acceptable rigidity and to the depth of the necessary loose material.  Back forms with compacted soil to the height of the completed walk.

608.06  Concrete Steps.  Construct concrete steps as follows:

A.      Excavation and Forms.  Excavate and construct forms according to 608.03.A and 608.03.B.

B.      Placement and Finishing.  Place and finish concrete according to Item 511, except finish the treads of steps to produce a sandy texture.

C.      Slope.  Slope step treads at a rate of 0.01 and toward the next lower step.

D.      Curing.  Cure steps according to 608.03.E.

E.      Railing.  If specified, install hand railing according to Item 517.

608.07  Curb Ramps.  Excavate, form, place, finish, and cure according to 608.03.A, 608.03.B, 608.03.C, and 608.03.E.  Finish ramps to a rougher final surface texture than the adjacent walk and with striations transverse to the ramp slope using a coarse broom or other method approved by the Engineer.

Provide detectable warning devices conforming to 712.14 in curb ramps.  Install the detectable warning devices according to manufacturer’s written recommendations and standard drawings.   Provide a warranty to conform with the requirements of 712.14.  Provide the manufacturer’s written installation instructions and the 5-year warranty to the Engineer at or before the pre construction meeting.

608.08  Method of Measurement.  The Department will measure Concrete Walk, Asphalt Concrete Walk, and Aggregate Walk by the number of square feet (square meters) of finished surface, complete in place.

The Department will measure curb ramps by the number of square feet (square meters) completed.  The Department will measure detectable warnings in existing curb ramps and at grade crossings by the number of square feet (square meters) completed.

The Department will measure Concrete Steps by the number of feet (meters), along the front edge of each tread.  Where steps are constructed with integral walls, the Department will include the thickness of the integral walls with the tread width measurement.

608.09  Basis of Payment.  Payment for walks, curb ramps, detectable warnings, and steps is full compensation for excavation, backfill, concrete cutting/sawing, base course material, reinforcing steel, hand railing, expansion joint materials, and any incidentals required to complete the installation as specified. The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

608             Square Foot                     Concrete Walk
                       (Square Meter)

608             Square Foot                     Asphalt Concrete Walk
                       (Square Meter)

608             Square Foot                     Aggregate Walk
                       (Square Meter)

608             Square Foot                     Curb Ramp

                       (Square Meter)

608             Square Foot                     Detectable Warning

                       (Square Meter)

608             Foot (Meter)                    Concrete Steps

ITEM 609  CURBING, CONCRETE MEDIANS, AND TRAFFIC ISLANDS

609.01  Description

609.02  Materials

609.03  Stone Curb

609.04  Cast-in-Place Concrete Curb and Combination Curb and Gutter

609.05  Asphalt Concrete Curb

609.06  Concrete Median and Traffic Island

609.07  Method of Measurement

609.08  Basis of Payment

609.01  Description.  This work consists of furnishing and constructing curb, combination curb and gutter, medians, and traffic islands.  This work also consists of excavating, backfilling, furnishing and installing joint materials, and disposing of surplus excavation and discarded materials according to Item 203.

609.02  Materials.  Furnish materials conforming to:

Concrete,
Class QC Misc or QC 1*......................................... 499
Preformed filler................................................... 705.03

Tie bar steel, epoxy coated

.......................................... 709.00, 709.01, 709.03, 709.05

Coated dowel bars................................................... 709.13

* Replacing Coarse aggregate in the concrete mixes with Recycled Concrete Aggregate conforming to Supplement 1117 is an option

Furnish the best quality of Berea or Amherst gray sandstone, or sandstone of equal quality.

Furnish asphalt concrete curb conforming to a 448 Type 1 intermediate course, designed for medium traffic, using a PG 64-22.  Conform the asphalt concrete to the composition requirements with the fine aggregate content set at the maximum allowed under this composition.  Provided the Contractor meets the composition requirements, the Contractor may add mineral filler conforming to 703.07.  Add the mineral filler using a method approved by the Laboratory.

609.03  Stone Curb

A.      Cutting and Dressing.  Ensure that 95 percent of all straight curb pieces are at least 5-feet (1.5 m) long, with no pieces less than 42 inches (1.1 m).  The Contractor may use a piece as short as 30 inches (0.8 m) for closure.  For curves with a radius of 50 feet (15 m) or greater, the Contractor may use radially jointed straight curb pieces between 36 and 42 inches (0.9 and 1.1 m) long.  For curves and corners with a radius of less than 50 feet (15 m), use pieces a minimum of 36-inches (0.9 m) long, and dress, joint, and set pieces to the radii specified.  For all curves and corners, use curb sections that are approximately uniform in length.

Dress all curb to a straight edge on top and on the exposed face and ends to a depth of at least 6 inches (150 mm) below the gutter elevation.  Dress the ends at right angles to the face for straight curb and radially for curb on curves.  Do not allow slack or hollow joints.  Do not leave any projections after dressing the ends of any curb section that exceed 1/8 inch (3 mm) from the plane of the end of that section.  Cut the edge next to the gutter to a 3-inch (75 mm) radius and dress the top to a 1/4-inch (6 mm) bevel rising from the exposed face.  Use a pitching tool on the edge at the back to hand dress curb to the specified width.

B.      Setting.  Set the curb on a thoroughly compacted subgrade and with a 1 in 20 batter from the vertical backward from the gutter.  If the subgrade consists of clay soils or soils of a character that do not allow free drainage, place a minimum 3-inch (75 mm) thick firm bed of porous material as a foundation for the curb.  Use a heavy rammer to settle the curb into place.  Place and compact a minimum 4-inch (100 mm) wide porous backfill behind the curb to within 6 inches (150 mm) of the top.  Bring the balance of the backfill to the level of the top of the curb for a distance of 2 feet (0.6 m) behind the curb with soil or other acceptable material.  Thoroughly tamp the backing in layers not exceeding 6 inches (150 mm) in thickness, loose measurement, with an approved tamper or rammer.  Perform as much of the backfilling and tamping as is consistent with alignment of the curb at the time the stone is first set.  Set circular curb in plastic concrete 6-inches (150 mm) thick as shown on the plans.  Extend concrete the width of the curb plus 6 inches (150 mm) behind the curb, and bring concrete up behind the curb to within 4 inches (100 mm) of the top.

C.      Joints.  Set curbs such that below the dressed portions the space between ends of adjacent sections of curbing is not less than 1/8 inch (3 mm) at any point and not more than 4 inches (100 mm).  Cushion the joints between the dressed portions of adjacent sections of curbing with 1/8-inch (3 mm) thick expansion joint material.  Trim expansion joint material flush with the curbing on all edges.

If placing sandstone curb after placing pavement, fill remaining joints with dry sand to within 2 inches (50 mm) of the surface of the pavement, and fill to the pavement surface with asphalt concrete.  Take care in filling this joint so that no asphalt concrete comes in contact with the exposed surface of the curb.

D.  Reusing Existing as New Curb.  If specifically allowed by the plans, and to the extent available, use acceptable stone curb sections removed under Item 202 instead of furnishing new stone curb.  Use salvaged curb at locations designated by the Engineer.  Place all salvaged sections of curb continuously without interspersing salvaged and new curb sections.  Haul and store salvaged curb as necessary.  Cut, dress, set, and install joints in salvaged curbs according to the requirements for new curbs.

609.04 Cast-in-Place Concrete Curb and Combination Curb and Gutter.

A.      Forms and Joints.  Use approved steel forms for curbs.  Securely brace and hold forms to the line and grade shown on the plans.  The Contractor may use approved flexible forms of steel or wood to construct the radius of a circular curb 200 feet (60 m) or less.  Immediately before placing concrete, clean the inner surface of the forms, and coat this surface with a form release agent.

Where curb and combination curb and gutter is not constructed integral with, or tied to, the base or pavement, construct 1/4-inch (6 mm) wide contraction joints at 10-feet (3 m) intervals using steel separator plates, a grooving tool, or a saw according to Item 451.  For combination curb and gutter, construct the joint to an average depth of 2 inches (50 mm) or more.  For curb, construct the joint to an average depth of one-fifth or more of the curb height.  Where expansion joints occur in the abutting pavement, separate the section being placed with 1-inch (25 mm) 705.03 preformed filler.

Where the curb is integral with, or tied to, the base or pavement, construct the same type of joints as used in the pavement.  Space joints identically with the joints in the base or pavement.

Leave curb forms in place until their removal will not crack, shatter, or otherwise injure the concrete.  Do not seal transverse joints in cast-in-place concrete curb and combination curb and gutter.

If curbs are to later serve as a support for a finishing machine in the placing of a surface course, align supporting edges so that the distance between the curbs is within 1/2 inch (13 mm) from that specified.

B.      Placing.  Place concrete in forms prepared as described above, and vibrate the concrete to eliminate all voids.

Place concrete for curb that is integral with the concrete base or pavement while the base or pavement concrete is plastic.  Where the presence of the finishing equipment on the forms at the end of the day’s run prevents completing the curb, install No. 5 (No. 16M) tie bars vertically in the pavement at 1-foot (0.3 m) intervals and in a line 3 inches (75 mm) inside of and parallel to the pavement edge.  Install these tie bars to within 1 1/2 inches (38 mm) of the subgrade or subbase and 2 inches (50 mm) above the concrete base or pavement surface.  Water cure this horizontal construction joint between the concrete base or pavement and the curb, or membrane cure the concrete base or pavement and remove the membrane before placing the curb.  Immediately before placing the concrete curb, brush mortar (consisting of one part cement to two parts sand with enough water to form a workable mortar) into the surface area of the hardened concrete pavement or base where the curb is to be placed.  Do not allow the mortar to dry before placing the curb on top of it.

C.      Slip-Form Placement.  The Contractor may use a self-propelled machine to place concrete curb or curb and gutter.  Force the concrete through a mold of the proper cross-section to obtain the proper density and cross-section.  If using a track, set and secure the track on which the machine operates to the exact line and grade given by the Engineer.  Use concrete of a consistency that provides the desired shape and remains as placed without slumping of the vertical faces.

D.      Finishing.  Without adding extra mortar, float the top of the curb to thoroughly compact the concrete and produce a smooth and even surface.  Round the edges of the curb using a tool specially designed for this purpose.  Immediately after removing the forms, rub the exposed face of the curb with a float to eliminate unnecessary tool marks.  Provide a finished surface free of irregularities and waves, and uniform in texture.

E.      Protection.  Cure concrete according to Item 451.

609.05  Asphalt Concrete Curb.  Use one of the following methods, or other method approved by the Engineer, to furnish and place an asphalt concrete curb of the required cross-section.

A.      Method A.  After completing the surface course, paint or spray only the area to be occupied by the asphalt concrete curb with asphalt material conforming to 407.02.  Apply the asphalt material at the rate of 0.15 gallon per square yard (0.7 L/m2).  Place the curb with a hand-operated or self-propelled machine consisting of a hopper and power-driven screw, which forces the material through an extrusion tube.  Force the material through a die attached to the end of the extrusion tube to obtain the proper density and cross-section.

B.      Method B.  As an independent operation preceding the final rolling of the asphalt concrete surface course that the curb is placed, place loose asphalt concrete of sufficient height and shape by hand methods using suitable templates or by other means to produce the specified cross-section.  Compact the loose asphalt concrete using a hand-operated mechanical vibrating tamper equipped with a compacting shoe of such shape that will produce the specified final cross-section dimensions of the curb.

609.06  Concrete Median and Traffic Island

A.      Forms and Joints.  Securely brace and hold approved steel forms to the line and grade shown on the plans.  The Contractor may use approved flexible forms of steel or wood to construct a radius of 200 feet (60 m) or less.  Immediately before placing concrete, clean the inner surface of the forms, and coat this surface with a form release agent.

Where medians and traffic islands are not anchored to the pavement, construct contraction joints at 10-foot (3 m) intervals using steel separator plates, a grooving tool, or saw according to Item 451.  Construct the joint using steel separator plates, a grooving tool, or saw according to Item 451.  Construct the joint to a minimum depth of 2 inches (50 mm).

Where, as shown on the plans, the medians or traffic islands are anchored to the pavement, construct the same type of joints in the median or traffic island as used in the pavement.  Space the joints identically with the joints in the pavement.

Leave forms in place until their removal will not crack, shatter, or otherwise injure the concrete.

B.      Placing.  Before placing a concrete median or traffic island on subgrade, sprinkle the subgrade with water until thoroughly moistened at times and in a manner directed by the Engineer.

Place the concrete in forms prepared as described above, and vibrate the concrete to eliminate all voids.

C.      Slip-Form Placement.  The Contractor may use a self-propelled machine to place medians and traffic islands.  Force the concrete through a mold of the proper cross-section to obtain the proper density and cross-section.  If using a track, set and secure the track on which the machine operates to the exact line and grade given by the Engineer.  Use concrete of a consistency that provides the desired shape and remains as placed without slumping of the faces.

D.      Finishing.  Without adding extra mortar, finish the top of the median or traffic island to a broom texture.  Round the edges using a tool specially designed for this purpose.  Immediately after removing the forms, rub the exposed faces with a float to eliminate unnecessary tool marks.  Provide a finished surface free of irregularities and waves, and a uniform texture.

E.      Protection.  Cure concrete according to Item 451.

609.07  Method of Measurement.  The Department will measure Sandstone Curb, Curb, Combination Curb and Gutter, and Asphalt Concrete Curb by the number of feet (meters) complete in place, measured along the front face of the curb section.

The Department will measure Concrete Traffic Island and Concrete Median by the number of square yards (square meters) or the number of cubic yards (cubic meters) complete in place.

609.08  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

609             Foot (Meter)                    Sandstone Curb

609             Foot (Meter)                    Curb, Type ___

609             Foot (Meter)                    Combination Curb and
                                                               Gutter, Type ___

609             Foot (Meter)                    Asphalt Concrete Curb,
                                                               Type ___

609             Square Yard or                Concrete Traffic Island
                       Cubic Yard
                       (Square Meter or
                       Cubic Meter)

609             Square Yard or                Concrete Median
                       Cubic Yard
                       (Square Meter or
                       Cubic Meter)

ITEM 610  CELLULAR RETAINING WALLS

610.01  Description

610.02  Approval by Director

610.03  Materials

610.04  Manufactured Units

610.05  Excavation

610.06  Backfill

610.07  Wall Construction

610.08  Method of Measurement

610.09  Basis of Payment

610.01  Description.  This work consists of constructing retaining walls composed of a series of cells formed by assembling precast reinforced concrete or galvanized metal units to form stable walls.

Concrete cellular walls consist of a series of rectangular or triangular cells formed by building up tiers of precast reinforced concrete units.

Metal cellular retaining walls consists of pairs of columns, one column in the plane of the front of the wall and the other column in the plane of the rear of the wall.  The column pairs are spaced longitudinally with overlapping S-shaped facing and rear members, and transversely with overlapping U-shaped members.

610.02  Approval by Director.  Submit to the Director for acceptance, 30 days before the work is to begin, drawings of the units to be furnished.  Only submit information for walls produced by manufacturers whose type of wall, and design of units comprising same, has been in successful commercial use for a period of at least 3 years.

610.03  Materials.  Furnish manufactured units conforming to:

A.      Concrete Cellular Wall.  Use concrete conforming to Item 499, Class QC 1.  Use reinforcing steel conforming to 509.02.

B.      Metal Cellular Wall.  Provide units made from galvanized metal sheets.  Use base metal conforming to AASHTO M 218.  Ensure that both sides of the sheets are galvanized by the hot-dip process.  Provide an average spelter coating of not less than 2 ounces per square foot (610 g/m²) on each side of the sheet and a spelter coating of at least 1.8 ounces per square foot (550 g/m²) on any 2 1/4 ´ 2 1/2-inch (57 ´ 64 mm) area on each side of double exposed surfaces.  Provide finished sheets that are free from injurious defects, such as blisters, flux, and uncoated spots.

Use metal sheets with a minimum thickness of 0.057 inch (1.45 mm), unless otherwise shown on the plans.

Furnish three copies of the manufacturer’s “Analysis and Coating Test Certificate” containing the following information covering each project or order on which galvanized metal walls are furnished.

A.      Heat or heats used for units.

B.      Analysis of each heat.

C.      Amount of spelter coating for each heat.

D.      Total units of each size and thickness.

E.      Name of Contractor.

F.      Name of County, Interstate, U.S., or State route number, and section.

G.      Project number or state purchase order number.

Send one copy of the certificate to the Laboratory and two copies to the Engineer.  With each copy of the certificate, include a written statement, signed by a person having legal authority to bind the manufacturer, that the information and test results are correct and that the material complies with all contract requirements.

Furnish 5/8-inch (16 mm) diameter bolts, galvanized according to 711.02 and at least 1 1/4 inches (32 mm) long, measured from the underside of the bolt head.

610.04  Manufactured Units.

A.      Concrete Cellular Wall.  Cast concrete cellular wall units in substantial, unyielding steel forms.  Properly assemble, clean, and oil the forms before placing concrete in the forms.  During the placing and setting of the concrete, hold the forms rigidly in place on a smooth and level platform.

Secure the reinforcement to ensure that it remains in the required position while placing concrete.

Vibrate the fresh concrete to fill all space in the form with concrete, to densify the concrete, and to surround the reinforcement.  Reject units with segregated areas.

Cure the units by covering with burlap, that is kept wet at least 7 days or by applying steam for at least 24 hours.

The Engineer will reject reinforced concrete units for any of the following reasons:

1.      Exposure of the reinforcing.

2.      Defects that indicate imperfect mixing, placing, or curing.

3.      Fractures and cracks.

B.      Metal Cellular Wall.  Fabricate galvanized metal cellular wall units so that units of the same nominal size are fully interchangeable.  Do not drill, punch, or drift holes to correct manufacturing defects.  Replace all units with improperly punched holes.

If possible, maintain a minimum forming radius of 1 inch (25 mm).  Hot-dip galvanize all units formed with less than 1-inch (25 mm) radius after forming.

610.05  Excavation.  Excavate according to Item 203.  Obtain the Engineer’s approval that the bearing for the foundation of the walls is firm and to the proper elevation before erecting the wall.

610.06  Backfill.  Below the elevation of the proposed ground line at the face of the wall, fill the cells formed by the units with soil as defined in 203.02.R.  Above the elevation of the proposed ground line at the face of the wall, fill the cells with material conforming to 203 Granular Material Type B, except that the percent passing the No. 200 (75 mm) sieve shall not exceed 5 percent.

Place the material in layers that compact to a depth not to exceed 6 inches (150 mm).  Compact the material to the density established by the Engineer using approved tampers or compactors.  Add water as directed by the Engineer.

Fill the space behind the wall according to 503.08, except as noted below.

Backfill around the wall and in the interior cells, concurrent with wall erection and as close to the wall elevation as allowed by the type of construction.

Do not use rolling equipment directly over a portion of the wall until placing at least 12 inches (0.3 m) of compacted fill.

610.07  Wall Construction.  Construct the wall types as follows:

A.      Concrete Cellular Wall.  Place sills to the required grade and alignment, and support the entire sill length on the foundation material.  Do not shim the sill.

Place and interlock the headers perpendicular to the sills and stretches.  Use templates to ensure that members are placed in the proper position and with the proper face batter.

Before placing sills, spread two layers of asphalt impregnated paper on all points of contact between the sills and the foundation material to ensure a uniform bedding.

After constructing two tiers of the wall, check and, if necessary, adjust the alignment, grade, and batter of the units, and backfill to this height before adding subsequent units.  Complete the remainder of the wall.

B.      Metal Cellular Wall.  Use templates to ensure that members are placed in the proper position and with the proper face batter.

After placing the columns and constructing two tiers of the wall, check and, if necessary, adjust the alignment, grade, and batter of the units, and backfill to this height before adding subsequent units.  Complete the remainder of the wall.

Carefully handle members, and remove and replace damaged members.

610.08  Method of Measurement.  The Department will measure Cellular Retaining Wall by the number of square feet (square meters) of facial area complete in place.

610.09  Basis of Payment.  Payment is full compensation for furnishing all materials, backfilling, including the interior filling, watering, and disposing of surplus materials.

The Department will not pay for replacing any unit with improperly punched holes.

The Department will not pay for removing or replacing members damaged during handling.

The Department will pay for Excavation Not Including Embankment Construction under Item 203.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

610             Square Foot                     Cellular Retaining Wall
                       (Square Meter)

ITEM 611  pipe culverts, sewers, drains,
and drainage structures

611.01  Description

611.02  Materials

611.03  Definitions

611.04  Submittals

611.05  Excavation

611.06  Bedding and Backfill

611.07  Laying Conduit

611.08  Joining Conduit

611.09  Exterior Coatings and Membrane Waterproofing

611.10  Drainage Structure Construction

611.11  Field Paving of New or Existing Conduit

611.12  Performance Inspection

611.13  Conduit Evaluation

611.14  Drainage Structure Evaluation

611.15  Surface Settlements

611.16  Method of Measurement

611.17  Basis of Payment

611.01  Description. This work consists of constructing conduits, and constructing and reconstructing drainage structures.  This work also includes preparing installation plans, performing inspections, and providing reports and other required documentation.

611.02  Materials. Furnish pipe of the specified conduit type and size or one size larger with the approval of the Engineer.  Conduit shown in the plans is designed for hydraulic capacity and durability only.  Furnish conduit that meets the performance requirements of this specification and meets the durability and hydraulic capacity specified in the plans.  If the material is not specified in the plans, furnish conduit conforming to any of the material requirements listed for that conduit type.  All listed materials for each conduit type can meet the performance requirements.  However, different materials may require varying installation procedures.

The Contractor may furnish concrete or plastic pipe of the same type with greater strength than specified.  The Contractor may furnish metal pipe with a greater thickness than specified, so long as the pipe has the same corrugation profile and is the same type. 

A.      Type A Conduit – Culverts

Non-reinforced concrete pipe, Class 3.................... 706.01

Reinforced concrete circular pipe............................. 706.02

Reinforced concrete pipe, epoxy coated..................  706.03

Reinforced concrete elliptical pipe............................ 706.04

Precast reinforced concrete box sections.................. 706.05

Precast reinforced concrete 3-sided flat

.... topped culverts.................................................. 706.051

Precast reinforced concrete arch sections.............. 706.052

Precast reinforced concrete round sections............ 706.053

Vitrified clay pipe (extra strength only)................... 706.08

Corrugated steel conduits........................ 707.01 or 707.02

Structural plate corrugated steel structures............... 707.03

Precoated, galvanized steel culverts......................... 707.04

Bituminous coated corrugated steel pipe and pipe arches
with paved invert................................ 707.05 or 707.07

Corrugated aluminum alloy pipe.............. 707.21 or 707.22

Aluminum alloy structural plate conduits................. 707.23

Corrugated steel box culverts................................... 707.15

Corrugated aluminum box culverts.......................... 707.25

Corrugated polyethylene smooth lined pipe
....................................... 707.33 with a welded bell inlet

Steel reinforced thermoplastic ribbed pipe
...................................... SS 938 with a welded bell inlet

B.      Type B Conduit – Storm or sanitary sewers under pavement

Non-reinforced concrete pipe, Class 3..................... 706.01

Reinforced concrete circular pipe............................. 706.02

Reinforced concrete elliptical pipe............................ 706.04

Precast reinforced concrete box sections.................. 706.05

Vitrified clay pipe (extra strength only)................... 706.08

Mortar lined corrugated steel pipe............................ 707.11

Corrugated steel spiral rib pipe................................ 707.12

Bituminous lined corrugated steel pipe.... 707.13 or 707.14

Corrugated aluminum spiral rib pipe........................ 707.24

Corrugated polyethylene smooth lined pipe............. 707.33

Polyvinyl chloride corrugated smooth interior pipe. 707.42

Polyvinyl chloride profile wall pipe......................... 707.43

Polyvinyl chloride solid wall pipe............................ 707.45

Polyvinyl chloride drain waste and vent pipe........... 707.46

Polyvinyl chloride ABS composite pipe.................. 707.47

Polyvinyl chloride large-diameter solid wall pipe…707.48

ABS drain waste and vent pipe................................ 707.51

ABS sewer pipe....................................................... 707.52

Polypropylene corrugated double wall pipe............. 707.65

Polypropylene triple wall pipe................................. 707.69

Steel reinforced thermoplastic ribbed pipe............... SS 938

Ductile iron pipe (sanitary)...................................... 748.01

Polyvinyl chloride pipe (sanitary)............................ 748.02

C.      Type C Conduit – Storm or sanitary sewers not under pavement

Non-reinforced concrete circular pipe...................... 706.01

Reinforced concrete pipe.......................................... 706.02

Reinforced concrete elliptical pipe............................ 706.04

Precast reinforced concrete box sections.................. 706.05

Vitrified clay pipe.................................................... 706.08

Mortar lined corrugated steel pipe............................ 707.11

Corrugated steel spiral rib pipe................................ 707.12

Bituminous lined corrugated steel pipe.... 707.13 or 707.14

Corrugated aluminum spiral rib pipe........................ 707.24

Corrugated polyethylene smooth lined pipe............. 707.33

Polyvinyl chloride corrugated smooth interior pipe. 707.42

Polyvinyl chloride profile wall pipe......................... 707.43

Polyvinyl chloride solid wall pipe............................ 707.45

Polyvinyl chloride drain waste and vent pipe........... 707.46

Polyvinyl chloride ABS composite pipe.................. 707.47

Polyvinyl chloride large-diameter solid wall pipe…707.48

ABS drain waste and vent pipe................................ 707.51

ABS sewer pipe....................................................... 707.52

Polypropylene corrugated double wall pipe............. 707.65

Polypropylene triple wall pipe................................. 707.69

Steel reinforced thermoplastic ribbed pipe............... SS 938

Ductile iron pipe (sanitary)...................................... 748.01

Polyvinyl chloride pipe (sanitary)............................ 748.02

D.      Type D Conduit – Drive pipes and bikeways

Non-reinforced concrete pipe, Class 3..................... 706.01

Reinforced concrete circular pipe............................. 706.02

Reinforced concrete elliptical pipe............................ 706.04

Vitrified clay pipe (extra strength only)................... 706.08

Corrugated steel conduits........................ 707.01 or 707.02

Structural plate corrugated steel structures............... 707.03

Corrugated aluminum alloy pipe.............. 707.21 or 707.22

Aluminum alloy structural plate conduits................. 707.23

Corrugated polyethylene smooth lined pipe............. 707.33

Polyvinyl chloride corrugated smooth interior pipe. 707.42

Polyvinyl chloride profile wall pipe......................... 707.43

Polyvinyl chloride solid wall pipe............................ 707.45

Polyvinyl chloride large-diameter solid wall pipe…707.48

Polypropylene corrugated single wall pipe.............. 707.62

E.      Type E Conduit – Miscellaneous small drain connections and headers

Non-reinforced concrete pipe................................... 706.01

Reinforced concrete circular pipe............................. 706.02

Reinforced concrete elliptical pipe............................ 706.04

Concrete drain tile, extra quality............................... 706.07

Vitrified clay pipe.................................................... 706.08

Clay drain title, extra quality.................................... 706.09

Corrugated steel conduit.......................... 707.01 or 707.02

Corrugated aluminum alloy pipe.............. 707.21 or 707.22

Corrugated polyethylene drainage pipe.................... 707.32

Corrugated polyethylene smooth lined pipe............. 707.33

Smooth-wall polyvinyl chloride underdrain pipe
(non-perforated).................................................. 707.41

Polyvinyl chloride corrugated smooth interior pipe. 707.42

Polyvinyl chloride profile wall pipe......................... 707.43

Polyvinyl chloride solid wall pipe............................ 707.45

Polyvinyl chloride drain waste and vent pipe........... 707.46

Polyvinyl chloride ABS composite pipe.................. 707.47

Polyvinyl chloride large-diameter solid wall pipe…707.48

ABS drain waste and vent pipe................................ 707.51

ABS sewer pipe....................................................... 707.52

F.      Type F Conduit – Conduit on steep slopes; underdrain outlets

Corrugated steel conduits
(steep slope conduit).............. 707.05 Type C or 707.07

Corrugated aluminum alloy pipe
(steep slope conduit)........................... 707.21 or 707.22

Corrugated polyethylene
smooth lined pipe (underdrain outlets)................ 707.33

Smooth-wall polyvinyl chloride underdrain pipe (non-perforated underdrain outlets)  707.41

Polyvinyl chloride corrugated
smooth interior pipe (underdrain outlets)............ 707.42

Polyvinyl chloride solid wall pipe (underdrain outlets) 707.45

G.      For constructing or reconstructing drainage structures, furnish materials conforming to:

Concrete, Class QC1............................................ 511, 499

Brick and masonry units............................................... 704

Precast reinforced concrete manhole, catch basin,
and inlet sections................................................. 706.13

Precast reinforced concrete outlet............................. 706.15

Preformed expansion joint filler............................... 705.03

Epoxy coated reinforcing steel................................. 709.00

Cast frames, grates, and covers. 711.12, 711.13, or 711.14

Welded frames and grates..................... 711.01 and 513.17

Steps.......................................... 711.13, 711.30, or 711.31

Resilient and flexible gasket joints........................... 706.11

Curing materials.......................................... 705.05, 705.07

Curing membrane for inlets............. 705.07, Type 1 or 1-D

Mortar........................................................................... 602

Nonshrink mortar….................................... ………705.22

H.     For bedding and backfill, furnish materials conforming to:

Structural backfill..................................................... 703.11

Coarse aggregate..................................... 703.02 or 703.13

Fine aggregate.............. 703.02, 703.03, 703.04, or 703.05

Embankment..................... 703.16A, 703.16B, or 703.16C

Aggregate................................................................ 703.17

Low Strength Mortar Backfill (LSM)........................... 613

I.       For concrete collars and encasement, furnish materials conforming to:

Concrete, Class QC1............................................ 511, 499

Reinforcing steel ..................................................... 509.02

J.       For field paving of conduit inverts, furnish materials conforming to:

Concrete, Class QC1............................................ 511, 499

Coarse aggregate, size No. 7, 8, or 78..................... 703.02

Galvanized welded wire fabric................................. 709.08

For material in items not specified above, furnish materials conforming to:

Mortar........................................................................... 602

Nonshrink mortar.................................................... 705.22

Bituminous pipe joint filler...................................... 706.10

Resilient and flexible gasket joints for:

.... Concrete pipe...................................................... 706.11

.... Vitrified clay pipe................................................ 706.12

Preformed flexible joint sealant................................ 706.14

Type 2 membrane waterproofing............................. 711.25

Type 3 membrane waterproofing............................. 711.29

Geotextile Fabric........................................ 712.09, Type A

Joint wrap...................................... ASTM C 877, Type III

Buried liner waterproofing membrane..................... 711.22

For Class QC1 concrete, provide batch plant tickets according to 499.07. 

If a precast reinforced concrete box culvert (706.05) is specified, the Engineer may allow the Contractor to substitute either a precast reinforced concrete 3-sided flat topped culvert, a precast reinforced concrete arch culvert, or a precast reinforced concrete round section (706.051, 706.052, or 706.053). If a 706.051, 706.052, or 706.053 is specified, the Engineer may allow the Contractor to substitute one for the other.  Refer to 611.04 for submittal requirements.

If bituminous coated corrugated steel pipe or pipe arch with paved invert (707.05 or 707.07) is specified, the Contractor may furnish conduit with a coating conforming to 707.04.

611.03  Definitions. The following terms, when used in this specification, are defined as follows:

Backfill. Material used to fill the trench or excavation, not including the bedding material.

Bed. The bottom of the trench or excavation.

Bedding Material. Material placed above the bed and below the conduit or drainage structure.  It is placed or shaped to fit the bell and spigot and typically placed or shaped to fit the conduit.  The bedding material may also extend up and around the sides of the conduit or drainage structure.

Conduit. Includes pipe, culverts, sewers, and drains.  Conduits are classified as Type A, B C, D, E, and F.

Corrugated Metal Conduit. Includes all conduit made from corrugated steel or corrugated aluminum.  Either material may also have coatings.  This includes all of the following types of materials: 707.01, 707.02, 707.03, 707.04, 707.05, 707.07, 707.11, 707.12, 707.13, 707.14, 707.15, 707.17, 707.21, 707.22, 707.23, 707.24, and 707.25.

Cut. A situation where the top of the conduit is below the existing ground surface or where a proposed embankment is constructed at least 2 feet (0.6 m) above the top of the conduit before installation.

Deflection.Racking, flattening or ovalization of the pipe’s cross-section.

Drainage Structures. Manholes, catch basins, inlets, inspection wells, junction chambers, and precast reinforced concrete outlets.

Fill. A situation where the top of the conduit is above the existing ground surface in an area where an embankment will be constructed.

Flexible Conduit. Plastic, corrugated metal, ductile iron (748.01), or steel casing pipe (748.06).

Infiltration. Water or other material that enters the conduit or drainage structure through the joints or conduit connections in excess of the limits for soil tightness or for the type of joint specified.

Lay Length. The length of a standard section of pipe as normally supplied by the manufacturer.

Plastic Conduit. Corrugated polyethylene, polyvinyl chloride, or ABS conduit.  This includes all of the following types of materials: 707.31, 707.32, 707.33, 707.41, 707.42, 707.43, 707.44, 707.45, 707.46, 707.47, 707.51, 707.52, 707.62, 707.65, 707.69, SS 938, and 748.02.

Rigid Conduit. Concrete pipe, vitrified clay pipe, or clay drain tile.  This includes all of the following types of materials: 706.01, 706.02, 706.03, 706.04, 706.05, 706.051, 706.052, 706.053, 706.08, and 706.09.

Run of Conduit. The conduit placed between drainage structures, between a drainage structure and an open outlet, between an open inlet and a drainage structure, or between the open inlet and open outlet.

Span.  Span is the conduit opening measured along the centerline of the roadway.  Mutiple cell openings are considered one span if the clear distance between the openings is less than half of the smaller contiguous opening.

Spring Line. A line along the length of the pipe at its maximum span.  For circular pipes the spring line is located at mid-height of the pipe (rise divided by two).

611.04   Submittals

A.      Shop Drawings. Prepare shop drawings and calculations for C&MS items 706.051, 706.052, 706.053, 706.13 and “Special Design” 706.02 as required below. Have an Ohio Registered Engineer prepare, sign, seal and date all drawings and calculations. Have another Ohio Registered Engineer check all drawings and calculations, then sign, and seal and date all drawings and calculations. Submit load rating report in accordance to the most current version of ODOT’s Bridge Design Manual along with one copy of the shop drawings and one copy of the calculations to the Office of Structural Engineering for all structures with a 10 foot or larger span. Submit an additional [RT1] copy of the shop drawings and calculations to the Engineer.

          1.      If Reinforced Concrete Circular Pipe, 706.02, requires a “Special Design” with a specified D-load requirement other than Tables 706.02-1 through 706.02-4, submit shop drawings and design calculations. Design the pipe to meet the D-load requirements to ensure the performance of this specification. Include the following information in the submittal: all structural design and loading information, all material specifications, all dimensions, and the installation plan.[RT2] 

          2.      Submittals for Precast reinforced concrete 3-sided flat topped culverts, precast reinforced concrete arch culverts, or precast reinforced concrete round sections, (706.051, 706.052, or 706.053) shall include structural analysis methods, structural design criteria and calculations, structure details, and shop drawings. Include details for a precast slab bottom if required.

          3.      To substitute a precast reinforced concrete 3-sided flat topped culvert (706.051), a reinforced concrete arch culvert (706.052), or a precast reinforced concrete round section (706.053) for one another, the submittal shall include hydraulic calculations. The proposed culvert shall meet or exceed the same hydraulic requirements as the specified culvert and minimum cover requirements. If the specified culvert is on pedestal walls, include the shop drawings for the pedestal wall design in the submittal because 3-sided flat topped culverts, arch culverts, and round sections require different pedestal wall designs.

          4.      To substitute either a precast reinforced concrete 3-sided flat topped culvert, a precast reinforced concrete arch culvert, or a precast reinforced concrete round section (706.051, 706.052, or 706.053) placed on a precast or cast-in-place slab bottom for a precast reinforced concrete box culvert (706.05), the submittal shall include hydraulic calculations. The proposed culvert shall [RT3] meet or exceed the same hydraulic requirements as the specified box culvert and minimum cover requirements. The Department may allow the bottom slab to be cast-in-place but will not issue a time extension for any delays resulting from the use of a cast-in-place bottom slab.

Department approval of shop drawings and calculations is not required.

B.      Installation Plan. Submit a written installation plan to the Engineer for installing all conduit and drainage structures for review and acceptance.

Submit the installation plan at least 15 days before any conduit or drainage structure work begins.  Do not perform work without an accepted installation plan.  Include the following required information for each conduit type and size, and type of drainage structure:

1.      Trench and excavation cross-sections with dimensions.

2.      Locations where the conduit is installed in a cut situation and where it is installed in a fill situation.

3.      Type of bedding and backfill material used and maximum lift thickness.

4.      Compaction density requirements for bedding and backfill and compaction equipment.

5.      Identify the starting location (outlet or inlet) for each run of conduit. All conduit must be laid from the outlet to the inlet unless approved by the Engineer.  Bell or groove-end Type A conduit must have a bell or groove-end at the inlet.

6.      Maximum allowable joint gap between conduit sections.

7.      Other installation details as necessary.

8.      Provide written confirmation from the conduit manufacturer that the pipe material and strength supplied are appropriate for the material and density requirements described in the installation plan for the backfill and bedding as well as the height of cover. Ensure the pipe material meets the durability design specified in the plans.  This confirmation by the conduit manufacturer will not relieve the Contractor of the responsibility for obtaining the required results.

Deviations from the installation plan during construction require a revision of the installation plan.  Resubmit all revisions to the installation plan to the Engineer within 5 days of the change with the conduit manufacturer’s written confirmation that the pipe material and strength supplied are appropriate for the material and density requirements described in the newly revised installation plan for the backfill and bedding.  If the conduit manufacturer does not provide this written confirmation to the newly revised installation plan, all the conduit installed according to the unconfirmed plan must be replaced.  No new installation plans will be considered until all previous installation plans have been confirmed and accepted.

Provide the conduit manufacturer's structural calculations when specified or within 10 days when requested by the Engineer.

For structural plate and metal pipe arch conduit with a span of 57 inches (1440 mm) or larger, ensure the manufacturer provides match-marked ends on the conduit.  Include a layout drawing in the installation plan.

For metal conduit with two structural plate thicknesses specified, identify the location of the thicker plates.  For precast concrete 3-sided flat and arch topped structures (706.051 and 706.052) provide a 3 inch (75 mm) deep keyway centered on the leg and at least 6 inches (150 mm) wider than the thickness of the leg at the bottom.  For precast concrete round sections (706.053) provide an 8-inch (200 mm) deep keyway for spans up to 24 feet (7.3 m) and a 10-inch (254 mm) deep keyway for spans greater than 24 feet, (7.3 m).  Center the keyway on the precast arch base.  The width of the keyway must be 8 inches (200 mm) greater than the thickness of the precast arch base.  For non-vertical leg arches set on pedestal walls, a one sided keyway is acceptable if the required pedestal wall design thickness is not sufficient for a full keyway.

The Contractor may choose to jack or tunnel any conduit with written approval from the Office of Hydraulic Engineering.  Submit a written request to the Office of Hydraulic Engineering and allow at least 28 days for review.

C.      Construction Inspection Forms.  Perform work only in the presence of the Contractor’s representative doing the inspection. Submit construction inspection forms to the Engineer for  each run of conduit and each drainage structure.  Use construction inspection form CA-P-1 for conduit and use construction inspection form CA-P-3 for drainage structures.  Ensure that all deviations from the installation plan are noted on the construction inspection form.  Ensure that the information on the construction inspection form is complete and accurate and that the form is signed by a representative of the Contractor certifying that the information on the form is accurate.  The Contractor’s representative must make the following statement on the form:

“I certify that the information on this form is accurate and all deviations from the current installation plan have been noted.”

Submit each day’s construction inspection forms before the start of the next work day.  If the Engineer gives notice that the information on the form is incomplete or not accurate, do not continue related work until complete and accurate forms are submitted and accepted by the Engineer.

Construction inspection forms CA-P-1 and CA-P-3 require trench and bedding measurement checks to be taken every 50 feet with a minimum of two per run.  Record measurements to the nearest 0.1 foot (30 mm).  If these measurements are not taken, do not continue related work until the Contractor submits a plan in writing to the Engineer for approval that explains how these measurements will be determined.

D.      Performance Report.  Provide a performance report for each performance inspection, and provide separate reports for each change in conduit size or change in material type.  Include the following in each performance report:

A.     Project number and County-Route-Section

B.     Date of performance inspection

C.     Type and size of conduit

D.     Time of video recording

E.      Location (e.g. station and offset) and viewing direction.  For Type A and B conduit, include the latitude and longitude of the conduit at the location where the culvert centerline and the roadway centerline intersect. Ensure the units are in decimal degrees to the sixth decimal place.  Use a Global Navigation Satellite System (GNSS) unit that is accurate to within 15 feet (4.5 meters).

F.      Summary of all defects including type, measurement, and location

G.     For remote inspections using a mandrel, indicate in the performance report, the size of the mandrel and how it was calculated.  Document all locations where the mandrel was unable to advance through the conduit.

H.     For remote inspections using a crawler mounted camera with laser profiler, include:

1.      Three dimensional model of the conduit based on the laser profile measurements.

2.      Digital profile of conduit extracted from the inspection video

3.      Calculations of the ovality, capacity and delta of the conduit

4.      Explanation as to why data was unattainable for any section of the conduit

Submit a performance report to the Engineer within 5 days of completing the performance inspection of the conduit run or drainage structure. Submit the performance report in a digital format that allows the Department to make additional copies.  Submit the results of the performance survey at the same time as the performance report or earlier.

611.05  Excavation. Excavate as described in the installation plan.  Record any deviations from the installation plan on the construction inspection forms and revise the installation plan. 

Excavate trenches along the centerline of the conduit.  When installing conduit in a fill situation, construct the embankment to the elevation of the spring line for the conduit or higher before excavating the trench. 

Provide a firm bed for the full width and length of the trench. If bedding material is not provided, loosen the middle third of the bed to seat the conduit.  Provide a firm bed beneath the drainage structure.

Remove any unsuitable material exposed in the bed for the width of the trench and a depth of at least 6 inches (150 mm).  Replace the unsuitable material with structural backfill, Type 1 or 2.  Remove any rock or shale exposed in the bed to a depth of at least 6 inches (150 mm). Replace the rock or shale with structural backfill, Type 1 or 2.  The Department will pay for this work according to 109.05, unless otherwise noted in the Contract Documents. If the Engineer changes the flow line by more than one foot (0.3 m), the Department will pay according to 109.05, unless otherwise noted in the Contract Documents.

611.06  Bedding and Backfill. Place and compact bedding and backfill as described in the installation plan.  Record any deviations from the installation plan on the construction inspection forms and revise the installation plan. 

If using coarse aggregate material for bedding and backfill below the ground water elevation, wrap the coarse aggregate with Type A geotextile fabric.  Shape the bedding with recesses to receive the bell of bell-and-spigot conduit.  Loosen the bedding in the middle third to seat the conduit.  If using LSM for bedding, also use LSM for backfill to at least 6 inches (150 mm) over the top of the conduit.  Install bedding and backfill for Type F conduits for underdrain outlets according to 605.03.C.

Ensure compaction density complies with the installation plan by performing compaction testing according to Supplement 1015 and the manufacturer’s recommendation.  If Structural Backfill Type 3 or open graded material is used, vibrate, tamp or compact to the compaction level required by the manufacturer in the installation plan. 

611.07  Laying Conduit. Maintain flows and drainage at all times until the new facilities are completed and in service.  Any temporary diversion of flows and drainage is the responsibility of the Contractor.  Maintain flows and drainage or provide temporary diversion at no additional cost to the Department.

Visually inspect all conduit in the presence of the Engineer before it is placed in the trench. Replace all conduit that is damaged as determined by the Engineer.  Before installation, measure and record on the CA-P-1 the widest inside dimension of each lay length of conduit.  This measurement is to be taken three times along each run of conduit.  For corrugated metal conduit measure to the inside peak of the corrugations.

Lay the conduit in the center of the trench at the invert elevation shown on the plans.  Any deviation must be approved by the Engineer.  If the Engineer does not approve the deviation, stop all related work until the conduit is relaid. Ensure that the conduit is in contact with the bedding for its full length and maintain the line and grade of the conduit.  The Contractor’s representative doing the inspection will visually inspect all conduit before placing any backfill. Rejoin, re-lay, or replace conduits that have settled, or that are damaged.

Lay all conduits as described in the installation plan and according to the following requirements.  The installation plan cannot change the following requirements.  Meeting these requirements does not relieve the Contractor of the responsibility for obtaining the required results.  Record any deviations from the installation plan on the construction inspection forms and revise the installation plan.

A. If the welded seam in a metal conduit is longitudinal, place the seam at the spring line.

B. For all metal conduit, use only lifting devices that do not require a hole through the material.

C. Lay metal conduit so that match marks align.

D. For all metal conduit that is cut at a drainage structure or headwall, treat the cut end with the same coating as the conduit.  Do not treat any cuts within the run.

E. Where two structural plate thicknesses are specified, place the thicker plates according to the installation plan.

F.  Set precast reinforced concrete 3-sided flat topped culvert sections (706.051) in the keyway. Place the units in a 1/2-inch (13 mm) bed of mortar.  If proper line and grade of the structure cannot be maintained on the bed of mortar, set the sections on 5 ´ 5-inch (125 ´ 125 mm) masonite or steel shims.  Fill the entire keyway joint with mortar.

G. Set precast reinforced concrete arch sections (706.052) in the keyway.  Place the units on 5 ´ 5-inch (125 ´ 125 mm) masonite or steel shims to provide a minimum 1/2-inch (13 mm) gap between the footing and the bottom of the leg.  Fill the entire keyway joint with mortar.

H. Set the precast reinforced concrete round sections (706.053) in the keyway.  Place the units on masonite or steel shims to provide a minimum 1.5-inch (38 mm) gap between the footing and the bottom of the precast arch base.  Fill the entire keyway joint with mortar.  Provide 5000 psi. (34.5 MPa) mortar.  For arches that gain structural continuity by a cast-in-place closure at the project site, provide concrete with the same compressive strength as the precast arch.

I.  For precast reinforced concrete culverts (706.05, 706.051, 706.052, and 706.053) fill the lifting devices with mortar.  Cover the exterior of the lifting devices with joint-wrap material if they are outside the limits of the membrane waterproofing.  Use joint-wrap with a minimum width of 9 inches (225 mm).  Use only lifting devices that do not require a hole through the structure.

J.  The inlet of all rigid conduit and plastic conduit used in a Type A application (open inlet) must have a bell. If field cutting is necessary to furnish a bell at the inlet, locate the cut end at an interior joint by removing part of a section within the run. Join the conduit as described below and encase the joint with a concrete collar to ensure a stable connection.

K. The top and bottom of reinforced concrete pipe that has elliptical or quadrant mat reinforcing will be clearly marked on the pipe. Handle and place this pipe so that the markings remain in a vertical plane through the center of the pipe. 

L. Handle and place reinforced concrete pipe with auxiliary reinforcements (stirrups) with the centerline of the auxiliary reinforcement system (stirrups) in a vertical plane through the center of the pipe.

M.          Fill all lifting holes in rigid conduit with concrete according to the manufacturer’s recommendations or using a method approved by the Engineer.

N. Immediately after placing conduit, construct the end treatments at both the outlet and inlet ends. Show this activity as part of the conduit construction on the progress schedule. These end treatments include headwalls, concrete riprap, rock channel protection, sod or other erosion control items.

O. When conduit is installed under pavement, perform the following immediately after the completion of backfill placement and compaction: remove and dispose of all surplus material according to 105.17, clear the site, and replace all pavement necessary to restore traffic. Show this activity as part of the conduit construction on the progress schedule.

611.08  Joining Conduit. Ensure the joints are clean and free from dirt or debris.  Join the conduit sections as described below. Visually inspect all conduit, joints, and gaskets in the presence of the Engineer before placing any backfill.  Rejoin, re-lay, or replace any conduit that does not meet the requirements.

The Engineer may allow joint materials other than those listed below, provided the Contractor demonstrates the proposed material will result in durable, sealed joints.

Join conduit as described in the installation plan and according to the requirements below.  For conduit material not listed below, join conduit as recommended by the manufacturer.  Record any deviations from the installation plan on the construction inspection forms and revise the installation plan. 

A. Corrugated Metal Conduit.         Join corrugated metal conduit, Types A, B, C, D, and F, using either coupling bands or bell and spigot joints.  Join the conduit according to the following requirements.

1.      Coupling bands.         Furnish coupling bands conforming to 707.01 or 707.02, and having the same coating as the conduit being joined.  Use either coupling bands with gaskets or wrap the joints with Type A geotextile fabric.

2.      Bell and spigot joints.         If using bell and spigot joints, place a gasket in the first corrugation of the spigot end and thoroughly lubricate the gasket and the bell end of the receiving conduit before assembly. Drive the spigot securely into the bell.

3.      For coorugated metal conduits with smooth steel  interior liner, furnish a joint conforming to 707.18, 707.19 and 707.20.

B. Rigid Conduit.   Join rigid conduit, Types A, B, C, D, and F, according to the following requirements.

1.      For all concrete pipe (706.01, 706.02, 706.04) that is not epoxy coated and vitrified clay pipe (706.08), seal the joints using one of the following methods:

a.      Fill the joint with bituminous pipe joint filler, providing a smooth transition on the inside and a complete seal on the outside.

b.      Use preformed flexible joint sealant to seal the joint.  Before installing the joint sealant, prime both surfaces of the joint with asphalt based primer according to the joint sealant manufacturer’s recommendations.

c.      Use resilient and flexible gasket joints.  If the conduit is a sanitary sewer pipe, test the joint for infiltration and exfiltration according to ASTM C 969 or ASTM C 1103.  If any joint does not meet the test requirements, make corrections until the joint meets the test requirements.

2.      For epoxy coated concrete pipe (706.03), seal the joint using fibrated coal tar joint compound applied according to the conduit manufacturer’s recommendations.

3.      For precast reinforced concrete box culverts, precast reinforced concrete 3-sided flat topped culverts, precast reinforced concrete arch culverts, and precast reinforced concrete round sections (706.05, 706.051, 706.052, and 706.053), place the sections according to the installation plan.  Clean the joint gap of all debris and apply one of the following:

a.      For joints in precast reinforced concrete box culverts (706.05), fill the top exterior joint gap and the bottom and side interior joint gap with mortar.  Next, for any exterior joint not covered by membrane waterproofing, cover the exterior joint with a 9-inch (225 mm) wide strip of joint wrap in accordance with the manufacturer’s recommendation.  Center the joint wrap on the joint.

b.      For precast reinforced concrete 3-sided flat topped culverts (706.051), fill the top keyway joint with nonshrink mortar.  If the side or leg joints are tongue and groove types, fill the joints as described above for concrete box culverts.  If the side or leg joints are keyway types, fill with nonshrink mortar.  Prepare, place, and cure the nonshrink mortar according to the nonshrink mortar manufacturer’s recommendations.  Wet all surfaces of the keyway joint, but do not allow free standing water in the joint.  Next, cover the exterior joint with a 12-inch (300 mm) wide strip of joint wrap.  Center the joint wrap on the joint.  Use a continuous length of joint wrap sufficient to extend from the bottom of the vertical face on one side to the bottom vertical face on the other side.  Apply membrane waterproofing to the precast sections after they are installed.

c.      For precast reinforced concrete arch culverts and precast reinforced concrete round sections (706.052 and 706.053), install a 7/8 ´ 1 3/8-inch (24 ´ 34 mm) preformed flexible joint sealant (706.14) along the outside joint chamfer.  Use a continuous length of joint sealant sufficient to extend from the bottom of the vertical face on one side to the bottom vertical face on the other side.  Before installing the joint sealant, prime the joint chamfer with a primer according to the joint sealant manufacturer’s recommendations.  For 706.052 and 706.053, cover all exterior joints with a 12-inch (300 mm) wide strip of joint wrap centered on the joint.   Use a continuous length of joint wrap sufficient to extend from the bottom of the vertical face on one side of the structure to the bottom vertical face on the other side.  Next, apply all waterproofing as shown on the plans.  Apply membrane waterproofing to the precast sections after they are installed.

d.      For precast reinforced concrete box culverts, precast reinforced concrete 3-sided flat topped culverts, precast reinforced concrete arch culverts, and precast reinforced concrete round sections (706.05, 706.051, 706.052, and 706.053), apply an approved epoxy-urethane sealer per the plans to all top surfaces not covered by membrane waterproofing.  Extend sealer 1 foot (0.3 m) below the backfill on all sides of the culvert sections including the joint.

C.      Plastic Conduit.          Join plastic conduit, Types A, B, C, D, and F, using either coupling bands, bell and spigot joints, or bell-bell couplers.  Join the conduit according to the following requirements.

1.      Coupling bands.         Furnish coupling bands of the same size as the conduit and that engage at least two full corrugations on each conduit section.  Furnish gasketed coupling bands of the same material as the plastic conduit.

2.      Bell and spigot joints.         If using bell and spigot joints, drive the spigot securely into the bell.  For gasketed joints, ensure that the gasket is properly seated after joining.

3.      Bell-bell couplers.       If using bell-bell couplers, drive the conduit securely into the coupler.

D.      Type E Conduit.         Join Type E conduits with open joints by butting the ends and wrapping with a minimum 4-inch (100 mm) wide tarred paper or tarred burlap.  Place soil around this material to hold it in place during backfilling.

611.09  Exterior Coatings and Membrane Waterproofing. Apply exterior coatings and membrane waterproofing as specified below.  Protect the exterior coatings and membrane waterproofing from damage during placing of the bedding, backfill, and embankment.

A.      For concrete conduit, clean the surfaces before placing the membrane waterproofing. Apply membrane waterproofing as specified. Apply the membrane waterproofing to all surfaces that will be in contact with the backfill (top and sides) according to the membrane waterproofing manufacturer’s recommendation.

B.      For structural plate metal structures and corrugated metal box culverts (707.03, 707.15, 707.23, and 707.25) with less than 8 feet of cover, apply waterproofing by one of the following methods.

1.      Coat the exterior of the conduit above the limits of the bedding and within the limits of backfill.  Ensure that all plate seams and bolts are thoroughly sealed.  Furnish coating material and apply it according to AASHTO M 243.  Allow asphalt mastic material to dry 48 hours and tar base material to dry 28 hours before placing the conduit backfill.  Rib stiffeners do not need to be coated.

2.      Construct buried liner waterproofing membrane protection in the fill according to  the manufacturer’s recommendations. The buried liner waterproofing membrane protection must be a continuous sheet placed over the conduit and extend at least 10 feet (3.3m) outside of the paved shoulder and for the width of the trench.  Seams constructed in the field are not acceptable.

611.10  Drainage Structure Construction. Install drainage structures as shown on the plans and standard construction drawings.  Maintain flows at all times until the new facilities are completed and in service.

Visually inspect all precast drainage structures in the presence of the Engineer before they are placed. Replace all drainage structures that are damaged as determined by the Engineer.

Install each drainage structure casting to the elevation, station, and offset shown on the plans.  Any deviations must be approved by the Engineer.  If the Engineer does not approve the deviation, stop all related work until the drainage structure is reinstalled.  The offset is to the center of the casting.  Place each manhole base so that it is in alignment with the pipe and its invert elevation according to the standard construction drawings.  Use flat slab top manholes as shown on the standard construction drawing.  Do not remove the flat slab top manhole lifting devices.

Locate or cut conduits so any protrusion inside the structure wall is minimized.

Set iron frames, tops, and covers in mortar with a flush joint.

Prevent earth or debris resulting from construction operations from entering the drainage structure.  Remove any debris resulting from construction.

Thoroughly grout the underdrain outlet pipe to the precast reinforced concrete outlet with a flush mortar joint.

Take adequate precautions to prevent concrete or mortar from freezing.  Preheat the brick, concrete block, or precast concrete structure throughout the entire mass to a temperature between 50 to 80 °F (10 to 27 °C) before placing mortar if the ambient temperature is 40 °F (4 °C) or less.

A.      Brick and Block Masonry.        For brick and block masonry drainage structure construction thoroughly wet the units before placing in mortar. Lay the units with a flush mortar joint. Cure the exposed surfaces of all brick and block masonry by covering with wet burlap or by applying a curing membrane according to 705.07.  Keep burlap wet for at least 48 hours.

B.      Modular Precast Concrete.       For precast concrete modular drainage structures furnish precast bases on a compacted bed with or without a bedding material as described in the installation plan. Ensure that the bed is level and uniformly supports the entire area of the base.  Seal all joints between modules as described above for concrete conduit.

All penetrations through precast drainage structures must be either manufactured or cored.

After placing the conduit, grout all openings less than 4 inches (100 mm) between the pipe and structure with mortar. Grout all openings greater than 4 inches (100 mm) between the pipe and structure with non-shrink mortar. Furnish the same curing membrane for barrier inlets as that used on the barrier.  Apply the curing membrane according to 622.07.

C.      Reconstruction to grade.  When reconstructing an existing manhole, catch basin or inlet to grade, follow the procedure below.

1.      Carefully remove and clean the existing castings.

2.      Remove the existing walls of manholes down to the spring line of the conduit or below as necessary.  Remove existing walls of catch basins and inlets below the window openings, grates, or any points of wall failure.

3.      Using the salvaged casting, reconstruct the structure to the new grade, conforming as nearly as practicable to the existing dimension and type of construction.

D.      Adjustment to grade.           When adjusting an existing manhole, catch basin, or inlet to match grade, follow the procedure below.

1.      Carefully remove and clean the existing frame, adjust the height of supporting walls, and reset the existing frame in mortar or concrete to the new grade.

2.      Carefully remove the existing cover or grate and install a casting or an acceptable adjusting device on file at the Laboratory or an adjusting device approved by the Engineer to the new grade and install according to the adjusting device manufacturer’s recommendations.

611.11  Field Paving of New or Existing Conduit. Field pave the bottom of the conduit with concrete as shown on the plans.

For new pipe installations, do not pave until at least 4 feet (1.2 m) of fill is placed on top of the conduit or the top of subgrade is reached.  If the paving is placed before completion of the entire fill, clean any gaps between the conduit and concrete paving, and then fill with heated bituminous material conforming to 705.04.

Reinforce the paving with 2 x 2-W0.9 x W0.9 galvanized welded wire fabric or comparable.  Provide a mesh with a width 4 inches (100 mm) less than the finished paving.  Securely fasten the mesh to the conduit near each edge and at the center of the mesh at points not more than 4 feet (1.2 m) apart along the flow line of the culvert.  Repair any damage to the galvanizing or other coating material caused by placement or by tack welding.  Use wire brushing and zinc rich paint to make the repairs.  Provide support beneath the mesh where necessary using galvanized support chairs or #4 reinforcing steel, meeting the material requirements of 509.02

For aluminum structural plate, securely fasten the mesh to the circumferential seam bolts with galvanized tie wire.

Construct paving so that it is 3 inches (75 mm) thick measured from the top of the corrugations of the conduit to a height equal to 1/3 of the rise.  Maintain the position of the mesh while placing concrete.  After placing the concrete, strike it off with a template to produce the proper radius, and finish with a float to produce a smooth finish. Cure the concrete according to 451.11.

611.12  Performance Inspection.  Notify the Engineer at least five workdays before conducting a performance inspection.  Ensure the Engineer is present during all performance inspection activities.

For all Type A, B, and C conduits, inspect all lengths greater than 20 feet with slopes of 25 percent or less and all new drainage structures.  A performance inspection is not required for projects that meet all of the following: 

All conduit is Type C

Conduit plan quantities are less than 100 feet (30.5m)

All conduit has less than 16 feet (4.8m) of maximum fill height

Perform the inspection no sooner than 30 days and no later than 90 days after the completion of the finished grade when not below pavement and after the completion of the  aggregate base when any portion of the conduit is below pavement.  The Engineer may permit inspection beyond the 90 day limit .  If any corrections are made to the installed pipe after the completion of the finished grade or aggregate base and prior to the performance inspection, wait 30 days after the correction was made to do the performance inspection.  If the contract duration will not permit a 30 day waiting period then the Engineer may adjust the waiting period.

Conduct a performance survey to verify that the elevation and location of each Type B and C conduit and drainage structure is within the tolerances listed in 611.13 and 611.14.  Conduct a performance survey to verify that the elevation and location of each Type A conduit matches the plan.  The 30 day waiting period does not apply to the performance survey.  Notify the Engineer at least two workdays before conducting the performance survey.

Furnish a video recording of each inspection.  On the recording, identify the date and time of the inspection, a description of the conduit or drainage structure being inspected, the location, and the viewing direction. Record the entire run of conduit being inspected.  Provide a source of light that allows all areas of concern to be readily observed on the video recording.  Furnish the video recording in a digital, reproducible format on one of the following media types: DVD, CD or other media type approved by the Office of Hydraulic Engineering.

Ensure that the condition of the conduit will allow an accurate inspection. Perform a manual inspection on drainage structures.  Perform either a manual inspection or remote inspection as follows:

Non-circular conduits – Manual inspection

Conduits with a rise of 48 inches (120000 mm) and greater – Manual inspection.

Conduits with a rise of 36 inches (900mm) up to 48 inches (1200mm) – Manual or Remote inspection.

Conduits with a rise of 12 inches or greater up to 36 inches (300 to 900 mm) – Remote inspection.

Conduits with a rise less than 12 inches (300 mm) and Type D, E, and F conduits – Remote inspection as directed by the Engineer.  The Department will pay for this inspection according to 105.10.

A.      Manual Inspection. Perform a manual inspection by entering the conduit or drainage structure to record video and to make measurements.  If the conduit or drainage structure is considered a confined space, provide entry for all project inspection personnel according to OSHA requirements.

Measure the deflection of the conduit using either a metal or fabric tape and read to the nearest ½ inch (10 mm).  Measure crack width using either a crack comparator or a feeler gage capable of measuring 0.01 inch (0.25 mm).  Measure joint gaps using a tape or ruler and read to the nearest ½ inch (10 mm).  Other measuring devices may be used if approved by the Engineer.  Record the measurements and include them in the performance report.  Measure the following:

1.      For all conduits, measure the location, length, and greatest width of each crack.

2.      For flexible conduit, measure the smallest inside diameter three times for each conduit section in the run.  Take the first measurement vertically from the crown to invert (12 o’clock to 6 o’clock positions).  Take the second measurement by rotating 60 degrees from vertical (2 o’clock to 8 o’clock positions).  Take the third measurement by rotating 120 degrees from vertical (4 o’clock to 10 o’clock positions).  For all measurements, stretch tape to full extent across inside of pipe.  For corrugated metal conduit, the inside diameter is defined as the distance between the inside peaks of the corrugations.

3.      For all conduits, measure the widest gap at each joint in the run.

4.      For conduit with manufactured seams, measure the location, length, and greatest width of any separation at the seam.

5.      For drainage structures, measure the location, length and greatest width of each crack and the widest gap at each conduit entering the drainage structure.

Record the location of any other defect not listed above and describe the defect.  For each measurement location in a conduit, record the length from the nearest drainage structure.

B.      Remote Inspection. Perform a remote inspection by using a crawler mounted camera to record video and using equipment described below to make measurements. Use equipment that meets the requirements of Supplemental Specification 902.  Remove all debris from the conduits being inspected according to 107.19.  Dewater the conduit if the water level hinders the performance of the equipment.

Based on the type of conduit, make measurements using the equipment listed in the following table.  Also record the location of any other defect not listed below and describe the defect.

Table 611.12.B

Conduit Type

Measurement Equipment

Type of Measurement

Rigid conduit and 707.11, mortar lined corrugated steel pipe

Crawler mounted camera according to 902.01with crack measuring capabilities according to 902.02 C

Joint gaps

Crack widths

Plastic conduit, 707.12, corrugated steel spiral rib conduit,  707.24, corrugated aluminum spiral rib conduit, 748.01, ductile iron pipe and 748.06, steel casing pipe, and Circular corrugated metal conduit not listed below

Crawler mounted camera with laser profiler according to 902.02 A, B, and C or Mandrel according to 902.03 and Crawler mounted camera according to 902.01 with crack measuring capabilities according to 902.02 C

Joint gaps

Crack widths

Deflection

The following types of corrugated metal conduit:

707.04, precoated, galvanized steel culverts

707.05 and 707.07, bituminous coated corrugated steel pipe with paved invert,

707.13 and 707.14, bituminous lined corrugated steel pipe

Crawler mounted camera with laser profiler according to 902.02 A, B, and C

Joint gaps

Crack widths

Deflection

611.13  Conduit Evaluation. Have an independent Registered Engineer evaluate the conduit and any defects as required by AASHTO LRFD Bridge Construction Specifications, Section 26 for metal conduit, Section 27 for concrete conduit, and Section 30 for plastic conduit with modifications according to this specification.  The independent Registered Engineer cannot be an employee of the Contractor or the conduit manufacturer.

When using a laser profiler, the conduit deflection must be calculated from the actual inside diameter at the measured location or calculated by inputting the nominal diameter.  When using a mandrel, the mandrel must be sized according to 902. .If the evaluation determines repairs are not necessary and repairs are not required based on the type or size of the defect in Table 611.13, have the independent Registered Engineer make the following statement in the evaluation:

“I certify that repairs are not required to address the defects identified during the conduit evaluation.  The conduit will function as designed in accordance with the contract documents.”

If the evaluation determines repairs are necessary, or if repairs are required based on the type or size of the defect in Table 611.13, have the independent Registered Engineer prepare, sign, seal, and date plans for the repair.  The independent Registered Engineer must make the following statement on the repair plans:

“I certify that this repair plan was designed to ensure the repaired conduit will function as designed and will meet the requirements described in the contract documents.”

Table 611.13

Metal Conduit

Evaluate if infiltration is observed.

Evaluate all racking, buckling or denting.

Evaluate vertical alignment of conduit – Ensure there are no vertical sags in the conduit that trap water.

Evaluate if the joint gap exceeds the tolerance* for a length less than 1/3 of the circumference.

Repair or replace conduit if the joint gap exceeds the tolerance* for a length greater than or equal to 1/3 of the circumference.

Repair all damage to coatings.

Repair or replace conduit if the mandrel per 902.03 does not pass through the conduit or the laser profiler per 902.02 indicates a deflection > 7.5%.

Rigid Conduit

Evaluate if infiltration is observed.

Evaluate if joint gap exceeds the tolerance* for a length less than 1/3 of the circumference.

Evaluate vertical alignment of conduit – Ensure there are no vertical sags in the conduit that trap water.  Repair or replace conduit if the joint gap exceeds the tolerance* for a length greater than or equal to 1/3 of the circumference.

Repair or replace conduit if cracks > 0.10 inch.

Repair or replace conduit if spalls or slabbing are observed.

Plastic Conduit

Evaluate if infiltration is observed.

Evaluate all racking, bulging or buckling.

Evaluate if joint gap exceeds the tolerance* for a length less than 1/3 of the circumference.

Evaluate vertical alignment of conduit – Ensure there are no vertical sags in the conduit that trap water.Evaluate all cracks.

Repair or replace conduit if the joint gap exceeds the tolerance* for a length greater than or equal to 1/3 of the circumference.

Repair or replace conduit if the mandrel per 902.03 does not pass through the conduit or the laser profiler per 902.02 indicates a deflection > 7.5%.

* Note:  The tolerance is defined as the maximum joint gap listed in the the Installation Plan.

Submit the evaluation, repair plans, and revised installation plan to the Engineer at least 7 days before performing the repairs. Provide written confirmation from the conduit manufacturer that the repair methods are appropriate.  The Department may review the submittal, but Department acceptance is not required.  If the Department does not review the plan, proceed with the repairs 7 days after delivering the submittal to the Engineer.  If the Department reviews the submittal and determines it does not conform to the Contract, revise, resubmit, and proceed with the repairs only after the Department accepts the resubmittal.

Perform the repair at no additional cost to the Department.  Perform an inspection to evaluate the repaired portion of the conduit and any conduit potentially affected by the repair work 30 days after the repair has been made.  Perform the inspections according to 611.12 and at no additional cost to the Department.

611.14  Drainage Structure Evaluation.  Have an independent Registered Engineer evaluate the drainage structures and any defects listed in the table below.  The independent Registered Engineer cannot be an employee of the Contractor or drainage structure manufacturer. 

Table 611.14

Defects requiring evaluation

Connection between conduit and drainage structure has free flowing water or infiltration.

Grate is more than 0.1 ft (30 mm) from horizontal or vertical location documented on construction inspection forms CA-P-1 or CA-P-3.

Invert elevation is more than 5 percent of the conduit diameter or 0.1 ft (30 mm) from plan elevation, whichever is greater.

Grates do not properly seat in the frame.

Grates are not placed on the required slope.

Grates or frames are broken or cracked.

Drainage structure does not match the details on the standard construction drawing.

Steps do not line up.

Manhole top does not match plans.

If the evaluation determines repairs are not necessary, have the independent Registered Engineer make the following statement in the evaluation:

“I certify that repairs are not required to address the defects identified during the drainage structure evaluation.  The drainage structure will function as designed in accordance with the contract documents.”

If the evaluation determines repairs are necessary have the independent Registered Engineer prepare, sign, seal, and date plans for the repair.  The independent Registered Engineer must make the following statement on the repair plans:

“I certify that this repair plan was designed to ensure the structure will function as originally designed and will meet the requirements described in the contract documents.”

Perform the repair at no additional cost to the Department.  Perform an inspection to evaluate the repaired portion of the drainage structure and any conduit potentially affected by the repair work 30 days after the repair has been made.  Perform the inspections according to 611.12 and at no additional cost to the Department.

611.15  Surface Settlements. Repair any surface settlement within the trench limits or within 4 feet (1.2 m) of a drainage structure.  Have an independent Registered Engineer evaluate the conduit according to 611.13 or the drainage structure according to 611.14.  Perform all repair work at no additional cost to the Department.

611.16  Method of Measurement. The Department will measure conduit by the number of feet (meters), measured from center-to-center of small drainage structures or between open ends including the length of pipe bends and branches.  The Department will not deduct conduit length for catch basins, inlets, or manholes where the distance measured in the direction of flow, including bends, is 6 feet (2 m) or less.  Where the location of a drainage structure or an open end is changed with the approval of the Engineer to accommodate full conduit sections, the Department will measure the length placed.  Conduits placed on slopes steeper than 3H:1V or with beveled or skewed ends will be measured along the invert.

The Department will measure field paving of existing pipe by the number of feet (meters).

The Department will measure Manholes, Inlets, Catch Basins, Inspection Wells, Junction Chambers, and Precast Reinforced Concrete Outlets, whether new, reconstructed, or adjusted to grade, by the number of each type of structure complete and accepted.

611.17  Basis of Payment.  Payment for all inspections is included with the contract unit price of the corresponding pay item.  When a pay item calls for concrete encasement, the Department will pay for furnishing and placing the concrete encasement and for any additional excavation required under the contract unit price for the encased conduit.  When a pay item calls for conduit to be field paved, all work and materials necessary for the item are included in the contract unit price for each conduit.

All required repairs, including any settlement problems, must be made prior to acceptance. Payment for the repair is included with the contract unit price of the corresponding pay item. The Department will not make additional payment for repair work on conduit installed under this specification.

The Department will pay for accepted quantities at the contract prices shown below according to the following schedule:

After installation of conduit or drainage structure                       60%

After performance inspection is completed                                  10%

After acceptance of the conduit or drainage structure               30%

Item           Unit                                Description

611             Foot (Meter)                    ___" (___ mm) Conduit, Type ___

611             Foot (Meter)                    ___ ´ ___ Conduit, Type ___

611             Foot (Meter)                    ___" (___ mm) Conduit Reconstructed,

                                                               Type ___

611             Foot (Meter)                    Type ___ Precast Reinforced Concrete 

                                                               Three-Sided Flat Topped
                                                               Culvert, ___' (___ mm) Span ´ ___'

                                                               (___ mm) Rise

611             Foot (Meter)                    Type ___Precast Reinforced Concrete 

                                                               Arch Sections,
                                                               ___' (___ mm) Span ´ ___' (___ mm) Rise

611             Foot (Meter)                    Type ___ Precast Reinforced Concrete 

                                                               Round Sections,
                                                                ___' (___ mm) Span ´ ___' (___ mm) Rise

611             Foot (Meter)                    ___' (___ mm) Rise ´ ___' (___ mm)

                                                               Span Conduit,
                                                               Type A Corrugated Steel Box Culvert,
                                                               ___' (___ mm) Minimum Cover,

                                                               ___' (___ mm) Maximum Cover

611             Foot (Meter)                    ___' (___ mm) Rise ´ ___' (___ mm)

                                                               Span Conduit,
                                                               Type ___Corrugated Aluminum Box Culvert,
                                                               ___' (___ mm) Minimum Cover, ___'

                                                               (___ mm) Maximum Cover

611             Foot (Meter)                    ___" (___ mm) Conduit, Type ___, with

                                                               Field Paving of Pipe

611             Foot (Meter)                    ___" (___ mm) Conduit, Type ___,

                                                               Field Paving of Existing Pipe

611             Foot (Meter)                    Conduit, Type F for underdrain outlets

611             Each                                Manholes

611             Each                                Inlets

611             Each                                Catch Basins

611             Each                                Inspection Wells

611             Each                                Junction Chambers

611             Each                                Manhole, Catch Basin or Inlet Reconstructed

                                                               to Grade

611             Each                                Manhole, Catch Basin, or Inlet Adjusted

                                                               to Grade

611             Each                                Precast Reinforced Concrete Outlet

ITEM 613  LOW STRENGTH MORTAR BACKFILL

613.01  Description

613.02  Materials

613.03  Mix Proportioning

613.04  Mix Adjustment

613.05  Alternate Mixes

613.06  Mixing Equipment

613.07  Mixing the Materials

613.08  Placing Mortar

613.09  Method of Measurement

613.10  Basis of Payment

613.01  Description.  This work consists of placing a low strength mortar backfill around conduits and at other locations.  Perform the work for this item according to Items 611 and 499, except as modified below.

613.02  Materials.  Furnish materials conforming to:

Cement.................................................... 701.01 or 701.04

Fly Ash.................................................................... 701.13

Furnish fine aggregate consisting of foundry sand, natural sand, sand manufactured from stone, gravel, or air-cooled blast furnace slag.  Conform to the fine aggregate gradation requirements of 703.05.  Use fine aggregate that is fine enough to stay in suspension in the mixture to ensure proper flow.

Furnish an air-entraining admixture that is designed for use in low strength mortar mixtures (also called controlled density fill or flowable fill).

613.03  Mix Proportioning.  Furnish a low strength mortar mixture listed below or provide an alternate mix conforming to 613.05.

Table 613.03-1

Type 1[1]

Type 2

Type 3

lb/yd³

kg/m³

lb/yd³

kg/m³

lb/yd³

kg/m³

Cement

50

30

100

59

0

0

Fly Ash, Class F

250

148

[2]

[2]

1500

890

Fly Ash, Class C [4]

0

0

0

0

297

297

Fine Aggregate [3]

2910

1726

2420

1436

0

0

Water (Target)

500

297

210-300

125-178

850

504

[1]  The Contractor may add an air-entraining agent specifically designed for the use in the low strength mortar mixture.

[2]  Entrained air is substituted for fly ash in this mix. (Approximately 25 percent)

[3]  Saturated Surface Dry

[4]  Class C Fly Ash may be substituted for Class F Fly ash in Type 1 mixes with an approved mix design meeting the alternate mix design criteria of this specification.

These mixtures of materials are expected to yield approximately 1 cubic yard (1 m³) of material of a flowable consistency.  Make small adjustments, as necessary, in the amounts of the materials in a mix to achieve the final product.

613.04  Mix Adjustment.  Make one or more 1 cubic yard (1 m³) trial batches at different water contents to ensure a flowable material.  The mixture is too dry if cracks develop in the mixture as it flows into place.

Adjust the proportions to maintain the total absolute volume.  For large adjustments, see 613.05.

In order to expedite the settlement of a Type 1 mixture without entrained air, bleed water may appear on the surface immediately after the material is struck off.  A delay in bleeding indicates there are too many fines in the mixture.  The Contractor may reduce the fly ash quantity in increments of 50 pounds (30 kg) until the mixture is bleeding freely.  Add approximately 60 pounds (36 kg) of sand to replace each 50 pounds (30 kg) increment of fly ash to maintain the original yield.

613.05  Alternate Mixes.  The Contractor may submit alternate mixes for approval.  Furnish the mix design and test data from an independent test laboratory 30 days before the intended usage for approval.

Submit an alternate mix design for all mixes that:

A.      Vary more than 300 pounds (178 kg) in fine aggregate, 100 pounds (59 kg) in water, 20 pounds (12 kg) in cement, or 200 pounds (119 kg) in fly ash from the 613.03 mixes.  These are considered large adjustments.

B.      Have less than 50 pounds (30 kg) of cement in the Type 1 mixes or less than 100 pounds (59 kg) of cement in the Type 2 mixes.

C.      Use alternate materials.

D.      Contain foundry sand.

E.      Contain fly ash not conforming to 701.13.

F.      Use fine aggregate gradations other than 703.05.

The Contractor may use foundry sand if it meets the requirements of the Division of Surface Water Policy 400.007 “Beneficial Use of Non-Toxic Bottom Ash, Fly Ash and Spent Foundry Sand and Other Exempt Wastes,” and all other regulations.  Ten days before using a mixture containing foundry sand on the project, submit written permission from the Ohio EPA to the Engineer.  The Contractor may elect to have an independent ODOT consultant pre-qualified in remedial design environmental site assessment review the proposed usage.  The consultant will provide all documentation utilized to ensure that the proposed usage obeys all Ohio EPA regulations.  The consultant shall coordinate all EPA required meetings, documentation, and testing requirements.  The consultant shall certify the report or reports to the Department.

Provide alternate mixes with an unconfined compressive strength between 50 and 100 pounds per square inch (345 and 689 kPa) at 28 days when tested according to ASTM D 4832.  Ensure that the long term (12-month) unconfined compressive strength is less than 100 pounds per square inch (689 kPa).

Ensure that the final mix has the required strength, fills the voids of the intended usages and sets up within 12 hours (4 hours for Type 3 or Type 3 alternate mixes).  The proportioning, yield, consistency, workability, compressive strength, and all other requirements are the sole responsibility of the Contractor.

613.06  Mixing Equipment.  Provide the mixing capacity and delivery equipment to place the material without interruption as much as practical.  Deliver and place Type 1 and 2 mixes or Type 1 and 2 alternate mixes from ready mixed concrete trucks, or deliver them from a batch plant.

Deliver and place Type 3 mix using volumetric mobile mixers.  Calibrate volumetric mixers properly and sufficiently mix the materials in the mixer to produce a uniform material.

613.07  Mixing the Materials.  Discharge the mixture within 2.5 hours after adding water.

613.08  Placing Mortar.  Unless specifically shown on the plans, do not place the mortar within 3 feet (1 m) of the subgrade elevation.  Discharge the flowable material from the mixer by any reasonable means into the space of the plan intended usage.  Bring the fill material up uniformly to the fill line shown on the plans.  The Contractor may begin placing the other fill material over low strength mortar backfill material as soon as the surface water is gone.  The Engineer reserves the right to reject the mix if a flowable mixture is not produced.

Before placing the low strength mortar backfill as backfill for 611 Conduit, secure the conduit to prevent it from floating during placement of the flowable material.

613.09  Method of Measurement.  The Department will measure Low Strength Mortar Backfill by the number of cubic yards (cubic meters) completed and accepted in place, computed from the plan lines.  The Department will not pay additional compensation for over excavated areas or for a change in the material blends.

613.10  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

613             Cubic Yard                      Low Strength Mortar Backfill
                       (Cubic Meter)

613             Cubic Yard                      Low Strength Mortar Backfill
                       (Cubic Meter)                  (Type ___)

ITEM 614  MAINTAINING TRAFFIC

614.01  Description

614.02  Traffic Facilities

614.03  Traffic Control - General

614.04  Work Zone Marking Signs

614.05  Road Closed

614.055 Surface Condition Signs

614.06  Detour Signing

614.07  Traffic Maintained

614.08  Flaggers

614.09  Law Enforcement Officer

614.10  Work Zone Traffic Signals

614.11  Work Zone Pavement Markings

614.115    Work Zone Raised Pavement Markers

614.12  Pavement Marking Operations

614.13  Asphalt Concrete for Maintaining Traffic

614.14  Performance

614.15  Method of Measurement

614.16  Basis of Payment

614.01  Description.  This work consists of maintaining and protecting vehicular, bicycle and pedestrian traffic according to these provisions.  For through traffic, the Special Provisions or the plans will designate whether the highway will be closed with detours, roads and run-arounds provided or whether traffic will be maintained through all or portions of the project.

614.02  Traffic Facilities.  Construct and maintain facilities for vehicular, bicycle,  and pedestrian traffic of the highway, including all walks, bicycle lanes,  roads, bridges, culverts, and traffic control devices.  The Department will maintain public highways used as a detour beyond the work limits of the contract.

A.      For local traffic, provide and safely maintain drives, roads, run-arounds, walks, structures, and other facilities.  Provide safe vehicular, bicycle,   and pedestrian ingress and egress for all property adjacent to any improvement.  Provide approaches and crossings of intersecting highways, bicycle lanes, and maintain them in a safe condition.  Maintenance includes snow and ice removal as needed.

B.      When the highway under construction is being used by through traffic, including periods of suspension of the Work, maintain it so that it is smooth, free from potholes, ruts, ridges, bumps, and  other pavement deficiencies.  Furnish proper maintenance of traffic facilities and proper provisions for traffic control as per 105.14.   For the portions of highway being used, provide the necessary outlets to allow free drainage.  Maintain pipe trenches or other openings left in hard surface pavements with material of comparable quality.  Contractor maintenance responsibilities, including pothole patching begins for a section of highway when the Contractor begins the Work in that section and ends with the acceptance of the Work under 109.11 or 109.12.  The two directions of a divided highway are considered separate highway sections and the start of Work on one direction does not begin maintenance responsibilities on the other direction.

C.      Remove from the Project as necessary, abrasives and salt residues left by Department or local government snow and ice control operations.

D.      Ensure positive drainage into structures that have inlet windows without grates during pavement overlay operations when traffic will be maintained on a pavement course lower than the inlet window.  Provide a minimum of 2 inch (50 mm) holes spaced at 2 feet (0.6 m) or a minimum of three 4 inch (100 mm) holes spaced at 4 feet (1.2 m) drilled into the vertical wall of the existing drainage structure below the inlet window.  Place steel or iron plating of at least ¼ inch (6 mm) thickness that completely covers the drilled holes prior to construction of the finished pavement course.

614.03  Traffic Control General.  Conform to the requirements of the plan, standard construction drawings shown on the plans, and the OMUTCD, for the installation, maintenance, and operation of all traffic controls and traffic control devices.  When the plans or standard construction drawings do not cover a specific traffic control situation, place the necessary traffic control devices according to the OMUTCD and use the procedures required by the OMUTCD.

Furnish portable changeable message signs, arrow boards, and impact attenuators that are pre-qualified according to the Department’s Approved List.

Furnish cones, drums, signs, sign supports, barricades and other traffic control devices that are certified to meet NCHRP 350 or MASH Test Level 3: Do not use heavy non-yielding devices or supports that are not crashworthy.

Use Type G, H or J reflective sheeting complying with 730.19, 730.192 and 730.193, respectively, for faces of construction signs, barricades, vertical panels, object markers, and stripes on glare screen panels.  In addition, the Contractor may also use Type G sheeting referred to as damage control for these devices, provided it meets 730.19.

Use fluorescent orange reflective sheeting for all orange construction signs, object markers, and stripes on glare screen paddles. Use standard orange or fluorescent orange reflective sheeting for the orange portions of drums, barricades and vertical panels.

Furnish drums with reboundable reflective sheeting complying with the requirements of 730.191.  Ensure that owner identification markings on construction drums are no more than 1 inch (25 mm) in character height and are located at least 2 inches (50 mm) below the reflectorized bands or on the top or bottom horizontal surfaces of the drum.  Ballast the drums according to the manufacturer’s recommendations.

Furnish traffic cones consisting of a highly visible orange predominant color.  Ensure that the pavement markings for traffic maintenance conform to Item 640.

Furnish warning signs in advance of channelizing devices such as barricades, drums, vertical panels, and cones. 

Keep retroreflective materials clean and in good condition.

Equip all project motor vehicles with photo strobe lights, LED warning lights, or rotating beacons meeting Class 1 specifications for color and intensity as defined by the Society of Automotive Engineers (SAE).

Photo strobe lights, LED warning lights, or rotating beacons shall be horizontally visible from all directions (360 degrees) at a distance of 100 feet minimum. In order to ensure this visibility, the light shall in no way be obstructed from view by any signs or appurtenances on the vehicle.

Activate the photo strobe lights, LED warning lights, or rotating beacons and all hazard lights anytime the vehicle is entering, exiting or operating in a traveled lane at a speed less than the posted speed within the limits of the work zone or one mile of either end of the work zone.

In addition, equip all project motor vehicles and trailers having a gross vehicle weight rating of 10,000 pounds or greater, in single or combination, with conspicuity tape. Also, delineate all NCHRP 350 Category IV equipment (arrow boards, portable changeable message signs, etc.) with conspicuity tape.

Conspicuity Tape:  Use red and white, Type G, H, or J retroreflective sheeting that complies with 730.19, 730.192, and 730.193.

A.      Apply one 2-inch wide (minimum) horizontal stripe of Type G, H, or J retroreflective sheeting to a minimum of 50 percent of the length of each side of the payload portion of the motor vehicle, rearward from the back of the cab, NCHRP 350 Category IV equipment and trailers. Space lengths of tape evenly over the length of the payload portion of the motor vehicle rearward from the back of the cab, NCHRP 350 Category IV equipment, and trailers. The centerline for each strip of retroreflective sheeting shall be between 15 inches and 60 inches above the road surface when measured with the vehicle empty or unladen, or as close as practicable to this area.

B.      Outline the lower rear facing area of the motor vehicle, NCHRP 350 Category IV  equipment, and trailers with 2-inch wide (minimum) horizontal stripe of Type G, H, or J retroreflective sheeting. Apply the lower horizontal markings extending the width of the motor vehicle, NCHRP 350 Category IV equipment, and trailer as close as practical to the edge of the motor vehicle, NCHRP 350 Category IV equipment, and trailer. The centerline for each strip of lower horizontal retroreflective sheeting shall be between 15 inches and 72 inches above the road surface when measured with the vehicle empty or unladen, or as close as practicable to this area.

C.      Outline the upper rear facing area with two pairs of strips of 2-inch wide (minimum) retroreflective Type G, H, or J sheeting, each pair consisting of strips 12 inches long, must be positioned horizontally and vertically on the right and left upper corners of the rear of the body of each motor vehicle or trailer, as close as practicable to the top of the motor vehicle or trailer and as far apart as practicable. If the perimeter of the body, as viewed from the rear, is not square or rectangular, the strips may be applied along the perimeter, as close as practicable to the uppermost and outermost areas of the rear of the motor vehicle or trailer on the left and right sides.

Escort transport or delivery vehicles without proper photo strobe lights, LED warning lights, or rotating beacons or conspicuity tape to and from the work zone only with the approval of the Engineer. This exception is intended for limited use at the discretion of the Engineer and will only be considered following a written request by the contractor. Otherwise, equip all project vehicles with photo strobe lights, LED warning lights, or rotating beacons and conspicuity tape as described herein.

If equipment, vehicles, and material are stored or parked on highway rights-of-way, locate them not less than 6 feet (2 m) behind existing guardrail or not less than 30 feet (9 m) beyond the traveled way unless otherwise permitted by the Engineer.  At night if any such material or equipment is stored between the side ditches, or between lines 6 feet (2 m) behind any raised curbs, clearly outline them with dependable lighted devices that are approved by the Engineer.

All temporary traffic control devices shall conform to the Quality Standards for Temporary Traffic Control Devices and Acceptable Delineation Methods for Vehicles.

614.04  Work Zone Marking Signs.  Furnish, install, maintain, and subsequently remove work zone marking signs and their supports within the work limits according to the following requirements:

A.      Erect a NO EDGE LINES sign in advance of any section of roadway lacking OMUTCD standard edge line markings.  Ensure these signs are in place before opening the roadway to traffic.  Erect these signs on each entrance ramp, at intersections of through roads to warn entering or turning traffic of the conditions, and at least once every 2 miles (3 km) along the roadway.  Remove these signs when they no longer apply.

B.      Erect a DO NOT PASS sign at the beginning and a PASS WITH CARE sign at the end of each no passing zone lacking OMUTCD standard center line markings.

614.05  Road Closed.  When the highway is closed to traffic, furnish, erect, maintain, and subsequently remove advanced warning signs and supports, barricades, ROAD CLOSED signs on the barricades, and Type B yellow flashing lights at the following locations:

A.      Work limits of the project.

B.      Work limits on all intersecting roads.

C.      Any other points specified in the Contract.

Throughout construction, furnish, erect, maintain, and subsequently remove all signs, lights, barricades and other traffic control devices required by the OMUTCD, plans, or standard construction drawings for the maintenance of local traffic.

614.055  Surface Condition Signs.  Erect a GROOVED PAVEMENT sign 250 feet (75 m) in advance of any section of roadway where traffic must travel on a planed surface.  Ensure these signs are in place before opening the roadway to traffic.  Erect these signs on each entrance ramp and at intersections of through roads to warn entering or turning traffic of the conditions. Payment for these signs to be included in Item 614 Maintaining Traffic.

614.06  Detour Signing.

A.      Department Detour Signing.  When the Contract Documents do not require the Contractor to furnish the signing for designated detour routes, the Department will furnish, erect, maintain, and subsequently remove the detour routing signs and supports required on the designated detour highways outside the Project.

B.      Contractor Detour Signing.  When the Contract Documents provide a pay item for Detour Signing and the plans provide a detour-signing plan, provide, maintain, and subsequently remove all required detour signing and supports according to the detour signing plan.

614.07  Traffic Maintained.  Where the highway under construction is being used by through traffic, including periods of suspension of the work, furnish and maintain pavement markings, lights, construction signs, barricades, guardrail, sign supports, and such other traffic control devices.  Maintain pre-existing roadside safety hardware at an equivalent or better level than existed prior to project implementation. Also, provide law enforcement officers, watchmen, and flaggers as necessary to maintain safe traffic conditions within the work limits as directed by the Engineer.

The Department will furnish and erect regulatory signs and guide signs, unless otherwise shown on the plans, within the work limits on all traffic maintained projects.  The Contractor is responsible for maintenance of these signs.  The Engineer will approve the erection and removal of any regulatory signs not shown on the plans.

Keep existing signs including 630.09 Specific Service and Tourist-Oriented Directional Signs and traffic control devices in use within the work limits during the construction period unless otherwise indicated on the plans.  If existing signs and other traffic control devices must be relocated or modified as a consequence of the work, provide suitable supports and modify the devices with prior approval of the Engineer and the concurrence of the maintaining agency.  Keep existing STOP or YIELD signs functioning at all times.  The Contractor may adjust the position of these signs with the Engineer’s approval.  Relocate existing signs that must be adjusted laterally according to the OMUTCD.  Restore relocated or modified signs to the position and condition that existed before construction as directed by the Engineer.  When signs are to be covered, provide an opaque covering that covers the entire message, symbol and all of the sign within the border.  Do not use fastenings that damage the sign or reflective face; however, the Contractor may use rivets to attach rigid overlay panels.  Do not apply adhesive tapes directly to the face of the sign.

When an existing signal operation must be interrupted for a period of time, provide a traffic control method approved by the Engineer.

Whenever it is necessary to divert the flow of traffic from its normal channel into another channel, clearly mark the channel for such diverted traffic with cones, drums, barricades, vertical panels, pavement markings, or arrow boards. Also use this method of marking where working adjacent to the part of the highway in use by the public.

Obtain the approval of the Engineer before closing a traffic lane or establishing a one-way traffic operation.

614.08  Flaggers.  Whenever one-way traffic is established, use at least two flaggers unless the Engineer authorizes otherwise, and erect signs, cones, barricades, and other traffic control devices according to the OMUTCD.  Reflectorize traffic control devices as previously noted.  Maintain positive and quick means of communication between the flaggers at the opposite ends of the restricted area.

Equip flaggers according to the standards for flagging traffic contained in the OMUTCD.  During a flagging operation, other than an intersection or a spot location best controlled by a single flagger, ensure that each flagger uses a STOP/SLOW paddle conforming to the OMUTCD.  Mount the paddle on top of a 6 1/2-foot (2 m) handle.  Ensure that each face of the paddle is made of Type G reflective sheeting meeting the requirements of 730.19.  While flagging, do not allow flaggers to perform other work activities.  The Contractor may, instead of using flaggers, or supplemental to them, furnish, install, and operate a traffic signal or signals, for the purpose of regulating traffic according to a written agreement approved by the Engineer.

614.09  Law Enforcement Officer.  When shown on the plans, furnish the services of a law enforcement officer and patrol car equipped with flashing lights.

614.10  Work Zone Traffic Signals.  If shown on the plans, furnish, erect, maintain, and subsequently remove signal equipment conforming to Items 632 and 732, and signal controller equipment of a proper type and capacity to provide the required operation.  Furnish and install Uninterruptible Power Supplies (UPS) conforming to 733.09.  Subject to the Engineer’s approval, the Contractor may use new equipment that is to be installed later on the project, or may install used equipment in good condition provided such used equipment meets current Department specifications.  The performance test in 632.28 and the working drawing requirements of 632.04 are waived.  Recondition used equipment as necessary to ensure proper operation.  Operate work zone traffic signals conforming to the requirements of the OMUTCD and subject to the approval of the Engineer.

Procure and pay for electric power for work zone traffic signals.  Do not alter the operation of an approved work zone traffic signal without the Engineer’s approval.  Correct any malfunctions or failures without delay.  Cover or remove work zone traffic signals not in use.

614.11  Work Zone Pavement Markings.  Furnish, install, maintain, and, when necessary, remove work zone retroreflective pavement markings on existing, reconstructed, resurfaced or temporary roads within the work limits, according to the following requirements.

A.      Acceptability and Expected Duration.  The Engineer will evaluate the markings according to the three performance parameters contained in Supplement 1047.  Repair or replace the markings when the numerical rating is seven or lower for durability, visual effectiveness and night visibility.  Repair or replace unsatisfactory markings immediately and at no additional cost to the Department, if the markings were in place for 120 calendar days or less.  The Department will compensate under the applicable contract pay item for work zone pavement marking for the ordered replacement of worn markings after 120 calendar days under traffic.

B.      Work Zone Marking Specifications.         Equip traffic paint striping equipment for Class I and Class III markings with a computerized Data Logging System (DLS) conforming to 641.04 when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent. Furnish the Engineer daily, biweekly and final DLS reports according to 641.04. 

Unless otherwise shown on the plans, the Contractor may use 740.02 Type 1 or Type 1A paint or 740.06 Type I or Type II preformed material for work zone pavement markings.  Furnish painted markings according to Item 642 except that:

1.      For Class I or Class II work zone pavement markings, use the specified application rate from Table 614.11-1.

Table 614.11-1

Type of Pavement Marking

Line Width (inch)

4

8

12

Gallon per Mile of Line

Solid Line

22

44

66

10-foot Dashed Line

5.5

--

--

4-foot Dashed Line

2.2

--

--

Dotted Line

7.3

--

--

Arrows, Symbols, and Words

1.4 gallons per 100 square feet

Glass Beads:  740.09, Type A

15 pounds per 100 square feet

Table 614.11-1M

Type of Pavement Marking

Line Width (mm)

100

200

300

Gallon per Mile of Line

Solid Line

52

105

157

3.0 m Dashed Line

13

--

--

1.2 m Dashed Line

5.2

--

--

Dotted Line

17.3

--

--

Arrows, Symbols, and Words

0.6 liters per square meter

Glass Beads:  740.09, Type A

7.3 kg per square meter

2.      For Class III work zone markings, use the specified application rate from Table 614.11-2.

Table 614.11-2

Type of Pavement Marking

Line Width (inch)

4

8

12

Gallon per Mile of Line

Solid Line

12

24

36

10-foot Dashed Line

3

--

--

Dotted Line

4

--

--

Arrows, Symbols, and Words

0.75 gallons per 100 square feet

Glass Beads:  740.09, Type A

7.5 pounds per 100 square feet

Table 614.11-2M

Type of Pavement Marking

Line Width (mm)

100

200

300

Gallon per Mile of Line

Solid Line

28

56

84

3.0 m Dashed Line

7

--

--

Dotted Line

9.4

--

--

Arrows, Symbols, and Words

0.3 liters per square meter

Glass Beads:  740.09, Type A

3.7 kg per square meter

Ensure that Type I and II preformed material conform to 740.06, except do not place any preformed material containing metal on any surface unless it will be removed later.  Remove work zone pavement markings of 740.06 preformed material before placement of 642 or 644 surface course markings at that location.  Ensure that preformed material conforms to Item 645.

C.      Work Sequence.  Ensure that work zone markings are complete and in place on all pavement, including ramps, before exposing the pavement to traffic.  When work zone markings conflict with the traffic pattern, remove them according to 641.10.

D.      Layout and Premarking.  Layout and premark all Class I and Class III Markings according to 641.06. Obtain the Engineer’s approval of the layout and premarking lines before marking operations are started.

E.      Tolerances.  Place lines for final surfaces according to the tolerances of 641.07.  On surfaces other than final, the Department will allow tolerances twice that in 641.07.

F.      Classes of Work Zone Pavement Markings.

1.      Class I Markings (Full Pattern, Full Rate). Use Class I Markings on all surfaces exposed to traffic for more than 14 days prior to application of final markings and to over-winter the project, with the following exception:  Do not use Class I Markings on a surface course if thermoplastic, spray thermoplastic or epoxy final markings are to be applied to the surface course. If thermoplastic, spray thermoplastic or epoxy final markings are to be applied to the surface course, use Class III Markings on that course. Apply Class I work zone markings to the standard dimensions as defined in Item 641, except as follows:

a.      Edge Lines.  Class I edge lines shall be 4 inches (100 mm) in width.

b.      Lane Lines.  Class I lane lines shall be 4 inches (100 mm) in width.

c.       Channelizing Lines.  Class I channelizing lines shall be 8 inches (200 mm) in width.

2.      Class II Markings (Abbreviated, Full Rate).  Use Class II Markings for short-term use when traffic is to be maintained in parallel lanes nominally in the same location as permanent lanes and where tapers or transitions are not required or other features will not likely divert traffic from the intended path. Class II Markings are limited to center lines, lane lines and gore markings defined as follows:

a.      Center Lines.  Class II center lines consist of single, yellow 4-inch (100 mm) wide by a minimum of 4 feet (1.2 m) long dashes spaced at a maximum of 40 feet (12.0 m) intervals. No Passing Zones must be marked with Class I or Class III Markings or final markings within 3 calendar days according to 614.11.H.1. Passing Zones must be marked with Class I or Class III Markings or final markings within 14 calendar days according to 614.11.H.2.

b.      Lane Lines.  Class II lane lines consist of white 4-inch (100 mm) wide by a minimum of 4 feet (1.2 m) long dashes spaced at a maximum of 40 feet (12.0 m) intervals. Class II Lane Line Markings must be marked with Class I or Class III Markings or final markings within 14 calendar days according to 614.11. H. 3.

c.      Gore Markings.  Class II gore markings are continuous, white 4-inch (100 mm) wide lines normally 50 to 100 feet in length placed at the theoretical gore of an exit ramp or diverging roadways. Class II Gore Markings must be marked with Class I or Class III Markings or final markings within 14 calendar days according to 614.11.H.3.

Computerized Data Logging Systems (DLS) are not required for Class II Markings.

3.      Class III Markings (Full Pattern, Low Rate). Use Class III Markings on surface courses that are expected to receive thermoplastic, spray thermoplastic or epoxy final markings within 30 days. Class III Markings use a lower application rate which reduces the surface preparation needed prior to application of thermoplastic, spray thermoplastic or epoxy final markings. If Class III Markings have been applied and weather conditions are expected to prevent thermoplastic, spray thermoplastic or epoxy final markings application for 30 days or more, re-apply Class III Markings if thermoplastic, spray thermoplastic or epoxy final markings application is expected to occur within 30 days or apply Class I Markings as necessary to carry the project through the season or over the winter.

Apply Class III work zone markings to the standard dimensions as defined in Item 641 except as follows:

a.      Edge Lines.  Class I edge lines shall be 4 inches (100 mm) in width.

b.      Lane Lines.  Class I lane lines shall be 4 inches (100 mm) in width.

          c.       Channelizing Lines.  Class I channelizing lines shall be 8 inches (200 mm) in width.

G.     Conflicting Markings.  Conflicting markings are considered to be any markings not actively in use, not behind channelizing devices or portable barrier and/or could be misinterpreted by the traveling public or cause confusion to the driver as determined by the engineer.  Before placing work zone markings, remove or cover all conflicting existing markings visible to the traveling public.

1.      Removal and Covering of Markings.

a.      Removal Methods.  Remove the markings so that less than 5% of the line remains visible. Repair damage to the pavement that results in the removal of more than 1/8 inch of pavement thickness.   Use sand, shot, or water blasting to remove markings on all asphalt or concrete pavement surfaces.  Use only sand, shot, or water blasting for removal of all pavement markings in preparation for placing Item 422 Chip Seal or Item 421 Microsurfacing.  A grinder may only be used to remove markings on temporary pavement or pavement that will be covered or removed prior to project completion (e.g., intermediate asphalt course).  When a grinder drum is mounted to a skid steer loader, the drum must be able to accommodate a minimum of 150 teeth.

b.      Covering Conflicting Markings.  With the Engineer’s approval, use removable, non-reflective, preformed blackout tape to cover conflicting markings.  Remove or replace the blackout tape within 15 days of installation. Furnish products according to the Departments Qualified Products List (QPL).

2.      Raised Pavement Markers.  Remove the prismatic retro-reflector within any raised pavement marker that is in conflict with the work zone pavement markings.  When the work zone pavement markings are removed and the raised pavement marker is no longer in conflict, thoroughly clean the recessed reflector attachment area of the casting and install a new prismatic retro-reflector of the same kind and color.  The cost for this work is incidental to the various pay items.

H.     Allowable Duration of Work Zone Markings.

1.      No Passing Zones. When existing permanent no-passing-zone markings are removed or obliterated as the result of a construction operation (pavement grinding, asphalt concrete pavement overlays, etc.) and the section of pavement continues to be used by the traveling public, place Class I Center Line Markings or final center line markings as specified by the plan within 3 Calendar Days unless thermoplastic, spray thermoplastic or epoxy final markings are to be applied on the surface course. If thermoplastic, spray thermoplastic or epoxy final markings are to be applied on the surface course, place Class III Center Line Markings or final center line markings as specified in the plan within 3 Calendar Days.

a.      Subsequent Work in No Passing Zones.  If, after the original markings are removed or obliterated, the Contractor returns to the subject no passing zone and places a plan-specified pavement course within the 3-Calendar Day limit, or performs work in preparation for a subsequent pavement course, the Contractor shall have temporarily satisfied the conditions of the previous paragraph.  In this event, the 3-Calendar Day limit will begin again.

b.      Liquidated Damages.  For each Calendar Day beyond 3 days that this work remains incomplete, the Department will assess liquidated damages in the amount of $1000 per Calendar Day.  The Department will treat the time for the completion of no-passing-zone markings as an interim Completion Date.

2.      Passing Zones. Sections of pavement where passing is permitted in both directions must be marked with Class I Center Line Markings or final center line markings as specified by the plan within 14 Calendar Days unless thermoplastic, spray thermoplastic or epoxy final markings are to be applied on the surface course. If thermoplastic, spray thermoplastic or epoxy final markings are to be applied on the surface course, place Class III Center Line Markings or final center line markings as specified in the plan within 14 Calendar Days.

3.      Allowable Duration of Class II Lane Lines and Gore Markings and Absence of Edge lines. Any time existing permanent lane lines, gore markings, or edge lines have been removed or obliterated as the result of a construction operation (pavement grinding, asphalt pavement overlays, pavement widening, etc.) and the section of pavement continues to be used by the traveling public, place Class I Markings or final markings as specified by the plan within 14 Calendar Days unless thermoplastic, spray thermoplastic or epoxy final markings are to be applied on the surface course. If thermoplastic, spray thermoplastic or epoxy final markings are to be applied on the surface course, place Class III Markings or final markings as specified in the plan within 14 Calendar Days. 

a.      Subsequent Work.  If, after the original markings are removed or obliterated, the Contractor returns to the subject section of pavement and places a plan-specified pavement course within the 14-Calendar Day limit, or performs specified work that requires a lane closure (except routine maintenance required by 614.02), the Contractor shall have temporarily satisfied the conditions of the previous paragraph.  In this event, the 14-Calendar Day limit will begin again.

b.      Liquidated Damages.  For each Calendar Day beyond 14 days that this work remains incomplete, the Department will assess liquidated damages in the amount of $1000 per Calendar Day.  The Department will treat time for the completion of these markings as an interim Completion Date.

(1)     Continuous Project.  If a section of pavement is in a continuous part of the project, then a new 14-day limit for renewed work on a section applies to all sections in that part.

(2)     Project in Sections.  If the project is in parts and the traveling public could not discern the parts as one continuous project, then a new 14-day limit in one part will not apply to the other parts.

(3)     Freeways and Divided Highways.  Treat the two directional sides of a freeway as separate parts.  Work on one side of a freeway does not create a new 14-day limit for the other side.

I.       Removal of Work Zone Markings.  Remove work zone retroreflective pavement markings when necessary. Accomplish removal of work zone pavement marking by using removal methods specified in 614.11G.1.a for removal of existing markings.

614.115                   Work Zone Raised Pavement Markers.  Furnish, install, maintain and subsequently remove work zone raised pavement markers (WZRPMs). Work zone raised pavement markers may serve as a substitute for, or supplement to, work zone pavement markings. They are provided in both yellow and white versions to match the appropriate pavement marking color.

White units provide reflectorization in one direction while yellow units may provide reflectorization in either one direction or two. They are available as units which are readily visible both night and day as a result of retroreflectors and brightly colored (white or yellow) housing (Type A) or visible only at night due to their retroreflectors (Type B).

A.      Materials. Furnish materials according to the Department’s Approved List.

Only use adhesives that are recommended by the reflector manufacturer and are not epoxy.

Provide markers of sufficient strength and properly shaped so as not to be dislodged or broken by impacts from vehicle tires, including those of high pressure truck tires loaded to 4500 pounds (2040 kilograms).

Provide reflectors having an area of 0.35 square inches (225 square millimeters) for Type A or 3.0 square inches (1935 square millimeters) for Type B with brightness or specific intensity (when tested at 0.2 degree angle of observation and the following angles of incidence) meet or exceed the following:

WZRPM SPECIFIC INTENSITY

Type

Incidence Angle

White

Yellow

A

0

1.0

0.6

A

20

0.4

0.24

B

0

3.0

1.8

B

20

1.2

0.72

B

45

0.3

0.2

Angle of incidence: Formed by a ray from a light source to the marker and the normal to the leading edge of the marker face (also horizontal entrance angle)

Angle of observation: Formed by a ray from a light source to the marker and the returned ray from the marker to the measuring receptor

Specific intensity: The mean candlepower of the reflected light (at given incidence and divergence angles) for each footcandle (10.7 lux) at the reflector (on a plane perpendicular to the incident light)

Type A markers, when viewed from above, have a visible area of not less than 14 square inches (9030 square millimeters).  When viewed from the front, parallel to the pavement, as from approaching traffic, Type A markers have a width of approximately 4 inches (100 mm) and a visible area of not less than 1.5 square inches (970 square millimeters).

B.      Patterns.  The patterns of WZRPMs required for the various types of pavement markings are shown in Table 614.115-1.

TABLE 614.115-1

SUPPLEMENTAL DELINEATION (TYPE A OR B)

Type of Line

Color

Spacing

Edge Line

1-way white

or yellow

20' (6.0 m) c/c

Lane Line

1-way white

40' (12.0 m) c/c

or at center of gap

Dashed Center Line

2-way yellow

40' (12.0 m) c/c

or at center of gap

Double Center Line

2-way yellow

2 units; 20' (6.1 m) c/c

Channelizing Line

1-way white

10' (3.0 m) or 20' (6.0 m) c/c

Exit Gore (Outline)

1-way white

10' (3.0 m) c/c

SIMULATED DELINEATION (TYPE A ONLY)

Type of Line

Color

Spacing

Edge Line

1-way white

or yellow

10' (3.0 m) c/c

Edge Line on 1-Lane, 2-Way

1-way white and

1-way yellow

white & yellow units

back-to-back[2] 10' (3.0 m)

Lane Line

1-way white

3 units at 5'(1.5 m) c/c

30'(9.0 m) gap

Dashed Center Line

2-way yellow

3 units at 5'(1.5 m) c/c

30'(9.0 m) gap

Double Center Line

2-way yellow

2 units[1]; 10' (3.0 m)c/c

Channelizing Line

1-way white

5' (1.5 m) c/c

Exit Gore (Outline)

1-way white

5' (1.5 m) c/c

[1]  Place units side by side about 4 inches (100 mm) apart.

[2]  Face the proper color and reflector to the oncoming traffic. Place the units back to back about one quarter inch (6.0 mm) apart.

C.      Installation. Attach work zone raised pavement markers to clean, dry and sound pavement. Remove all loose gravel, sand and dirt from the area of the line. The minimum pavement temperature for installation is 50  °F (10  °C). When markers are being attached to new concrete pavement with curing compound remaining, remove the curing compound membrane by sandblasting or other mechanical cleaning method. Install markers in accordance with the manufacturer's recommendations.

Work zone raised pavement markers are not suitable for use from October 15 to April 1.  If the Contractor elects to start or continue work zone pavement markers during this period, and they fail or are subsequently removed or destroyed by snow and ice control activities, immediately, at his expense, provide a substitute traffic guidance system which is effective during day and night and which is acceptable to the Engineer.  Other than for replacement of failed WZRPMs, new installations of WZRPMs are not permitted from October 1 to April 1.

Place markers accurately to depict straight or uniformly curving lines. The longitudinal location of WZRPMs are described in Table 614.115-1 except that the spacing of an individual WZRPM may be varied by as much as 2 feet (0.6 m) or 10 percent of the nominal spacing in order to avoid poor pavement conditions, but the average spacing remains unchanged. Poor pavement conditions include separated joints, cracks, deteriorated pavement, usually uneven pavement or where pavement marking material will interfere with the bond.

The lateral location of WZRPMs follows:

1.      Edge Lines:  Install the WZRPM 12 inches (300 mm) outside the work zone pavement marking, if any, or the theoretical edge of the lane.  This offset may vary +6 inches (150 mm) as necessary to avoid poor pavement conditions.

2.      Lane lines and dashed center lines: Install the WZRPM in the center of the gap between pavement marking dashes, if any. If a pavement joint exists, locate the marker approximately 2 inches (50 mm) clear from the joint (and to the left of it for lane lines). Otherwise, center the WZRPM on the theoretical edge of the lane.

3.      Double center line: Install each WZRPM of the pair in line with the appropriate pavement marking stripe, if any. If the edge of lane is demarcated by a crack or joint, the pair of WZRPMs straddle the joint and install each approximately 2 inches (50 mm) clear from the joint. Otherwise center the pair on the theoretical edge of lane.

4.      Channelizing Line: Install the WZRPM in line with the pavement marking stripe or immediately adjacent to the line, except when used at exit gore outlines where the WZRPM is installed within the painted gore vee and approximately 12 inches (300 mm) from the pavement marking stripe. Do not install WZRPMs directly on a painted line.

D.      Replacement.  Maintain WZRPMs in good condition. A marker will be considered to have failed when the marker is broken, the marker is worn to the extent that daytime visibility is significantly diminished or of an unacceptable color (type B only), the reflector is broken or detached, the marker is detached from the adhesive, the adhesive is detached from the pavement or the marker or reflector is covered by tar or paint.

Individual replacement of each failed marker as it occurs is not recommended due to increased exposure of workers to traffic. However, maintain the following minimum levels of marker effectiveness:

1.      For a given line, no more than 20 percent of the WZRPM units failed in any manner;

2.      For a segment of any line, the number of failed units does not exceed the maximums permitted in Table 614.115-2.

TABLE 614.115-2

Line Type

Normal Spacing

Feet (Meter)

Segment

Length

Feet (Meter)

Normal No.

Contained

In Segment

Maximum

No. Permitted

To Fail

Edge

10 (3.0)

20 (6.0)

5 (1.5)

100 (30.0)

6

3

Center,

Double/Solid

20 (6.0)

10 (3.0)

100 (30.0)

50 (15.0)

12

6

Lane or

Dashed Center

40 (12.0)

5 (1.5)

200 (60.0)

1-Stripe

6

3

Channelizing

20 (6.0)

10 (3.0)

5 (1.5)

100 (30.0)

50 (15.0)

25 (7.5)

6

3

Replace all failed units within any line or segment before conditions deteriorate below the minimums established in Table 614.115-2. Replace all failed units within the line or segment within 24 hours after notification by the Engineer.

E.      Removal.  Accomplish removal of work zone raised pavement markers in such a manner that no adhesive remains on the pavement. Do not cause permanent pavement surfaces to be scarred, broken or significantly roughened.

614.12  Pavement Marking Operations.  Perform moving marking operations with a truck equipped with necessary flashers and signs, and protect the operations with a similarly equipped vehicle or vehicles separated a sufficient distance to provide adequate advance warning.  Use the extreme left or right lane for the marking operation when possible.  Where three or more lanes exist in one direction, perform the marking operation so that traffic passes on one side only.

Protect stationary marking operations in intersections, school zones, gores and other areas with traffic control devices such as advance warning signs and cones.

For stationary operations such as loading material and cleaning equipment, make every effort to have all equipment completely off the traveled way.  When equipment cannot be removed from the traveled way, operate all traffic control devices on the vehicles and station flaggers and vehicles to protect the worksite and the traveling public while maintaining traffic.

614.13  Asphalt Concrete for Maintaining Traffic.  The Contractor may use either a Type 1 or Type 2 mix of Item 448 asphalt concrete PG 64-22, or an asphalt concrete surface course the Engineer approves. 

Where materials are placed in small quantities or under adverse conditions, the Engineer may waive specification requirements for placing and finishing if, in the judgment of the Engineer, it is determined that the Contractor can obtain satisfactory results in providing a smooth and durable pavement surface.

614.14  Performance.  If, in the opinion of the Engineer, the Contractor is not furnishing proper maintenance of traffic facilities and proper provisions for traffic control, the Department may take the necessary steps to place them in proper condition, and the Department will deduct the cost of such services from any money that may be due or become due the Contractor.

Identify all pavement deficiencies within the work area.  Repair deficiencies as soon as possible and within 24 hours from notice of the deficiency.

614.15  Method of Measurement.  The Department will measure Work Zone Marking Signs as the number of sign installations, including the sign, necessary supports, and all attachment hardware.  The Department will include all other work zone signs under Maintaining Traffic unless separately itemized.

The Department will measure Work Zone Pavement Markings complete in place, by class and material, in the units designated. Line quantities will be the length of the completed stripe, including gaps, intersections and other sections of pavement not normally marked.  Work Zone Pavement Markings will include the layout, application and removal of the markings, when required.

The Department will measure line quantities as the length of the completed stripe, including gaps, intersections, and other sections of pavement not normally marked.

  The Department will measure Sign Months for Portable Changeable Message Signs by the number of months each sign is at the project or project storage yard and immediately available to the project for use.  Measurement will begin when each unit is in active service and will continue until the Engineer determines the Portable Changeable Message Sign is no longer needed for the remaining duration of the project.  A Sign Month will be deducted if a PCMS is not working properly for more than 24 hours in one sign month or if the contractor removes the PCMS from the project/project storage yard without the Engineer’s determination that it is no longer needed for the project.

614.16  Basis of Payment.  The Department will make partial payments according to 109.09 and as modified by the following schedule:

A.      If the project duration from first day of physical work to original completion date is greater than or equal to 45 calendar days,

1.      The Department will pay 30 percent of the lump sum amount bid for Maintaining Traffic with the first estimate, but not sooner than 15 days after the start of work at the project site.

2.      The Department will pay the remaining 70 percent of the lump sum amount bid for Maintaining Traffic according to 109.09.

B.      Unless separately itemized, the lump sum price bid for Maintaining Traffic shall include the cost of removal or covering of conflicting pavement markings, layout, application and removal of pavement markings when required, maintaining the existing highway in a safe condition for public use, removing abrasive and salt residue remaining from snow and ice control performed by the Department or local governments, providing flaggers and their equipment, and furnishing, maintaining in an acceptable condition, and subsequently removing the following work zone traffic control items as required by the Contract Documents:

1.      Signs, supports, and warning lights.

2.      Drums, cones, gates, barricades, and vertical panels.

3.      Arrow boards.

4.      Work zone traffic signals.

5.      Lighting for work zone signals and flaggers.

C.      If traffic permanently damages beyond use any of the following items, the Department will compensate the Contractor for the fair market value of the damaged item according to 109.05 provided the Contractor has pursued but failed to obtain compensation from the motorist.  Follow the procedures given in 107.15 for compensation for traffic damage to completed permanent items of Work, to obtain compensation from the motorist before requesting compensation from the Department.

1.      Arrow board.

2.      Work zone signal, pole, or controller.

3.      Lighting unit or pole.

4.      Changeable message sign.

5.      Work Zone Impact Attenuator

The lump sum price bid for Detour Signing includes the cost of the Contractor furnishing, installing, maintaining, and removing the detour signing shown on the plans and their necessary supports.

The Department will pay for the following items under their associated item numbers: 502 Bridges, 615 Roads and Pavement, 622  Concrete Barrier.  The Department will pay for aggregate and calcium chloride authorized by the Engineer and used for Maintaining Traffic under Items 410 and 616.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

614             Lump Sum                      Maintaining Traffic

614             Lump Sum                      Detour Signing

614             Each                                Replacement Drum

614             Each                                Replacement Sign

614             Each                                Object Marker, ___ - Way

614             Each,                               Work Zone Pavement
                       Mile, Foot                    Markings
                       (Kilometer,
                       Meter)

614             Each                                Work Zone Raised Pavement Marker

614             Sign Month                     Portable Changeable Message Sign

614             Each                                Work Zone Speed Limit Sign

614             Each                                Work Zone Marking Sign

614             Hour                                Law Enforcement Officer with Patrol Car

614             Each                                Barrier Reflector

614             Each                                Work Zone Crossover Lighting System

614             Each                                Work Zone Impact Attenuator

614             Mile (Kilometer)              Work Zone Lane Line, Class ___, ___*

614             Mile (Kilometer)              Work Zone Center Line,
                                                               Class ___, ___*

614             Foot                                 Work Zone Channelizing
                       (Meter)                            Line,     Class I, ___*

614             Mile (Kilometer)              Work Zone Edgeline, Class I, ___*

614             Foot                                 Work Zone Gore Marking,

                   (Meter)                               Class II, ___*

614             Foot                                 Work Zone Stop Line,
                       (Meter)                            Class I, ___*

614             Foot                                 Work Zone Arrow,
                       (Meter)                            Class I, ___*

614             Foot                                 Work Zone Crosswalk

                       (Meter)                            Line, Class I, ___*

614             Foot                                 Work Zone Dotted Line,
                       (Meter)                            Class I, ___*

614             Cubic Yard                      Asphalt Concrete for
                       (Cubic Meter)                  Maintaining Traffic

*   Type material (642 paint; 740.06, Type I or Type II; or left blank to allow any of the three.

ITEM 615  ROADS AND PAVEMENTS FOR MAINTAINING TRAFFIC

615.01  Description

615.02  Fences

615.03  Earthwork

615.04  Guardrail

615.05  Pavement

615.06  Sidewalk

615.07  Maintenance

615.08  Removal

615.09  Method of Measurement

615.10  Basis of Payment

615.01  Description.  This work consists of providing, maintaining, and subsequently removing roads and appurtenances, and pavements for maintaining traffic.

615.02  Fences.  If necessary, replace permanent fencing with temporary fencing while occupying any temporary Right-of-Way, provide, erect, and maintain comparable temporary fencing during the period of construction.  Take ownership of the existing fence.  The Contractor may use this material in the erection of the temporary fence.

Before occupancy of the temporary Right-of-Way is terminated and before removal of the temporary fence, the Engineer will notify the property owner to reinstall permanent fencing according to the Right-of-Way settlement.

615.03  Earthwork.  Excavate and construct embankment necessary for providing and maintaining temporary roads and any associated drainage facilities, as well as subsequent removal of temporary roads and restoration of the areas to their original condition, according to Item 203.  Construct adequate side ditches in cut sections, and provide drainage pipe and culverts where necessary.  Ensure that the width of the road from out to out of the shoulders is not less than 26 feet (7.8 m) and the side slopes are not steeper than 1.5:1, unless otherwise shown on the plans.  If sidewalks are required, increase the width of embankment accordingly.

615.04  Guardrail.  Where the height of the embankment is 5 feet (1.5 m) or more, measured at the outside edge of the berm, and the side slope is steeper than 4:1, provide guardrail at a distance of at least 1.5 feet (0.5 m) from the edge of the required width of the surface course.  Conform to one of the types of guardrail specified in Item 606, except that the Department will allow the Contractor to re-use material in good condition.

615.05  Pavement.  Unless otherwise shown on the plans, ensure that the pavement surface is not less than 20-feet (6.0 m) wide and is constructed of the materials and in the manner specified.

Prepare the subgrade in accordance with 204.03 and 204.04

Provide subgrade conforming to Item 204.03.  Soft subgrade will be determined and replaced according to Item 204.04.

If a traffic-compacted surface course is shown on the plans, construct it according to Item 410.  Furnish and apply calcium chloride according to Item 616.  The Engineer will specify the amount of original and subsequent applications of aggregate and calcium chloride.

Where Class A or Class B pavement is shown on the plans, provide either rigid pavement or flexible pavement conforming to the following minimum requirements:

MINIMUM COURSE THICKNESS REQUIRED

Pavement Type

Course Make-Up

Class A

Class B

Rigid

452

9 in (230 mm)

7 in (180 mm)

Flexible

448 Type 1[1]

1-1/4 in (32 mm)

1-1/4 in (32 mm)

448 Type 2[2][5]

1-3/4 in (45 mm)

1-1/2 in (38 mm)

302[3][5]

5-1/2 in (140 mm)

3-1/2 in (90 mm)

304[4][5]

6 in (150 mm)

6 in (150 mm)

[1]          Meet surface course requirements.  The Contractor may use Type 2 surface.

[2]          Meet intermediate course requirements.

[3]          The Contractor may use 301 or 448 Type 2 intermediate course.

[4]          The Contractor may use 2-1/2 inches (65 mm) 301, 302, or 448 Type 2 intermediate course in lieu of 6 inches (150 mm) of 304.

[5] The Engineer may waive maximum placement lift thicknesses if quality control testing conforming to Supplement 1055 is performed and a final density between 93 and 96.5 percent is achieved.

For the indicated pavement type and courses, conform to the requirements of the specified items except as modified below.

For rigid pavements, conform to Item 452.  Tiebars or hook bolts for longitudinal joints are not required.  Use dowels only at transverse expansion and construction joints.  Conform to the quality requirements set forth in 499.02 for the materials, except the requirements of 703.13.  Use Class QC-1 concrete.  For any part of the 452 pavement that is to be incorporated into the permanent pavement, the above exclusions do not apply and conformance to Items 452 and 499 is required.

For a 448 course, if the Contractor spreads and finishes the materials by acceptable hand methods, the Department will waive the requirements for smoothness.

Use a PG 64-22 asphalt binder for temporary asphalt pavement.  If any part of the temporary pavement will be incorporated into the project permanently, then use the contract-specified PG asphalt binder grade for the pavement course.

For a 304 course, if the Contractor spreads the aggregate by approved hand methods, the Department will not require side forms.  If the 304 course is to be removed, the Contractor may use reclaimed asphalt concrete or Portland cement concrete pavement.

Determine the thickness of the courses by field measurement.

615.06  Sidewalk.  If temporary walks are required, provide one of the types specified in Item 608.

615.07  Maintenance.  Maintain all portions of the temporary facilities in good condition with respect to both safety and smoothness for travel as long as it is needed for maintenance of traffic.  If the Engineer determines that the Contractor is not properly maintaining the temporary facilities, the Department may put them into proper condition according to 105.15.

615.08  Removal.  If the temporary facilities are no longer needed, remove them, except such portions of the embankment as are shown on the plans to be a part of the new roadway embankment, and leave the area in a neat condition.

Take ownership of all material removed, unless otherwise shown on the plans.  Use all suitable material in the work or legally use, recycle, or dispose in accordance with 105.16 and 105.17.

615.09  Method of Measurement.  The Department will measure the quantity of Pavement by the number of square yards (square meters) of pavement surface placed, maintained, and removed as directed, measured complete in place.

The Department will measure areas of soft subgrade, undercut and replaced, according to 204.08.

The Department will measure the quantity of Traffic Compacted Surface under Item 410 and Calcium Chloride under Item 616.

615.10  Basis of Payment.  Payment for Roads for Maintaining Traffic will not include those specified for Item 410 Traffic Compacted Surface or Item 616 Calcium Chloride.

Payment for Roads for Maintaining Traffic includes the installation, maintenance, and removal of all fencing, earthwork, guardrail, sidewalk, and all other items as necessary to provide a complete, functional, and safe installation for public use. 

The Department will pay for areas requiring undercut and replacement conforming to 204.04 according to 204.09.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

615             Square Yard                    Pavement for Maintaining Traffic, Class A
                       (Square Meter)

615             Square Yard                    Pavement for Maintaining Traffic, Class B
                       (Square Meter)

615             Lump Sum                      Roads for Maintaining Traffic

ITEM 616  DUST CONTROL

616.01  Description

616.02  Construction Requirements

616.03  Method of Measurement

616.04  Basis of Payment

616.01  Description.  This work consists of applying water or dust palliative for the alleviation or prevention of dust nuisance originating from earthwork construction operations from within the project construction limits.

616.02  Construction Requirements.  Perform dust control operations at the time and location and in the amount ordered by the Engineer.  Maintain control of the application of water or dust palliative at all times to minimize dust but not to create saturated soil conditions.  The Engineer will determine whether water or dust palliative is to be used to alleviate or prevent dust nuisance, and the amounts of each material to be used.  Do not apply calcium chloride to areas that will be subsequently seeded or sodded.

Furnish and apply water used for dust control by means of tanks equipped with suitable sprinkling devices.

Use dust palliative consisting of 712.02 calcium chloride or a brine solution containing a minimum of 30 percent by weight of calcium chloride.  Spread the calcium chloride uniformly over the surface.

616.03  Method of Measurement.  The Department will measure Water by the number of M gallons or 1000 gallon units (cubic meters) applied and measured either in tanks, tank wagons, or trucks of predetermined capacity; or by means of meters of a type and furnished and installed by the Contractor at no expense to the Department; or determined by weight conversion.

The Department will measure Calcium Chloride by the number of tons (metric tons) by weight measurement, furnished and applied.  When brine is used, the Department will determine the weight of calcium chloride by multiplying the number of gallons (cubic meters) by the factor 0.0024 (0.575).

616.04  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

616             M Gallons                       Water
                       (Cubic Meter)

616             Ton (Metric Ton)            Calcium Chloride

ITEM 617  RECONDITIONING SHOULDERS

617.01  Description

617.02  Materials

617.03  Prosecution

617.04  Shoulder Preparation

617.05  Furnishing and Compacting Additional Aggregate

617.06  Method of Measurement

617.07  Basis of Payment

617.01  Description.  This work consists of preparing the shoulder, and furnishing and compacting additional aggregate on the existing or prepared shoulder.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

617.02  Materials.  Furnish materials conforming to 703.18.

617.03  Prosecution.  If reconditioning shoulders as part of a resurfacing project and traffic is maintained, place shoulder material along with the paving operations as rapidly as possible.  Complete all shoulder reconditioning within four days following the placement of the surface course or any course that results in a drop-off of 2.0 inches (50 mm) or greater.

617.04  Shoulder Preparation.  If shoulder preparation is specified, loosen the existing surface to a depth of 1 to 2 inches (25 to 50 mm).  If the surface is an asphalt mix or seal, cut the surface along the edge of the pavement with a blade or disc to give a straight vertical edge.  Reduce pieces of loosened material that exceed approximately 1 1/2 inches (38 mm) in size to at least this maximum size or consider these pieces unsuitable material.  Remove and dispose of oversized or other unsuitable material that would interfere with placing of aggregate.  Reshape the loosened material as necessary to conform to the requirements for placing aggregate.

617.05  Furnishing and Compacting Additional Aggregate.  Spread aggregate with approved spreaders.  Do not dump or store aggregate on the pavement.  Remove spilled aggregate from the pavement as spreading progresses.

Where the shoulder is relatively level, compact the material using crawler-type tractors, tamping rollers, trench rollers, suitable pneumatic tire rollers, or other suitable equipment. Use a minimum of four passes with compaction equipment weighing at least 6 tons (5 metric tons). Perform the final compaction of the surface of the shoulder using a pneumatic tire roller. Where it would be unsafe to use the above compaction equipment due to the grade or width of the shoulder, use a side-mounted roller or side-mounted vibrating plate compactor that is securely attached to a tractor or other construction equipment. The side-mounted roller or side-mounted vibrating plate compactor must be able to adequately compact the aggregate while the equipment to which it is mounted remains on the paved surface. Use a minimum of four passes with the side-mounted roller and two passes with the side-mounted vibrating plate compactor. Compact the aggregate immediately after the spreading operation to prevent the loss of contained moisture and displacement of the material.

Apply water as directed by the Engineer when required to aid compaction and to prevent segregation of the material.

617.06  Method of Measurement.  The Department will measure Shoulder Preparation by the number of square yards (square meters).

The Department will measure Compacted Aggregate, by the number of cubic yards (cubic meters) in place computed from the profile grade and typical sections.

The Department will measure Water by the number of M gallons or 1000 gallon units (cubic meters) according to 616.03.

If the plans provide for the use of aggregate in a variable width or depth course and the Department cannot readily calculate the quantity from profile grade and typical sections, the Department will measure the cubic yards (cubic meters) by converting from weight using the following conversion factors:

Table 617.06-1

Material

Conversion Factor

Crushed stone

3800 lb/yd³

2250 kg/m³

Crushed gravel

3900 lb/yd³

2310 kg/m³

Crushed slag [1]

   less than 90 lb/ft³ (1450 kg/m³)

3600 lb/yd³

2140 kg/m³

   90 to 100 lb/ft³ (1450 to 1600 kg/m³)

4000 lb/yd³

2375 kg/m³

   more than 100 lb/ft³ (1600 kg/m³)

4500 lb/yd³

2670 kg/m³

Recycled Portland Cement Concrete

3400 lb/yd³

2020 kg/m³

Recycled Asphalt Concrete Pavement

4000 lb/yd³

2375 kg/m³

[1]  Based on average dry rodded weight of standard sizes of slag aggregates on record at the Laboratory.  The conversion factors listed are the long gradation weights.  These numbers are based on the dry rodded weights of No. 67, 57, or 8 gradation.  The Department will determine slag weights based on weights obtained from the original source.

The Department will classify salvaged or mixed materials according to the material that makes up the majority of the mixture.

The moistures of the delivered material will be less than 2 percent above saturated surface dry condition or the payment will be based on the dry densities and dry weights.

Furnish freight bills or certified weigh bills according to Item 109.

617.07  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

617             Square Yard                    Shoulder Preparation
                       (Square Meter)

617             Cubic Yard                      Compacted Aggregate

                    (Cubic Meter)                

617             M Gallons                       Water
                       (Cubic Meter)

ITEM 618  RUMBLE STRIPS ON SHOULDERS

618.01  Description

618.02  Construction of Rumble Strips on Shoulders

618.03  Method of Measurement

618.04  Basis of Payment

618.01  Description.  This work consists of grinding depressions (rumble strips) in paved shoulders.

Construct rumble strips according to the standard construction drawings.

618.02  Construction of  Rumble Strips on Shoulders.  Furnish equipment to grind the depressions with a rotary cutting head that will produce the required dimensions and a pattern of cutting tips to produce a smooth cut with approximately 0.06 inches (1.5 mm) between peaks and valleys.  Ensure that the cutting head is on its own suspension system, independent from that of the power unit, to allow the head to align itself with the slope of the shoulder or any irregularities in the shoulder surface.  Equip the cutting tool with guides or a guidance system, clearly visible to the operator, to provide for consistent alignment.  Take effective measures to control dust during the grinding operation.  Remove and dispose of all grinding materials deposited on the roadway pavement in a manner approved by the Engineer and before opening the roadway to traffic.

618.03  Method of Measurement.  The Department will measure Rumble Strips by the number of feet (meters) or mile (kilometer) as the sum of the lengths of the individual segments.  The Department will measure lengths along the inside edge of the shoulder, from the center of the first depression in a segment to the center of the last depression in that segment.  If Rumble Strips are provided on more than one shoulder, the Department will measure lengths separately for each shoulder segment and add the individual lengths together to obtain the total length.

618.04  Basis of Payment.  The Department will not pay for repairing surface damage and extraneous marks caused by the Contractor’s operations.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

618             Feet (Meter),                   Rumble Strips, (Asphalt Concrete)
                       Mile (Kilometer)             

618             Feet (Meter),                   Rumble Strips, (Concrete)

                       Mile (Kilometer)             

Item 619  FIELD OFFICE

619.01  Description

619.02  General

619.03  Method of Measurement

619.04  Basis of Payment

619.01  Description.  This work consists of providing, maintaining, and subsequently removing a field office for the exclusive use of the Department for the duration of the Contract at a location approved by the Engineer.

619.02  General.  Furnish a completely functional field office of the type specified in the Contract by the date directed by the Engineer.

Furnish each field office with a means for maintaining a room temperature between 68 and 80 °F (20 and 27 °C).

Furnish electric service for each field office.

Furnish potable hot and cold water for each field office.

Furnish neat, sanitary, enclosed toilet accommodations for each field office.  Furnish associated lavatory and sanitary supplies.  Portable facilities may be provided with the approval of the Engineer.

For projects requiring moisture and density control of construction materials, provide the field office with a lockable wood or metal storage box of sufficient size to store a nuclear density gauge and with a working electrical connection to charge the gauge. Provide two independent lock systems: one that locks the box the gauge is stored in; and the second one that locks the box to the facility within which the box is housed. The second lock system may consist of bolting the box to the office floor or wall. The storage box must be at least 15 feet (5 meters) from any occupied work area.

For the type of field office specified, provide the items indicated in Table 619.02-1

Table 619.02-1  Field Office

Item

Type A

Type B

Type C

Minimum ceiling height, ft (m)

7 (2.1)

7 (2.1)

7 (2.1)

Floor space, ft² (m²)

150 (14)

500 (46)

1000 (93)

Separate enclosed room, ft² (m²)

   (Part of specified floor space)

0 (0)

0 (0)

100 (9)

Telephone service & telephones [1]

2

2

2

Internet service connection [5]

1

1

1

Multi-Function copier that is setup for scanning, printing, faxing and copying. [2]

1, 11×17

1, 11×17

1, 11×17

Calculator with tape

1

2

3

Desk and chair set

1

3

5

Work table, 30 ´ 72-inch  (750 ´ 1800 mm)

1

2

3

4-drawer, legal size, lockable metal file cabinet

---

1

2

2-drawer, metal file cabinet

1

2

2

Portable fire extinguishers [3]

1

1

2

Plan rack [4]

1

1

2

All-weather parking spaces

8

16

20

[1]    For each telephone specified, provide the telephone itself, all wiring necessary to connect the phone and multi-function copier to the phone company system, and a working separate phone number for each telephone.  Connect one phone to a recorded answering device.  For Types B and C, provide one speakerphone.

[2]    Copier must meet minimum specifications provided for each field office type. Contractor responsible for paper supplies, copier supplies, and maintenance of copier.

          Type A:

          Copy/Print Speed: 20 Pages Per Minute (Letter), 15 Pages Per Minute (Legal), 12 Pages Per Minute (Ledger) or higher

          Duplex printing support

          Automatic document feeder with 40 sheet duplexing document feeder

          Copier Memory: 256 MB

          Data Security Kit

          Paper Capacity - 250 sheet × 2 trays, 50-sheet Bypass tray

          Network Interface: 10/100Base-TX, 1000Base-TX

          Analog Fax Support Included with machine

          Color Scanning with following requirements:

                        Up to Up to 600 × 600 dpi

                        Scan Area up to 11" × 17"

                        Scanning Protocol Support - TCP/IP, SMTP, SMB, FTP, POP3, NCP

                        File Scan Types Supported: Single Page TIFF, JPEG, PDF, Multi- Page TIFF, PDF, and

                        Scanning Support for Scan-to-Email, SMB (Folder), URL, and TWAIN

          Network protocol support for TCP/IP

          Client and Server Print Driver Support for PCL Print Drivers

          Server Operating System Support for Windows Server 2008 and Windows Server 2008 R2 (32 Bit/64 Bit)

          Client Print driver support for Windows XP/Windows 7 (Both PCL/(32 Bit and 64 Bit))

          Minimum print/copy resolution of 600 × 600 dpi

          Type B:

          Copy/Print Speed: 30 Pages Per Minute (Letter), 15 Pages Per Minute (Legal), 15 Pages Per Minute (Ledger) or higher

          Duplex printing support

          Automatic document feeder with 50 sheet duplexing document feeder

          Copier Memory: 768 MB

          Installed HDD: 40 GB

          Data encryption and HDD Erase Support included with machine

          Internal Stapler Support

          Paper Capacity - 250 sheet × 2 trays, 50-sheet Bypass tray

          Network Interface: 10/100Base-TX, 1000Base-TX

          Analog Fax Support Included with machine

          Color Scanning with following requirements:

                        Up to Up to 600 × 600 dpi

                        Scan Area up to 11" × 17"

                        Scanning Protocol Support - TCP/IP, SMTP, SMB, FTP, POP3, NCP

                        File Scan Types Supported: Single Page TIFF, JPEG, PDF, Multi- Page TIFF, PDF, and OCR PDF

                        Scanning Support for Scan-to-Email, HDD, SMB (Folder), URL, and TWAIN

          Network protocol support for TCP/IP

          Client and Server Print Driver Support for PCL Print Drivers

          Server Operating System Support for Windows Server 2008 and Windows Server 2008 R2 (32 Bit/64 Bit)

          Client Print driver support for Windows XP/Windows 7 (Both PCL/(32 Bit and 64 Bit))

          Minimum print/copy resolution of 600 × 600 dpi

          Secure printing with password or pin from client to copier

          Type C:

          Color Print/Copy/Scan

          Copy/Print Speed: 30 Pages Per Minute (Letter), 15 Pages Per Minute (Legal), 15 Pages Per Minute (Ledger) or higher

          Duplex printing support

          Automatic document feeder with 50 sheet duplexing document feeder

          Copier Memory: 1 GB

          Installed HDD: 40 GB

          Data encryption and HDD Erase Support included with machine

          Internal Stapler Support

          Paper Capacity - 250 sheet × 2 trays, 50-sheet Bypass tray

          Network Interface: 10/100Base-TX, 1000Base-TX

          Analog Fax Support Included with machine

          Color Scanning with following requirements:

                        Up to Up to 600 × 600 dpi

                        Scan Area up to 11" × 17"

                        Scanning Protocol Support - TCP/IP, SMTP, SMB, FTP, POP3, NCP

                        File Scan Types Supported: Single Page TIFF, JPEG, PDF, Multi- Page TIFF, PDF, and OCR PDF

                        Scanning Support for Scan-to-Email, HDD, SMB (Folder), URL, and TWAIN

          Network protocol support for TCP/IP

          Client and Server Print Driver Support for PCL Print Drivers

          Server Operating System Support for Windows Server 2008 and Windows Server 2008 R2 (32 Bit/64 Bit)

          Client Print driver support for Windows XP/Windows 7 (Both PCL/(32 Bit and 64 Bit))

          Minimum print/copy resolution of 600 × 600 dpi

          Secure printing with password or pin from client to copier

[3]    Type 2-A:10-B:C, 5-pound (2.27 g) size

[4]    Capable of handling the breakdown of 22 ´ 34-inch (559 ´ 864 mm) sized plans into ten sections.

[5]    Provide a broadband internet connection capable of minimum download speeds as follows:

               Type A: 2 Mbps download 768 Kbps upload - Network Latency less than 50 milliseconds

               Type B: 5 Mbps download 1Mbps upload - Network Latency less than 50 milliseconds

               Type C: 10 Mbps download 2 Mbps upload - Network Latency less than 50 milliseconds

          If speeds are not available through an individual or singular circuit, provide the highest speed available in the area and install multiple circuits to achieve the specified speeds.  When multiple broadband services are available the following is the preferred order: Cable, DSL, Cellular, and Wireless Radio (Satellite Communication is not compatible with ODOT VPN connection and will not be accepted).  Supply modems capable being configured in Bridge Mode. If a cellular network is used, provide the cellular equipment, including software and router equipment to connect to the ODOT provided Cisco ASA 5505 firewall. Supply ODOT with all documentation for the broadband circuit including all username/user ids, passwords and account information. Verify that the broadband internet connection is active and working as specified. ODOT IT personnel will confirm that bandwidth and network latency are compliant with the required field office specifications. All field office Internet connections are for ODOT use only.

With the Engineer’s written approval, the Contractor may modify the requirements for the field office.

Maintain all utility services (e.g., electric, security, telephone, water) for the duration of the project.

Furnish a concrete cylinder curing box capable of holding at least eight 6 × 12 inch (150 × 300 mm) cylinders at 73 °F (23 °C) ± 3 degrees no matter what the ambient temperature is when constructing either portland cement concrete pavement over 10,000 square yards (8000 m²) or over 50 cubic yards (38 cubic meters) of bridge structure repair or replacement concrete.  The box will have a sealed lid.

619.03  Method of Measurement.  The Department will measure Field Office, Type ___ by the number of months the office is maintained.  A partial month at the end of the project will be paid as a full month.

619.04  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

619             Month                             Field Office, Type ___

ITEM 620  DELINEATORS

620.01  Description

620.02  Materials

620.03  Layout

620.04  Removal

620.05  Installation

620.06  Method of Measurement

620.07  Basis of Payment

620.01  Description.  This work consists of furnishing and installing delineators, removing existing delineators for  disposal, and restoring the surface where delineators are removed.

620.02  Materials.  Furnish materials conforming to:

Reflectors................................................................. 720.01

Posts, flexible.......................................................... 720.03

Steel hardware......................................................... 730.08

Brackets................................................................... 730.09

Stainless steel hardware........................................... 730.10

Aluminum hardware................................................ 730.17

Reflective sheeting.................................. 730.192, 730.193

Delineators consist of reflectors mounted on flexible posts or brackets. Reflectors are reflective sheeting adhered to either a flexible post or an aluminum plate. The colors of reflectors of each type are:

Type C      White

Type D      Yellow

Type E      Red

Delineator reflector and flexible post color shall match that of the nearest edge line.

620.03  Layout.  Lay out all delineator locations to ensure their proper placement.  The Engineer will approve the layout before installation is started.

620.04  Removal. Remove delineators, including reflectors, posts, brackets, and miscellaneous hardware.  The delineator becomes the property of the contractor.  Remove and dispose of concrete for delineator post embedment.

Restore surfaces where delineator posts or concrete for embedment are removed. 

620.05  Installation.  Install delineators facing traffic, except install red reflectors facing wrong-way traffic.  Do not remove the protective paper covering the face of flexible post-mounted reflectors until after installation.  Ensure that posts are not more than 1:50 out of plumb.  If soil conditions may cause the post to be out of plumb, the Contractor may drive a pilot shaft before installation.

Install flexible posts using methods and equipment that conform to the post manufacturer’s recommendations.

620.06  Method of Measurement.  The Department will measure Delineator by the number, including reflectors, supports and hardware, in place, completed and accepted.

The Department will measure Removal of Delineator, by the number.

620.07  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

620             Each                                Delineator

620             Each                                Removal of Delineator

ITEM 621  RAISED PAVEMENT MARKERS (RPM)

621.01  Description

621.02  Materials

621.03  Layout

621.04  Installation RPM Casting

621.05  Installation RPM Retroreflector

621.06  Reflector Replacement

621.07  Reflector Color

621.08  Raised Pavement Markers Removed

621.09  Method of Measurement

621.10  Basis of Payment

621.01  Description.  This work consists of preparing the pavement and furnishing and placing plowable raised pavement marker castings (RPMs) and prismatic retroreflectors, and removing existing RPMs for disposal.

621.02  Materials.  Furnish materials  conforming to :

Castings................................................................... 721.01

Prismatic Retroreflectors and Adhesive................... 721.02

Casting adhesive...................................................... 721.03

621.03  Layout.  Before placing RPMs, lay out the location of all RPMs.  Locate RPMs within 5 percent of specified spacing.  Do not place RPMs under the following conditions:

A.      On pavement surfaces with cracking, spalling, or failure of underlying base material.

B.      Within 1 foot (0.3 m) of active signal detector loop wires.  Exercise care to ensure that detector lead-in cables are not cut.

C.      Over pavement markings except with the Engineer’s approval.

D.      Closer than 2 inches (50 mm) to a pavement construction (transverse or longitudinal) joint or within an intersection.

E.      Within 3 feet (1 m) of a bridge expansion joint.

If the initial location of a RPM is determined to violate one of the aforementioned conditions, relocate the affected RPM longitudinally.  Relocate the RPM within a distance not exceeding 25 percent of the specified RPM spacing.  If necessary to relocate the RPM to a distance greater than 25 percent of the specified RPM spacing, do not install the affected RPM.

RPMs along double yellow centerline are to be placed in line or on line, but no closer than 2 inches (50 mm) to a pavement construction (transverse or longitudinal) joint.  RPMs installed along a channelizing line are to be placed no more than 1 inch (25 mm) from the edge of the painted line and no closer than 2 inches (50 mm) to a pavement construction (transverse or longitudinal) joint.   Place the RPMs installed along a lane line or dashed yellow centerline between and in line with the dashes no closer than 2 inches (50 mm) to a pavement construction (transverse or longitudinal) joint.

Install replacement RPMs within 3 feet (0.9 m) longitudinally of the damaged or missing RPM.

621.04  Installation RPM Casting.  Cut parallel slots with 1/16 to 1/8 inch (1.5 to 3 mm) clearance on each side for installing RPM castings. 

Pavement cuts should be inspected prior to adding casting adhesive.

When a casting is inserted in the cut without casting adhesive to test proper cut, at least 3 of the 4 leveling lugs/tabs must contact the pavement surface and all four keel-ends of castings must be below the pavement surface.

Each casting must be centered lengthwise and should have 1/16 to 1/8 inch (1.5 to 3 mm) clearance between pavement cut and casting for casting adhesive to bond properly.  Only the leveling lugs/tabs should be in contact with the pavement surface after insertion of casting in pavement so that a minimum of 1/16 inch (1.5 mm) of casting adhesive is the bonding adhesive between the casting and pavement.  The casting adhesive must fill all voids.

The pavement cut must be completely dry and free of dust, dirt or any other material that will interfere with the adhesive bond to the casting and the pavement.  Casting adhesive on the active reflector face must be removed immediately.

Install the RPM casting within 24 hours after cutting the slots into the pavement.  On new pavement surfaces, the Contractor may begin RPM placement as soon as the pavement markings for that section are completed and dry.

Ensure that the RPM casting is free of dirt, dust, oil, grease, rust, moisture, or any foreign matter that impairs adhesion to the pavement.

Place RPMs when the pavement surface temperature and the ambient air temperature are at least 40 °F (5 °C) and the pavement is dry.  Heat both parts of the RPM casting adhesive to 100 ± 10 °F (38 ± 5 °C) during installation when either the pavement surface or ambient air temperature is between 40 and 50 °F (5 and 10 °C).

Ambient Air

Temperature

Minimum Period

Protected from Traffic

°F

(°C)

Minutes

100

(38)

15

90

(32)

20

80

(27)

25

70

(21)

30

60

(16)

35

50

(10)

45

40

(5)

60

Do not allow traffic on the RPMs until the adhesive has cured.

Two component approved casting adhesive is used to fill the pavement cut to within approximately 3/8 inch (9 mm) of the top of the pavement cut.  A minimum of 3 of the 4 leveling lugs/tabs must be in contact with the pavement surface and the casting adhesive should ooze out from under the casting from all sides filling all voids around the casting and be level with the pavement surface.

Mix the casting adhesive according to the manufacturer’s recommendations.  Complete the mixing operation and placing of the RPMs rapidly.  Do not use any mixed batch that becomes so viscous that it cannot be readily extruded from under the RPM with light pressure.

621.05  Installation RPM Retroreflector.  Attach the reflector to the casting before installation or after the adhesive in the pavement slots has cured. 

Remove all dirt, dust, oil, grease, rust, moisture, parts of damaged reflectors, or any foreign matter that impairs adhesion of the reflector to the casting.

Peel the release liner from the back of the reflector with butyl pad.  Apply a wide bead (approximately 3/8 inch (9 mm)) of  reflector adhesive sufficient to squeeze out on all sides when pressure is applied to seat the reflector.

Apply approximately 100 pounds (45 kg) of pressure on the reflector or foot pressure for 1 to 3 seconds.  Do not allow adhesive material on the reflective surface of the reflector.  Any adhesive on the active reflector must be removed immediately.

Apply the reflector when the pavement surface temperature and the ambient air temperature are at least 35 °F (2 °C) and the casting surface is dry.  Do not attach the reflector to the casting when rain over the work site is imminent.

621.06  Reflector Replacement.  Replace damaged, non-retroreflective, or missing reflectors within the existing marker installations where the casting remains intact with the appropriate reflector type.  The Engineer will determine the location of replacement reflectors.

Perform the cleaning and attachment procedure for replacing reflectors within existing RPM installations according to 621.05.

621.07  Reflector Color.  Use the appropriate reflector color for the following applications:

A.      Channelizing Lines.  White/red two-way reflectors with white facing traffic.

B.      Lane Lines.  White one-way or white/red two-way reflectors as specified, with white facing traffic.

C.      Edge Lines.  One-way reflectors facing traffic matching the edge line color or two-way reflectors with the edge line color facing traffic and red in the opposite direction.

D.      Center Lines.  Yellow two-way reflectors.

621.08  Raised Pavement Markers Removed.  As designated, remove existing raised pavement markers.  Fill all depressions caused by removing the castings with asphalt concrete by the end of the next workday.  Remove all standing water from the hole before filling.  Compact the asphalt concrete flush with the pavement.  Removed raised pavement markers become the property of the Contractor.

621.09  Method of Measurement.  The Department will measure RPMs by the number of each furnished, complete with reflectors, in place, and accepted.

The Department will measure RPM, Reflectors by the number of each, complete in place, for use on existing RPM castings in the pavement, and accepted.

The Department will measure Raised Pavement Markers Removed by the number.  Payment will include the cost of asphalt concrete to fill depressions caused by removal of the castings.

621.10  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

621             Each                                RPM

621             Each                                RPM Reflector

621             Each                                Raised Pavement Marker Removed

ITEM 622  CONCRETE BARRIER

622.01  Description

622.02  Materials

622.03  Placing Concrete

622.04  Portable Barrier

622.05  Joints

622.06  Finish

622.07  Curing

622.08  Method of Measurement

622.09  Basis of Payment

622.01  Description.  This work consists of furnishing and placing portland cement concrete barrier on the accepted and prepared subgrade, subbase course, or existing pavement.  This item also consists of furnishing, placing, maintaining, and removing portable barrier.

622.02  Materials.  Furnish materials conforming to:

Concrete,
Class QC 1 *............................................................ 499
Reinforcing steel and wire fabric......................... 509.02

Forms ..................................................................... 515.14

Preformed filler ....................................................... 705.03

Curing materials......................................... 705.05, 705.06,

................................................................ or 705.07 Type 2

Precast concrete ...................................................... 706.13

Dowel bars........................................... 709.01 thru 709.05

Steel......................................................................... 711.01

* Replacing Coarse aggregate in the concrete mixes with Recycled Concrete Aggregate conforming to Supplement 1117 is an option

622.03  Placing Concrete.  Construct concrete barrier by cast-in-place, precast, or slip-form methods.  For slip-form construction, conform to 609.04.C.

622.04  Portable  Barrier.  Furnish individual sections not less than 10 feet (3 m) long.  If intending to use the barrier at one location on the project, the Contractor may slip-form barriers in place without joints, or with grooved or sawed joints to facilitate removal.  As directed by the Engineer, repair or replace barrier sections damaged during handling or by traffic, for the life of the project.  The Contractor may substitute approved proprietary portable barrier products which can be found on the Office of Roadway Engineering’s website.

622.05  Joints.  Construct joints for cast-in-place or slip-formed barrier of the type and dimensions and at the locations specified.

A.      Contraction Joints.  The Contractor may construct unsealed contraction joints by either sawing, using metal inserts inside the forms, using a grooving tool, or using full-width 3/4-inch (19 mm) thick preformed joint filler conforming to 705.03.  Make joints that are sawed, tooled, or formed by inserts a minimum of 1/8 inch (3 mm) wide and 3 inches (75 mm) deep.  Saw joints as soon as curing allows sawing to the required depth with minimal spalling of the concrete surface.

B.      Expansion Joints.  Use 3/4-inch (19 mm) preformed joint filler conforming to 705.03 to construct expansion joints at locations as shown in the plans.

C.      Horizontal Construction Joints.  If and as shown on the plans, the Contractor may place horizontal construction joints.

622.06  Finish.  Immediately following removal of fixed forms or slip-form construction, check the surface of the barrier with a straightedge and correct all irregularities of more than 1/4 inch in 10 feet (6 mm in 3 m).  Finish and make corrections to the barrier surface according to 511.18.

622.07  Curing.  Cure concrete according to 511.14, Method B and the following additional requirements.  Apply the curing compound using an approved mechanical sprayer equipped with a shield to protect the spray from wind.  For small areas, the Engineer will allow the use of other acceptable methods.

Do not apply any load or conduct any work that will damage newly placed concrete.  Allow a minimum of 36 hours of cure time to elapse on any concrete placed first at a horizontal construction joint.  The Contractor may cure precast sections according to 515.15.  With the Engineer’s approval, the Contractor may also use radiant heated forms for curing.

The Contractor may use 511.14, Method A for curing of short sections of barrier (leave-outs); however, before the curing is completed for any leave-outs, apply material conforming to 705.07, Type 2 at the normal rate specified in 511.14, Method B.

The Contractor may cure horizontal construction joints between the foundation and the upper portion of the barrier, and between portions of the upper barrier placed separately according to 511.14, Method A or B.  Do not remove the membrane before placing the next portion of the concrete barrier.

622.08  Method of Measurement.  The Department will measure Concrete Barrier by the number of feet (meters) along the centerline of the top of the barrier, including all transitions, and bridge pier sections as specified, complete in place excluding end anchorages and excluding sections.

The Department will measure Reinforced End Anchorages of the type specified by the number each complete in place.

The Department will measure End Sections of the type specified by the number each complete in place.

The Department will measure Portable  Barrier and Portable Barrier, Bridge Mounted by the number of feet (meters) for each application of the barrier placed according to the plans.  The Department will measure each re-use of barrier sections at a different location required by the plans separately.

The Department will not measure repaired or replacement barrier sections damaged during handling or by traffic.

622.09  Basis of Payment.  The cost of all inserts, sleeves, fittings, connectors, reinforcement, dowels, preformed filler, excavation, aggregate base, and backfill is incidental to these items.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

622             Foot (Meter)                    Concrete Barrier, Type ___

622             Each                                Concrete Barrier End Anchorage, Reinforced,                                                        Type ___

622             Each                                Concrete Barrier End Section, Type ____

622             Foot (Meter)                    Portable  Barrier, ___" (___ mm)

622             Foot (Meter)                    Portable  Barrier, ___" (___ mm)

                                                               Bridge Mounted

ITEM 623  CONSTRUCTION LAYOUT STAKES
and Survey Monuments

623.01  Description

623.02 Materials

623.03 Definitions

623.04  Verification

623.05 Placement, Protection and Restoration of Survey Monuments

623.06 Primary Project Control

623.07 Right-of-Way Staking

623.08 Construction Layout Staking

623.09 Providing Electronic Instrumentation

623.10  Method of Measurement

623.11 Basis of Payment

623.01 Description.  This work consists of furnishing, placing, and maintaining construction layout stakes necessary to perform the Work under the Contract.  This work also includes verification, placement, protection, and necessary restoration of primary project control monuments, monument assemblies, reference monuments (which include centerline monuments and centerline reference monuments), and Right-of-Way monuments.

Ensure that all work associated with locating and setting reference monuments, Right-of-Way monuments, and steel rods in monument assemblies is performed by a Registered Surveyor.  Ensure that all other surveying and layout work described below is supervised by a Registered Engineer or a Registered Surveyor.

623.02 Materials.  Furnish materials conforming to:

Concrete, Class QC Misc or QC 1............................... 499

Cast frames and covers.............. 711.12, 711.13, or 711.14

Concrete sand (fine aggregate)............................. 703.02.A

Stainless steel bolts.................................................. 730.10

Steel rods................................................................. 709.01

Pipe........................................... 706.07, 706.09, or 707.45

623.03 Definitions

A.      Survey Monuments.  Includes primary project control monuments (including azimuth marks and temporary benchmarks), monument assemblies, centerline monuments, centerline reference monuments, and Right-of-Way monuments.

B.      Primary Project Control Monument.  A surveyed position that is established and constructed according to the Department’s  Survey and Mapping Specifications.  Primary project control monuments will have associated azimuth marks and may have associated temporary benchmarks.

C.      Monument Assembly.  A surveyed position typically set inside pavement that consists of a steel rod housed inside a monument assembly box with a cast frame and cover according to SCD RM-1.1.

D.      Reference Monuments

1.      Centerline Monument.  A surveyed position outside of pavement that consists of a steel rod and aluminum cap encased in concrete according to SCD RM-1.1 that defines the centerline. 

2.      Centerline Reference Monument. A surveyed position outside of pavement that consists of a steel rod and aluminum cap encased in concrete according to SCD RM-1.1, that defines the centerline based on a specific offset from that centerline. 

E.      Right-of-Way Monument. A property boundary monument set according to SCD RM-1.1 to comply with Ohio Administrative Code Section 4733-37, “Standards for Boundary Surveys in the State of Ohio” and recited in the Right-of-Way deeds to convey the property or easement rights.  Right-of-Way monuments are set at property corners, property line intersections, points along the Right-of-Way and angle points on the Right-of-Way.

F.      Azimuth Mark.  A project control monument set at the end points of the project for use as a “backsight” point.

G.     Temporary Benchmark.  A vertical position transferred from a primary project control monument.

623.04  Verification.  Verify the position of all survey monuments shown in the Contract Documents prior to construction activities.  Use standard acceptable surveying measurement techniques suitable to meet the requirements of Ohio Administrative Code Section 4733-37, “Standards for Boundary Surveys”.  Have a Registered Surveyor prepare a verification report with the coordinates, station, offset, and a description of each survey monument found before beginning earth moving, resurfacing, or paving activities.  Include the size, material, condition, any cap stamping or markings, and note any differences from the plan locations of the survey monuments.  Have the Registered Surveyor sign and seal the verification report and submit it to the Engineer and the District Survey Operations Manager.  If additional survey monuments not shown in the Contract Documents are encountered, protect, reference, and preserve them in the same manner as survey monuments that are shown in the Contract Documents.  Include the additional survey monuments in the verification report.

623.05 Placement, Protection and Restoration of Survey Monuments.  When specified in the Contract Documents, locate, construct, and position primary project control monuments according to the Department’s Survey and Mapping Specifications. Construct all other survey monuments according to SCD RM-1.1.

Do not disturb survey monuments, cornerstones, or boundary monuments during construction unless specified in the Contract Documents.  Restore survey monuments damaged or destroyed by construction activities, unless directed otherwise by the Engineer.

Have a Registered Surveyor prepare a report and drawing with the coordinates, station, offset, and description of each survey monument that is constructed or restored.  Have the Registered Surveyor sign and seal the verification report and submit it to the Engineer and the District Survey Operations Manager.

If the Department must repair, replace, or resurvey the location of any survey monuments, cornerstones, or boundary monuments that are damaged, destroyed, or made inaccessible by the Contractor or its employees, subcontractors, or their agents, then the Engineer will deduct the costs incurred by the Department from the estimates to the Contractor.

623.06 Primary Project Control.  Primary project control governs all positioning for Department projects.  Use project control information provided in the plans for all project related survey operations.  Establish and construct primary project control monuments according to the Department’s Survey and Mapping Specifications. 

623.07 Right-of-Way Staking.  Stake Right-of-Way lines where work will be performed before beginning the work.  Stake Right-of-Way lines by placing tall stakes, properly identified and readily discernible, at points of change in width or direction of the Right-of-Way line and at points along the line so that at least two stakes can be seen distinctly from any point on the line.  The Engineer will not require the Contractor to set additional stakes to locate a utility line that is not included as a pay item in the contract, or to determine the property line between properties.

623.08 Construction Layout Staking.  Furnish construction layout staking as required to construct the project and along both sides of the centerline of construction, 3 feet (1 m) outside of the grading limits at maximum spacing intervals shown in the table below.  Replace staking as directed by the Engineer.

Table 623.09-1
Maximum Spacing of Construction Layout Stakes

Length of project

Spacing

Length of project

Spacing

Less than 1/2 mile

200 feet

Less than 1 km

50 m

1/2 mile to 1 mile

500 feet

1 km to 2 km

200 m

Over 1 mile

1000 feet

Over 2 km

500 m

Before performing a portion of the Work, submit a copy of the construction layout notes for that portion to the Engineer.  The construction layout notes must contain information sufficient for the Engineer to verify the construction layout.

The Contractor is responsible for having the finished Work conform to the lines, grades, elevations and dimensions shown on the plans.  Any inspection or checking of the Contractor’s layout by the Engineer and the acceptance of all or any part of it does not relieve the Contractor of that responsibility.

The removal of construction layout stakes at the completion of the Work is a final cleanup item that is required as a condition of full payment for Item 624 Mobilization.

623.09 Providing Electronic Instrumentation.  If specified as a pay item, provide the Engineer with electronic instrumentation so that the Department can verify the construction layout, perform check sections, and document pay items.  Provide a survey-grade, global navigation satellite system (GNSS) receiver and data collector.  Provide equipment that meets the requirements of the Department’s Survey and Mapping Specifications.

Provide equipment, software, and all three dimensional models needed to verify layout, perform check sections, and document pay items.  Train the Engineer on how to use the provided equipment and software and provide technical assistance during the duration of the Work.

Upon completion of the Work, the electronic equipment, computer and software will remain the property of the Contractor.

If using GNSS methods to construct the project and a pay item for providing electronic instrumentation is not specified, provide the Engineer with the three dimensional models in electronic format when requested.  Provide the models at no additional expense to the Department.

623.10  Method of Measurement.  Estimated quantities for replacement of Primary Project Control Monuments, Monument Assemblies, Reference Monuments, and Right-of-Way Monuments expected to be destroyed that are within the project construction work limits are included in the Contract Documents.  Estimated quantities for new monuments are also included in the Contract Documents.

Primary project control monuments, monument assemblies, reference monuments, Right-of-Way monuments, and boundary monuments on or outside the project construction work limits are the Contractor’s responsibility to protect and restore as required.  The Department will not pay for restoration of these items.

623.11 Basis of Payment.  Payment for Construction Layout Stakes and Surveying includes payment for Right-of-Way staking and verifying the location of existing survey monuments. The Department will consider the cost for locating new survey monuments to be included in the unit price bid for the survey monument.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

623             Lump Sum                      Construction Layout Stakes and Surveying

623             Lump Sum                      Providing Electronic Instrumentation

623             Each                                Primary Project Control Monument, Type A

623             Each                                Primary Project Control Monument, Type B

623             Each                                Monument Assembly

623             Each                                Reference Monument

623             Each                                Right-of-Way Monument

ITEM 624  MOBILIZATION

624.01  Description

624.02  Limitation

624.03  Method of Measurement

624.04  Basis of Payment

624.01  Description.  This work consists of the preparatory work and operations including, but not limited to, those necessary for the movement of personnel, equipment, supplies, and incidentals to the project site; for the establishment of all field offices, buildings, and other facilities necessary for work on the project; for all other work and operations that must be performed or costs incurred before beginning the Work on the other contract items; and for demobilization.

If Mobilization is not included as a pay item in the Contract, the Department will not pay for this work separately but will consider it incidental to the other Contract Items.

624.02  Limitation.  The Department will limit the sum of the partial payments specified in 624.04.A and 624.04.B to the amounts shown in Table 624.02-1 under “Maximum Total of Partial Payments”.  The Department will pay the balance of the lump sum amount bid, as specified in 624.04.C.

Table 624.02-1

Total Contract Amount

Maximum Total of Partial

Payments

More than

Up to, inclusive

($)

($)

($)

0

50,000

0

50,000

100,000

2,000

100,000

200,000

4,000

200,000

500,000

10,000

500,000

1,000,000

20,000

1,000,000

2,000,000

40,000

2,000,000

5,000,000

100,000

5,000,000

10,000,000

200,000

10,000,000

20,000,000

400,000

20,000,000

40,000,000

800,000

40,000,000

60,000,000

1,200,000

60,000,000

80,000,000

1,600,000

80,000,000

--

2,000,000

If the lump sum amount bid for Mobilization exceeds the total shown in Table 624.02-1 for partial payments, the Department will pay the excess upon completion of the project.

624.03  Method of Measurement.  The Department will measure Mobilization as a unit, acceptably performed.

624.04  Basis of Payment.  The Department will make partial payments according to 109.09 and as modified by the following schedule:

A.      The Department will release 50 percent of the lump sum amount bid for Mobilization or 50 percent of the amount shown in 624.02, whichever is less, to the Contractor with the first estimate payable, but not sooner than 15 days after the start of work at the project site.

B.      The Department will release an additional 40 percent of the lump sum amount bid for Mobilization or 40 percent of the amount shown in 624.02, whichever is less, with the first regular estimate after 10 percent of the original total contract amount, including payments for delivered materials but excluding Mobilization, is earned.

C.      Upon completion of all work on the project, including final cleanup, the Department will release payment of the remaining 10 percent of the lump sum amount bid for Mobilization and any amount of the lump sum price bid for Mobilization, in excess of the total amount shown in 624.02 for partial payment.  Final cleanup includes but is not limited to the removal of construction layout stakes and sediment and erosion control items.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

624             Lump Sum                      Mobilization

ITEM 625 HIGHWAY LIGHTING

625.01  Description

625.02  Definitions

625.03  Codes

625.04  Permits

625.05  Materials

625.06  Working Plans

625.07  Incidentals

625.08  Luminaires

625.09  Luminaire Supports

625.10  Foundations

625.11  Junction Boxes (Handholes) & Pull Boxes (Manholes)

625.12  Raceways and Conduits

625.13  Trenching

625.14  Jacking or Boring

625.15  Power Service (Control Equipment)

625.16  Grounding 

625.17  Wiring and Cabling

625.18  Connections

625.19  Testing of Installations

625.20  Plastic Caution Tape

625.21  Removal of Lighting Equipment

625.22  Method of Measurement

625.23  Basis of Payment

625.01  Description.  This work consists of furnishing and installing highway lighting equipment complete and ready for service.  This work shall also include necessary excavation and backfill, disposal of discarded materials, restoration of disturbed facilities and surfaces, and testing as specified.

625.02  Definitions.  Lighting terminology herein is defined in the American National Standard Practice for Roadway Lighting.

625.03  Codes.  Follow the National Electrical Code, The National Electrical Safety Code and local codes where applicable.

625.04  Permits.  Obtain all permits required as an incidental to the construction of the lighting installation.

625.05  Materials.  Furnish materials conforming to:

Concrete QC Misc or QC 1.................................. 499, 511

Reinforcing steel...................................................... 509.02

Sand......................................................................... 703.06

Cable........................................................................ 725.02

Unit type duct-cable systems................................... 725.03

Conduit...................................... 725.04, 725.051, 725.052

Pull boxes......................... 725.06, 725.07, 725.08, 725.12

Junction boxes......................................................... 725.10

Luminaires............................................................... 725.11

Lamps...................................................................... 725.11

Cable connectors and connector kits........................ 725.15

Cable splicing kits.................................................... 725.15

Ground rods............................................................ 725.16

Power service components...................................... 725.19

Wood service poles.................................................. 725.19

Multiple cell conduit................................................ 725.20

Anchor bolts and nuts.............................................. 725.21

Light poles............................................................... 725.21

Light towers............................................................. 725.21

Portable power units................................................ 725.21

Plastic caution tape................................................... 725.22

625.06  Working Drawings.  Submit, to the Engineer prior to incorporation, two copies of the shop drawings and catalog cuts which identify and describe each manufactured item which is being incorporated into the construction.  Certify in writing that each manufactured item is in conformance with all contract requirements for that item.  Ensure that the documents describing each item indicate the project number (including the construction year) and the bid reference number under which the item is being installed and that the documentation contains all of the information needed to allow the Engineer to determine that the item to be supplied meets all applicable requirements along with all of the information needed by the maintaining agency to obtain an identical replacement unit from the manufacturer.  When a given item is to be incorporated into the construction under multiple bid item reference numbers, furnish a separate and complete documentation package for each bid item reference number under which the item is to be installed.  When multiple items are to be incorporated under a single bid reference number, submit the documentation for all such items together.

625.07  Incidentals.  Furnish and install all incidentals necessary to provide a complete and practical working unit or system.

625.08  Luminaires.  A luminaire consists of a housing with a lamp, a lamp socket, the optical components to direct the output from that lamp, and the electrical components needed to operate the lamp.

Ensure that luminaires of the same type (i.e. high mast, low mast, conventional, underpass, post top, etc) in a given installation (i.e. interchange, rest area, weigh station, etc.) are of the same brand.

Align each luminaire vertically and horizontally to the roadway as specified.  Where the profile grade exceeds 4 percent and the luminaire is mounted less than 60 feet (18 m) above the roadway, adjust the luminaire to be perpendicular to the roadway rather than gravimetric level.

At the locations designated in the plans or as directed by the Engineer, furnish and install glare shields obtained from the manufacturer of the luminaire

After all other work has been completed, clean the reflector, refractor and other components of the optical assembly just prior to leaving the job.

625.09  Luminaire Supports.  Luminaire supports fall into three categories:  bracket, light pole, light tower.

A bracket is the attaching hardware used to mount a luminaire onto the face of a wall or pier cap, or hang a luminaire from the bottom of a deck or beam or other similar installation.  A bracket is often supplied for the luminaire by the luminaire manufacturer to facilitate the installation of the luminaire.  A more complex situation will require extensive work to fabricate a bracket for the situation.

A light pole is the pole with one or more fixed brackets or arms for supporting luminaires above the roadway to be lighted. A light pole also includes a lower portion of the pole which is embedded or a mounting plate, any base for housing components or wiring, and when specified a breakaway device such as a frangible base, frangible couplings or slip plates.

A light tower is a shaft with a base plate, head frame, ring or similar structure on which one or more luminaires are mounted with a mechanism for lowering the mounting ring and luminaires for servicing and a lightning protection system.

Ensure that luminaire supports of the same type (i.e. high mast, low mast, conventional, underpass, post top, etc.) in a given installation (i.e. interchange, rest area, weigh station, etc.) are of the same brand.

Plumb each light pole and each light tower.  When shims are used, use only shims of an approved design and installed in an approved manner.  Do not install more than the minimum number needed to plumb the pole and neither exceed the maximum allowed total thickness of the shim pack nor the maximum number of shims permitted.  When leveling nuts are used, ensure that such nuts are installed in approved locations and that both the anchor and the leveling nuts are properly tightened. 

Ensure that the grounding connections for each light pole or light tower have been made and that the resultant ground is within the earth resistance limit specified

Apply a suitable lubricant to prevent seizing to each cover fastener and install all such fasteners.

After erection, the Engineer shall inspect each pole for defects in the surfaces and determine for each defect discovered whether the defect is minor enough that the Contractor may be allowed to field repair the finish or major enough that the Contractor must replace the pole.  Make finish repairs and provide and install replacement poles as directed by the Engineer for no additional charge to the project.  

Label each light pole and light tower with the alpha numeric identifier.  Place the identifier on the quadrant of the surface of the pole that faces oncoming traffic at approximately 7 feet (2 meters) above the roadway surface.  Apply the identifier letters and numerals when the ambient air temperature, the temperature of the labeling material and the temperature of the surface to which the labels are applied are all above 40° F (4° C).  Identification of the light poles or light towers and the removal of any previous such identifier in the case of light poles or light towers being reassigned shall be considered as incidental work.

625.10  Foundations.  Excavate for each foundation to the dimensions given.

If a cave in should occur during excavation, excavating using casing, sleeving or other methods may continue with the approval of the Engineer.

Where, in the opinion of the Engineer, the excavation for a foundation has revealed an unstable condition at the bottom of the excavation, drill the foundation shaft deeper, enlarge the diameter of the drilled shaft, or make other modification to the foundation as directed by the Engineer who shall initiate the appropriate arrangements to compensate the Contractor for the addition work required.

When rock is encountered, continue excavation to a minimum of 3 feet (1 meter) into rock.  The Engineer may then decrease the total depth of the foundation to not less than 6 feet (2 meters) for a light pole or 10 feet (3 meters) for a light tower.

Reinforce each foundation with steel as specified and such steel reinforcing shall be placed in accordance with 509.

Install the anchor bolts for the light pole or light tower in each foundation using anchor bolt setting templates.

Place Class QC Misc or QC 1 concrete for the foundation in accordance with 511 except that forms will not be required for portions of foundations extending more than 6 inches (150 mm) below the ground line, unless the soil does not have sufficient stability to stay in place during the placing of the concrete.

Finish the top of each foundation smooth and level.

After forms have been removed, backfill the excavated spaces around each foundation with suitable material placed and tamped in thin layers as directed by the Engineer.

625.11  Junctions Boxes (Handholes) & Pull Boxes (Manholes).

Furnish and install a junction box of the size and type specified.  Furnish each junction box embedded in concrete with a drain.  Lubricate each cover screw with a compound to prevent the screw from seizing and install all cover screws.

Furnish and install a pull box of the size and type specified.  Excavate for each pull box as nearly as practicable to the outside dimensions of the pull box.  Install a 6 inch (150 mm) gravel base with a 4 inch (100 mm) underdrain to a suitable outlet below each pull box.  After setting the pull box to proper grade, backfill the excavated spaces around the pull box with suitable material placed and thoroughly tamped in thin layers.

When a pull box is to be installed in a paved area, remove an adequate area of the paving by saw cutting the sides of the area to be removed, or by removal of the paving back to an expansion joint as instructed by the Engineer.  After setting the pull box to proper grade, backfill the excavated spaces around the pull box with suitable material placed and thoroughly tamped in thin layers, and restore the pavement base and paving to match the surround.

Metal pull box lids shall be bonded by attachment of the equipment grounding conductor to the frame diagonal.

625.12  Raceways and Conduits. Furnish and install conduit of the sizes and types specified.  When the location, type or size of a conduit has not been indicated, submit to the Engineer working drawings showing the location and size and type of each such conduit along with the number and size of wires contained in each such conduit and secure the approval of the Engineer prior to installing the conduit.

When not otherwise specified, all conduit and fittings on an individual run of conduit shall be of the same material except for approved manufactured transition fittings required at end of the run when the item into which the conduit terminates is not of the same material as the conduit.

Install each conduit with a minimum amount of bending and ensure that the total bending between adjacent access points (junction boxes, pull boxes, light poles, control equipment enclosures, etc.) does not exceed 270 degrees. Do not bend any conduit to a bend radius of less than 12 times the internal diameter of the conduit. Bend each conduit in such a manner as to avoid damage to the conduit and any protective coating and such that the internal diameter of the conduit will not be reduced.

Remove the rough edges from the cut end of each conduit.  In addition, ream the cut end of each metallic conduit.  Bush each end of each conduit to further protect the wire insulation and cable jackets from damage.

Where threads have been cut onto ferrous metallic conduit after galvanizing, paint the threaded area with an electrical conductive paint in such a manner that there will be no unprotected surfaces.

Make each conduit joint tight to provide structural integrity in all conduits and to electrically bond the jointed sections of metallic conduit.  Provide an equipment grounding conductor that is not in a jacketed cable assembly in metallic conduits when not otherwise available and bond the conduit to this grounding conductor.

Securely fasten onto or build into the structure each conduit.

Install the appropriate expansion or deflection joint in each conduit at all locations where movement must be accommodated (such as expansion joints on structures) and install suitable bonding to assure electrical continuity of the grounding system.

Bond all metallic items enclosing electrical conductors together and to good earth ground.

Furnish each enclosure, junction box, pull box and conduit with a drain.  When the low point of a conduit does not occur at a drained access point, install a T coupling at the low point of the run and route the side outlet to drain.

Where underground conduits are to be encased in concrete, use Class QC Misc or QC 1 concrete and furnish a minimum of 3 inches (75 mm) of concrete on all sides using spacers.

After installation of the conduit and prior to installing the cables, run a mandrel whose diameter is at least 90% of the interior diameter of the conduit through the conduit.

If a conduit is to remain empty upon completion of the project, leave a 10 AWG copper clad, aluminum clad or galvanized pull wire in the conduit and cap the ends in an approved manner.

Temporarily seal the ends of a conduit immediately after placement of conduit when the conductors or cable cannot be installed promptly.

After installing the wire or cable, seal the end of a conduit entering the base of a signal pole, sign support, light pole, a light tower or a pad mounted equipment enclosure through the foundation.

625.13  Trenching. Follow the routing shown on the plan. Keep the trench within 6 inches (150 mm) of the designated line where the trench is adjacent to and parallel with a curb or pavement.

In unpaved areas, a plow may be used in lieu of trenching with the approval of the Engineer.  Use a machine that can install the duct uniformly at the specified depth without stretching or abrading the duct and which leaves a narrow self closing slit which presents no significant hazard during the self closing period.

In unpaved areas, make the trench a minimum of 2 feet (0.6 m) deep and not more than 12 inches (300 mm) in width.  Backfill the trench in layers not more than 4 inches (100 mm) in loose depth and compact each layer with a mechanical tamper or other approved method as directed by the Engineer.  Use suitable soil to backfill a trench in earth.  Use granular material to backfill a trench in an aggregate.  Ensure that the backfill material around and in the first 4 inches (100 mm) above the top of unit type duct cable not encased in concrete is sand or earth with no stones larger than 1/2 inch (13 mm).

In paved areas, either make a slit or T type trench. Cut the pavement along existing joints or grooves where possible. Mark the pavement with cut lines and secure the Engineer’s approval of the location of the cut before cutting the pavement.

625.14  Jacking and Boring. In addition to the requirements of 625.12 to furnish and install conduit, use jacking or horizontal boring when the plan calls for such methods to be used.  Use these methods in lieu of trenching only with the approval of the Engineer.

Jack only rigid galvanized steel conduit.  Use only a machine designed for jacking conduit not the bucket or blade of a machine designed for earthwork.

Horizontal boring may be used to install any conduit or duct which has the adequate strength, flexibility and joints to withstand the process.  Make the diameter of the bore no more than 5 percent larger than the outside diameter of the conduit or duct being installed.

625.15  Power Service. Furnish and install all equipment necessary to provide a complete electrical service to the roadway lighting facilities.

The power service equipment includes, but is not necessarily limited to: poles or other support structure for the mounting of the equipment, hardware for dead ending an overhead service drop or trench and conduit for receiving an underground service line, lightning arrestor when required, meter base, customer service disconnect, magnetically held lighting contactor, photoelectric cell and Hand-Off-Automatic switch for control of contactor, over current protection devices for each individual lighting circuit, enclosures, conduits, fittings, cables and connectors.

If the power service has multiple enclosures, mark each enclosure in white letters engraved on a black plastic placard with the function of the equipment contained therein such as “SERVICE DISCONNECT”, “LIGHTING CONTACTOR”, “LIGHTING PANEL”, or other appropriate designation.

When an apparatus enclosure contains circuits above the 600 volt class, mark the enclosure in white letters on a red plastic placard with the warning “DANGER-HIGH VOLTAGE” on each enclosure door.

Install each photoelectric cell facing North unless the Engineer directs that a specific cell face otherwise to reduce interference from surround lighting.

Bond all metallic portions of the supporting structure, equipment housings and conduits properly and to an adequate earth ground.

Install a wood or plastic wire moldings from grade to 3 feet (1 meter) above grade over any grounding cables installed on a wood pole.

Coordinate and cooperate with the power company in the making of the connections to establish electrical service.  Charges made by the power company for establishing of the account, extension of company facilities, connection of customer equipment to the power company facilities and energy will be borne by the maintaining agency.

625.16  Grounding. Connect each light pole or light tower to a local earth ground.

Connect each power service to a local earth ground.

Provide continuity of grounding by bonding the metallic portions of fixtures, apparatus enclosures, supports, conduits, raceways, junction boxes and pull boxes together and connecting to earth ground.  At a light pole or a light tower, install a bonding cable between the grounding bushing on each metal conduit and the ground lug or bolt in the pole base.  At a junction box or a pull box, install a grounding bushing on each metallic conduit not bonded to the box through the conduit connector, and install a bonding cable between the grounding bushings on the conduits and the ground lug or bolt in the box.

For a light pole, light tower, power service or other such item mounted independently, install one or more grounding electrodes.

For a luminaire, light pole, light tower, switch enclosure, or other such item mounted in or on major highway structures (i.e. bridges), connect the item to the structure grounding system.

For a lighting contactor, lighting circuit panel or other such item mounted in a building (i.e. motorists services building, weigh station scale house, etc.), connect the item to the grounding system provided for the building.

For each bridge, wall, or other structure having electrical elements contained therein or attached thereto, furnish all materials necessary including grounding electrodes and install a complete structure grounding system to bond all exposed metallic portions of the structure (i.e. beams, railings, etc.) electrically together and connect those items to good earth ground.  In the case where structures are separate but adjacent, connect the multiple structures together to avoid any difference in earth potential between the structures.

Make the permanent connection between the each ground rod and the grounding conductor by exothermic welding.

If the earth resistance measurement exceeds 10 ohms for a ground for a traffic signal controller or a light tower or 25 ohms for any other ground, install a second ground rod at least 20 feet (3 meters) from the first and temporarily connect the second rod to the first.  If the earth resistance still exceeds the above specified values, permanently connect the first two rods using the same type of cable used for the grounding conductor and continue to add rods one at a time as directed by the Engineer.

Where rock does not permit the driving of ground rods, develop an earth connection by constructing a grid from the partially driven rods supplemented by buried bare cable as directed by the Engineer.

625.17  Wiring and Cabling. Furnish and install electrical wires and cables of the types and sizes required with no in-line splices between terminations at devices unless specifically called for by the plan or directed by the Engineer.

Install wire mesh cable grips on vertical runs of wire or cable in poles and attach said grips to the “J” hook at the tops of the poles in such a manner as to prevent the weight of the vertical run from abrading the wire insulation or cable jacket where the wire or cable passes into or from the pole.

Identify all wires and cables, except bare ground bonding cables, as to circuit and function with tags or bands in the base of each light pole or light tower, each junction box or pull box, each apparatus cabinet, and other similar locations.

Pay out each wire, cable and duct cable by “unwinding” it from the shipping reel, spool or coils and not allow the wire cable or duct-cable to “spiral” from off the side of the spool reel or coil.  In addition when wire cable or duct cable is being placed in trench, move the reel spool or coil along the side of the trench to allow the wire or cable to pay out into the trench as directly as practical.  Seal the ends of each run of duct cable in the same manner as conduit as each run is installed.

Do not install duct cable when the temperature of the duct-cable cannot be kept above 32 °F (0 °C) except with the permission of the Engineer.

If the end of a wire or cable or duct must stand exposed to the elements or construction activities, protect said exposed end by enclosing it in a plastic bag or wrapping it with tape until the termination or connection can be made.

625.18  Connections. Make each wire and cable connection above grade (i.e. bases of light poles or light towers, junction boxes on structure or in concrete barrier medians, etc.) with an approved cable connector kit.  Use quick disconnect type kits in the base of each light pole with a fused type in each line or phase conductor.  Plug unused line side wire opening in each connector kit installed in the base of the light pole at the outer end of a circuit.

Make each cable connection below grade (i.e. pull boxes, junction boxes in retaining walls, etc.) with a  cable splicing kit.

Protect partially assembled connections from damage and the elements.

625.19  Testing of Installations. Furnish equipment and personnel to perform each test as an incidental to the construction of the lighting installation.  The Engineer shall witness each test and judge the results. 

A.      Equipment Calibration. Submit to the Engineer the types, styles, or catalog numbers of all testing equipment to be used for such tests.  Include a current Certificate of Calibration for each instrument showing that the instrument is in current calibration using standards traceable to The National Institute of Standards in accordance with the manufacturer's recommended process by a service center authorized by the manufacturer to calibrate the instrument.  Certify and demonstrate to the satisfaction of the Engineer that the instrument has remained sealed since the calibration, and that the manufacturer's recommended process for ensuring that the instrument is in working order and producing valid results has been followed in conducting the test.

B.      Grounding Electrodes and Grounding Systems. Furnish two certified copies of the completed test records to the Engineer on test reporting forms supplied to the Contractor by the Engineer or on alternate forms approved by the Engineer.

Measure the earth resistance in ohms of each ground immediately after it is installed and before the ground is attached to the item being grounded.

When the ground connection is by driven ground rods, measure each rod separately.  In the event that a ground rod has a high resistance and additional rods are being added, measure the earth resistance of the combined group.

Measure a structure grounding system at each point where an exposed metallic item is to be connected to the system.  Where driven ground rods are used as the electrodes of the structure grounding system, measure each ground rod separately prior to measuring the system.

Measure each ground grid at the each point where equipment is to be connected to the grid.

C.      Circuit Continuity. Upon completion of each lighting circuit but prior to energizing the circuit, verify the continuity of each conductor of the lighting circuit from the power service to the load side socket in the line side of the quick disconnect connector kit in the base of each light pole and the line side of each disconnect switch at each light tower, lighted sign and underpass lighting system shall be verified.  Demonstrate that there is no cross connection between the conductor being tested and any other conductor (including conductors for other circuits) or earth ground.  Conduct this test by applying a low test voltage between the conductor under test and one of the companion conductors for the same circuit and demonstrating that the test voltage is available between only those two conductors at the power service; the load side socket in the line side of the quick disconnect connector kit in base of each light pole; and the line side of each disconnect switch for a light tower, a lighted sign or an underpass lighting system and repeating the process until all possible pairs have been so checked.  Throughout this test, ensure that each disconnect switch is in the open position and that the load side of each connector kit is unplugged. Temporarily disconnect the grounded neutral conductor from earth ground and check all pairings involving the neutral after which again connect the neutral to earth ground and check all pairings, both those involving the neutral and those that do not.

D.      Cable Insulation. After the continuity of a conductor has been verified, test the insulation of that conductor and its connections.  Ensure that each disconnect switch is in the open position and that the load side of each quick disconnect connector kit is unplugged during this test.  Temporarily disconnect a grounded neutral conductor from earth ground when it is being tested.  In addition, when a grounded neutral is under test and the circuit utilizes local equipment earthing rather than a continuous equipment grounding back to the power service, temporarily connect one of the companion line conductors to provide the equivalent of the continuous equipment grounding cable.

When the circuit conductor is comprised of both new wire or cable and wire or cable installed prior to the current project, test the insulation by the megohmmeter method and the resistance of the conductor under test to earth ground or any other conductor shall exceed 10 megohms.

When the circuit conductor is comprised of entirely new wire or cable, test the insulation by the high potential method in accordance with Supplement 1003.

E.      Lowering Device Operation. Demonstrate to the Engineer that lowering devices on any luminaire supports so equipped operate properly by lowering and raising the luminaire assembly through the full range of motion of the device for each device on two separate occasions at least 10 days apart.  The Engineer shall record the dates of operation for each device and in case of failure the details of both the failure and the date and details of the correction.  The Engineer will consider a particular unit satisfactory when the device has operated twice in succession on separate occasions without malfunction.

F.      System Performance. Prior to acceptance and after all other tests are done, the completed lighting system shall be operated on electrical energy from the power company through the permanent customer service connection in its intended normal manner for ninety consecutive days.  Notify the Engineer at least 3 days prior to the commencement of this performance test.  In addition to the beginning and ending dates of the test period, the Engineer shall record the date and details of each failure and the date and details of the repair.  The Engineer will consider the performance satisfactory when the lighting installation has operated for ninety consecutive days without a failure due to the workmanship of the Contractor.

625.20  Plastic Caution Tape.  Install tape approximately 6 to 10 inches (150 to 250 mm) below the final finished grade.  Place with the printed side up and parallel with the finished surface.  Insure that the tape is not pulled, distorted or otherwise misplaced in completing the trench backfill.

625.21  Removal of Lighting Equipment.

A.      Luminaire Removal.  Remove the luminaire from its support taking care not to damage the luminaire, support or wiring connections.  If the luminaire is to be reused within the same project, carefully store the luminaire on the project site.  If the luminaire is to be reused, but not within the same project, carefully store the luminaire on the project site for pick up by the owner.  If the luminaire is not to be reused, properly dispose of the luminaire off the project site.

B.      Luminaire Support Removal.  Remove the luminaire support taking care not to damage the luminaire support, foundation or structure to which it is attached or wiring connections.  If the luminaire support is to be reused within the same project, carefully store the luminaire support on the project site.  If the luminaire support is to be reused, but not within the same project, carefully store the luminaire support on the project site for pick up by the owner.  If the luminaire support is not to be reused, properly dispose of the luminaire support off the project site.

C.      Luminaire Support Foundation Removal.  Remove the luminaire support foundation a minimum of one foot (0.3 m) below finished grade or clear of proposed construction, backfill the resultant depression with compacted soil and restore the disturbed area.

D.      Pull Box Removal.  Remove the pull box, properly dispose of it off the project site, backfill the resultant depression and restore the disturbed area.

E.      Disconnect Existing Circuit.  Disconnect the portion of the lighting circuit to be removed or abandoned from the portion of the circuit to remain in service at the designated node point.  Remove the cable from the link no longer to remain in service from the node point enclosure.  Remove the conduit or duct for the link no longer in service from the node point enclosure and properly close the resultant openings in the enclosure unless the conduit or duct is to be left in place to allow another circuit link to enter the node enclosure.

F.      Power Service Removal.  Remove the existing power service equipment and properly dispose of the equipment off the project site.  Equipment to be removed includes the wood pole or other supporting structure, foundation work pads, equipment enclosures, photoelectric cell and associated conduits, wiring, overhead or underground service lateral and all other appurtenances.  Cut the cable enclosed in conduit which runs into the ground at the lower end of the bend to horizontal approximately 2 feet (0.6 m) below grade.  Backfill the resultant depression and restore the disturbed area.

Coordinate with the power company to insure that the company disconnects the service and that items which belong to the power company that are removed, such as the meter base, are returned to the power company. 

625.22  Method of Measurement. Bracket arms will be included with the light pole, light tower or combination support on which they are mounted for payment. However, when a bracket arm is to be mounted onto an existing support or a support provided by another aspect of the project, it may be a separate item for the purpose of payment in which case payment will be made for each bracket arm.

Transformer bases will be included with the light pole, light tower or combination support on which they are mounted for payment. However, when a transformer base is to be fitted to an existing light pole, it may be a separate item for the purpose of payment in which case payment will be made for each transformer base.

Light pole anchor bolts will be furnished with the light pole and the setting of the anchor bolts included with the foundation.  However, in the case of a light pole mounted onto structures such as bridges and retaining walls where the bolts normally furnished with the light pole are not of the proper length and shape and/or the setting of the bolts must be done when the structure is constructed rather than being at the time of construction of the light pole foundation, the bolts shall be a separate item for payment in which case payment will be for each bolt with the count being the number of bolt ends projecting for the anchoring of the light pole.  Separate payment shall also be made when the bolts are being set in a normal light pole or light tower foundation but the light pole or light tower is not being furnished by the Contractor or by others to the Contractor.

Foundations for light poles or light towers include excavation, reinforcing steel, raceways, concrete, backfilling, and when required the 8 foot or 10 foot foundation section of concrete barrier, and the disposal of surplus excavation. For light poles or light towers mounted on median barrier or retaining walls, the junction box at the point where the stub conduit to the light pole or tower joins the main lighting circuit raceway and the stub conduit from the junction box to the light pole or light tower are also included.  Anchor bolts, conduit ells and surface restoration not included elsewhere are also included with the foundation. Junction boxes include the drain.

Pull boxes include the aggregate for base.

Power service includes the control equipment, the support and foundations on which the equipment is mounted, the pull boxes with underdrain for gathering the lighting circuits into the control equipment at the power service location, ground rods and incidentals required for a completed power service.  Also included are any poles, conduits, wire and cable to be provided by the owner to receive the incoming power from the power company.

Structure grounding system includes any ground rods or ground grids required as part of the system. 

Ground grids include any ground rods required as part of the grid and includes the associated grounding conductor and connections from the resultant grid to the first point (or points) of connection. Ground grids that result from the addition of ground rods as a result of earth ground resistance measurements will be the sum of each ground rod installed such sum will also include all connecting cable and trenching.

A ground rod includes the associated grounding conductor and connections from the rod to the first point of connection.

Trench will be measured to the center of a light pole foundation, the center of a light tower foundation, the center of a pull box, the center of the pole of an embedded pole mounted power service, the center of the foundation for a power service with a foundation, or the wall of the building when the power service for the lighting in, on or within the building with no allowance for elevation change.  The payment for trench includes all excavation, granular and other backfill material, compaction, disposal of surplus materials and restoration to match surrounding surface including any seeding, sodding or other plantings which were disturbed and the replacement of any minor items such as guardrail or fence panels, and return to former position and mounting of items such as trash containers, planter boxes or parking meters and small signs which were temporarily moved to facilitate the trenching.  The payment for trench in paved areas includes the aforementioned and in addition sawing and removal of pavement, along with the repaving over the trench. Trench in paved areas shall be separated for payment into Type A for pavements or sidewalks less than 6 inches (150 mm) thick and Type B for pavements 6 inches (150 mm) or greater.

Conduit will be measured to the center of a light pole foundation, the center of a light tower foundation, the center of a pull box, the center of the pole of an embedded pole mounted power service, the center of the foundation for a power service with a foundation, or the wall of the building when the power service for the lighting in, on or within the building with no allowance for elevation change.  The payment for conduit includes couplings (plain, expansion, and alignment), bends, hubs, bushings, condulets and other such appurtenances but not junction boxes and pull boxes.  Conduit to be encased in concrete or installed by jacking or boring will be paid separately from conduit to be traditionally installed. Concrete and other materials for encasement or the jacking or boring are included with such conduit where specified. 

Distribution cable will be measured to the center of foundation, pull box, junction box or power service, plus an allowance of 5 feet (1.5 meters) on each end except for a power service where the allowance will be 10 feet (3 meters) to allow for slack and connections with the sum multiplied by the number of conductors required.

Pole and bracket cable will be measured as the light pole support height plus the designated arm length with the sum multiplied by the number of conductors required.  For twin arm poles the sum shall be increased by the length of the second arm plus the length of the first arm.

Duct cable will be measured to the center of foundation, pull box, junction box or power service, plus an allowance of 5 feet (1.5 meters) on each end except for a power service where the allowance will be 10 feet (3 meters) to allow for slack and connections with no multiplier for the number of conductors.  Duct-cable includes the cable(s) and being a factory assembly is differentiated by the number and size of the conductors in each assembly.

Plastic caution tape will be measured to the center of a light pole foundation, the center of a light tower foundation, the center of a pull box, the center of the pole of an embedded pole mounted power service, the center of the foundation for a power service with a foundation, or the wall of the building when the power service for the lighting in, on or within the building with no allowance for elevation change.  

625.23  Basis of Payment. The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

625             Each                                Luminaire, (Functional Type),

                                                               (Housing Size if Conventional),

                                                               (Light Distribution), (Lamp Wattage),

                                                               (Light Source), (Voltage)

625             Each                                Glare Shield

625             Each                                Light Pole, (Pole Style),(Design Number)

625             Each                                Light Tower,(Design Number)

625             Each                                Light Pole Anchor Bolts

625             Each                                Light Pole Foundation

625             Each                                Light Tower Foundation

625             Each                                Junction Box, (Length × Height × Depth)

625             Each                                Pull Box, (Material Type), (Length × Height ×
                                                               Depth)

625             Foot (Meter)                    Conduit, (Material Type), (Nominal Diameter)

625             Foot (Meter)                    Trench

625             Foot (Meter)                    Trench in Paved Area,(Type)

625             Foot (Meter)                    Conduit Jacked or Drilled,(Material Type),

                                                               (Nominal Diameter)

625             Each                                Power Service

625             Each                                Ground Rod

625             Each                                Ground Grid

625             Each                                Structure Grounding System

625             Foot (Meter)                    Pole and Bracket Cable, (Size of Conductors
                                                               in AWG), (Voltage Rating)

625             Foot (Meter)                    Distribution Cable, (Size of Conductors in
                                                               AWG), (Voltage Rating)

625             Foot (Meter)                    Duct Cable, (Duct Diameter) with

                                                               (Number of Conductors),

                                                               (Size of Conductors in AWG),

                                                               (Voltage Rating) Conductors

625             Each                                Connection

625             Each                                Service to Underpass Lighting

625             Each                                Portable Winch Drive Power Unit

625             Each                                Luminaire Removed

625             Each                                Luminaire Support Removed

625             Each                                Luminaire Support Foundation Removed

625             Each                                Pull Box Removed

625             Each                                Disconnect Circuit

625             Each                                Power Service Removed

625             Foot (Meter)                    Plastic Caution Tape

ITEM 626  BARRIER REFLECTORS

626.01  Description

626.02  Materials

626.03  Layout

626.04  Installation

626.05  Method of Measurement

626.06  Basis of Payment

626.01  Description.  This work consists of furnishing and installing barrier reflectors on guardrail blockouts, concrete barrier, retaining wall, and bridge parapets.

626.02  Materials.  Furnish materials  conforming to:

Barrier Reflectors..................................................... 726.01

Conform to the manufacturer’s recommendations for corrosion resistant fasteners, brackets, or adhesives.

Use barrier reflectors that are mountable on guardrail blockouts, concrete barriers, retaining walls, and bridge parapets.  For wall or parapet mount, the barrier reflector may not extend further than 5 inches (125 mm) in a horizontal direction towards the traffic lanes.

626.03  Layout.  Lay out all locations to ensure proper placement.  The Engineer will approve the layout before installation of the reflectors.

Furnish reflectors at the beginning and the end of all barrier runs and at least one additional point evenly spaced between the termini.  Space the reflectors at 100 feet (30 m) on tangents and on curves of less than 5 degrees (more than 350 m radius).  Space the reflectors at 50 feet (15 m) for curves of greater than 5 degrees (350 m radius or less).

The Contractor may vary the spacing on tangents and curves of less than 5 degrees (more than 350 m radius) from 65 feet to 125 feet (20 m to 40 m) in the final 250 feet (80 m) to achieve even spacing of the reflectors.

If using a buffer end section or similar device on the end of the guardrail, place the first reflector so that it is visible to approaching traffic.

If tying guardrails, barriers, retaining walls, or bridge parapets together in a continuous run, use the total length of the run for determining the number and location of reflectors.

If installing a run of rail or barrier that is at varying distances from the edge of pavement, place a reflector where the run first approaches closest to the pavement.  If this results in spacing greater than 125 feet (40 m), or 65 feet (20 m) in cases where 50-foot (15 m) standard spacing is required, install an additional reflector.  If a non-reflectorized impact attenuator is in place, place an additional reflector on the face of the attenuator nearest to, and directed toward, approaching traffic.

626.04  Installation.  Attach the reflector with a suitable corrosion resistant fastener  or adhesive conforming to the manufacturer’s recommendations.

On concrete barriers, retaining walls, and bridge parapets, place the top of the reflector so its height is 26 inches (650 mm) above the near edge of pavement, except that the top of the reflector is at least 3 inches (75 mm) below the top of the concrete barrier.

Install guardrail blockout reflectors on the side of the blockout away from traffic.  Install guardrail blockout reflectors on the side of the blockout nearest the edge of pavement.  Install the guardrail blockout reflector so that the reflective surface is above the guardrail.

Remove loose concrete, rust, dirt, and other loose material from the surface of the concrete barrier using a wire brush.  Remove dust created by wire brushing before applying adhesive.  Apply adhesive to clean and moisture-free surfaces according to the manufacturer’s recommendations.

Ensure that the reflector face is clean and free of dust, dirt, adhesive, or any foreign material after installation.

Except if mounted on a guardrail blockout, rotate the reflective face of one-way reflectors upward from the vertical (or plumb) position 2 to 3 degrees to facilitate “rain washing” of the reflector face.

When replacing reflectors on a concrete surface, locate the new reflector approximately 3 inches (75 mm) horizontally in either direction from the old location.

If specified, use bi-directional reflectors (white/white) on the outside of curves on two-lane highways.

Use barrier reflectors that are the same color as the adjacent edge line.

The Department will classify the reflectors as follows:

Mounting Location

One-Way

Bi-Directional

Guardrail

Type A

Type A2

Concrete barrier, retaining walls, or bridge parapets

Type B

Type B2

626.05  Method of Measurement.  The Department will measure Barrier Reflector by the number of each in place, completed and accepted. 

If a bi-directional reflector consists of two one-way reflectors mounted back-to-back, the Department will measure it as one bi-directional reflector.

626.06  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

626             Each                                Barrier Reflector

ITEM 630  TRAFFIC SIGNS AND SIGN SUPPORTS

630.01  Description

630.02  Materials

630.03  Certified Drawings

630.04  Sign Fabrication

630.05  Foundations

630.06  Sign Supports

630.07  Sign Erection

630.08  Sign Shipment and Storage

630.09  Specific Service and Tourist-Oriented Directional Signs

630.10  Covering of Signs

630.12  Removal and Delivery, Storage, Reerection, or Disposal of Signs and Supports

630.13  Inspection

630.14  Method of Measurement

630.15  Basis of Payment

630.01  Description.  This work consists of furnishing and installing traffic signs, sign supports, and foundations complete and ready for service.  This work also includes necessary excavation and backfill, disposal of discarded materials, and restoration of disturbed facilities and surfaces to a condition equal to that existing before this work started.

630.02  Materials.  The acceptance of materials and products is based on Certified Test Data, furnished in triplicate, or on test results of samples according to 106.02, as required by the Laboratory.

Transfer manufacturers’ guarantees or warranties on all traffic sign material to the Department or other maintaining agency upon completion and acceptance of the project.

Furnish materials conforming to:

Concrete, Class QC Misc or QC 1....................... 499, 511

Steel:

.... Structural steel..................................................... 711.01

.... Reinforcing steel................................................. 509.02

.... U-channel posts................................................ 730.015

.... Square posts...................................................... 730.016

.... Wooden Box Beam……………………………730.017

.... Tube and pipe...................................................... 730.01

.... Anchor bolts and nuts......................................... 730.02

.... Poles and arms.................................................... 730.03

.... Base and arm plates............................................. 730.04

.... Handhole covers................................................. 730.05

.... Pole caps............................................................. 730.06

.... Arm caps............................................................. 730.07

.... Hardware............................................................ 730.08

.... Stainless steel...................................................... 730.09

.... Stainless steel hardware...................................... 730.10

.... Messenger wire................................................... 732.18

Aluminum:

.... Sheet and plate.................................................... 730.11

.... Extrusions........................................................... 730.12

.... Tube and pipe...................................................... 730.13

.... Castings.............................................................. 730.14

.... Forgings.............................................................. 730.15

.... Welding rods....................................................... 730.16

.... Hardware............................................................ 730.17

Other materials:

.... Decals................................................................. 725.21

.... Reflective sheeting, Type F................................. 730.18

.... Reflective sheeting, Type G................................ 730.19

.... Reflective sheeting, Type H.............................. 730.192

.... Reflective sheeting, Type J................................ 730.193

.... Nonreflective acrylic opaque sheeting ................ 730.20

.... Silk screen inks................................................... 730.22

.... Transparent acrylic electronic cuttable films ....... 730.23

630.03  Certified Drawings.  Furnish certified drawings according to 625.06.  Submit sign support certified drawings that cover all design types such as ground mounted, rigid overhead, span wire mounted, and overpass structure mounted supports.  On the drawings, show overall height, sign clearance above foundation, span length, sign locations, sign overall heights and widths, and glare shield height and location, if applicable.

630.04  Sign Fabrication.  Sign types include flat sheet, double faced, extrusheet, and temporary overlay.  Flat sheet signs consist of one-piece units made of aluminum.  Double faced signs consist of flat sheet aluminum or extruded aluminum blanks with legend on both sides.  Extrusheet signs consist of a number of horizontal panels assembled to form a complete sign.  Temporary overlay signs consist of an aluminum sheet covering portions or entire surfaces of extrusheet signs.

Prior to reflective sheeting application, clean aluminum sign surfaces either by total immersion in a tank containing an alkaline solution of the manufacturer’s specification or by steam cleaning with an alkaline solution of the manufacturer’s specification, followed by a thorough rinsing with running water.  After cleaning, etch the surface with an acid solution, and dry.  Do not allow cleaned and etched surfaces to become contaminated by contact with oil or grease.  Drill or punch bolt holes to finish size.

Use sign legends according to the OMUTCD and the Sign Designs and Markings Manual.  Use Clearview font for positive contrast legends on freeway and expressway guide signs and on all other guide signs when permitted in the Sign Designs and Markings Manual.  For negative contrast legends, use the Standard Alphabets for Traffic Control Devices.  Use capital legends and upper/lower case legends in accordance with the Sign Designs and Markings Manual.  When either is permitted in the Sign Designs and Markings Manual, use upper/lower case legends.

For flat sheet, double faced mile marker, double faced street name and ground mounted extrusheet signs, use Type G, H or J reflective sheeting for background and reflective legends.  For overhead extrusheet signs, use Type G, H or J reflective sheeting for the background, and use Type H or J reflective sheeting for reflective legends, shields and symbols (including hazardous material plaque, airport symbol, arrows and borders). Apply reflective sheeting to the surface according to the manufacturer’s recommendations, with no blisters, wrinkles, tears, or blemishes.  Do not use reboundable or damage control sheeting for permanent signs.

For reflective legends on flat sheet, double faced mile marker and double faced street name signs, use reverse silk screen transparent ink, transparent acrylic electronic cuttable film, or direct applied reflective sheeting copy.  When using direct applied reflective sheeting copy, apply all legend on a sign with the same rotation angle orientation.  For nonreflective legends, use direct silk screen black ink or direct applied nonreflective acrylic opaque black sheeting  copy.  For double faced mile marker signs, use flat sheet aluminum and apply reflective sheeting and legend to both sides.  For double faced street name signs, use extruded aluminum blanks with a minimum thickness of 0.063 inch (1.6 mm) and thicker, stiffened edges, and apply reflective sheeting and legend to both sides.

Extrusheet panels consist of flat sheet aluminum reinforced with aluminum extrusions attached by spot welding.  Panels extruded in a single operation may be used in lieu of spot welded  panels.  Do not use extruded panels and spot welded  panels in the same sign.  Bolt together the minimum number of full length, sheeted panels to achieve the sign height, using aluminum bolts, washers, lock washers and nuts.  For reflective legends, shields and symbols (including hazardous material  plaque, airport symbol, arrows and borders) use direct applied reflective sheeting.  Apply all reflective legend on a sign with the same rotation angle orientation.  For nonreflective legends, use direct applied nonreflective acrylic opaque black   sheeting copy.

For temporary overlay signs, use 0.080-inch (2.0 mm) thick flat sheet aluminum, with a maximum panel size of 8 ´ 4 feet (2.4 ´ 1.2 m).  Apply sheeting and legend as described above for extrusheet signs.  Attach temporary overlays to extrusheet signs in the shop or field using aluminum blind rivets at a maximum spacing of 18 inches (0.5 m) on the peripheries of the temporary overlays and 24 inches (0.6 m) within the interior.

Use fluorescent yellow-green reflective sheeting for the following signs and plaques: School (S1-1), School Bus Stop Ahead (S3-1), SCHOOL BUS TURN AHEAD (S3-2), SCHOOL ENTRANCE (S3-H3), SCHOOL (S4-3P), School Speed Limit Ahead (S4-5, S4-5a), yellow portions of School Speed Limit (S5-H1), Pedestrian Crossing (R1-6, R1-6b, R1-9), Bicycle (W11-1), Pedestrian (W11-2), Handicapped (W11-9), Bicycle/Pedestrian (W11-15), Trail Crossing (W11-15a), Playground (W15-1), and SAFETY ZONE (W15-H2).  Fabricate supplemental warning plaques [such as Advisory Speed (W13-1P), SHARE THE ROAD (W16-1P), Distance (W16-2P, W16-2aP, W16-3P, W16-3aP), Supplemental Arrow (W16-5P, W16-6P, W16-7P) and AHEAD (W16-9P)] from fluorescent yellow-green reflective sheeting when used with a sign above.

Use fluorescent yellow reflective sheeting for all yellow signs, yellow portions of multi-colored signs, and yellow sign post reflectors, except for signs and portions of signs required to be fabricated with fluorescent yellow-green reflective sheeting.

For lighted signs, cover glare shield and rectangular luminaire support tube with nonreflective acrylic sheeting matching the predominant sign color.

Furnish 4 ´ 2.5 inch (100 ´ 62 mm) sign identification stickers of Type F reflective sheeting as shown in Figure 1.  For signs fabricated in English based sizes, use white stickers with red ink legend.  For signs fabricated in hard metric based sizes, regardless of the sign message units contained on the sign face, use yellow stickers with red ink legend.  Place the stickers on the back side of the sign in the lower right corner of rectangular signs, or in an equivalent location for other sign shapes, approximately 3 inches (75 mm) from side and bottom sign edges (for smaller signs, these dimensions may be reduced).  Position the sticker so it can be read horizontally and is clearly visible, not near bolt holes or rivets, and not obstructed by the sign support when erected.

Silk screen the fabrication data onto the face of the sticker, and include the sheeting manufacturer identification code and year of fabrication.  Alternatively, the numbers 0-1-2-3-4-5-6-7 and 13-14-15-16-17 may be silk screened onto the sticker with the correct sheeting manufacturer identification code and fabrication year punched out, respectively.  At the time of sign erection, indicate the erection data by scratching out the appropriate month and year.

Figure 1

Sticker design:

PROPERTY OF THE STATE OF OHIO

UP TO $2500 FINE AND 5 YEARS

IMPRISONMENT FOR DAMAGING

OR REMOVING THIS SIGN

OHIO REV. CODE  SEC. 4511.17

MANU ID  *

FAB.  **

EREC    1   2   3   4   5   6   7   8   9   10   11   12

     13     14     15     16     17     18     19     20

*ID No.                                  **Year of Manufacture

Alternate design:

PROPERTY OF THE STATE OF OHIO

UP TO $2500 FINE AND 5 YEARS

IMPRISONMENT FOR DAMAGING

OR REMOVING THIS SIGN

OHIO  REV. CODE SEC. 4511.17

0  1  2  3  4  5  6  7

  13  14  15  16  17

EREC    1   2   3   4   5   6   7   8   9   10   11   12

     13     14     15     16     17     18     19     20

Fabricate sign post reflectors with flat sheet aluminum and Type G, H or J reflective sheeting.  Install red sign post reflectors on each post with the following post-mounted signs:  Stop (R1-1), Yield (R1-2), Do Not Enter (R5-1), and Wrong Way (R5-1a).  Install yellow sign post reflectors on each post with the following post-mounted signs:  One-Direction Large Arrow (W1-6), Two-Direction Large Arrow (W1-7), Chevron Alignment (W1-8), and Stop Ahead (W3-1).

630.05  Foundations.  Locate sign support foundations so the plane of the sign surface is at a right angle to the roadway lanes served (except for signs not intended for this orientation).  Install foundations in accordance with 632.14.  Furnish and install a ground rod at each rigid overhead and span wire sign support foundation, in accordance with 625.16.

Before placing foundation concrete for embedded supports, brace the supports in a vertical position.  Seven days after concrete placement, remove bracing for embedded supports and erect signs.

630.06  Sign Supports.  Sign supports consist of ground mounted, rigid overhead, span wire, and overpass structure mounted types.  Fabricate sign supports according to the applicable requirements of Item 513, and weld according to 513.21.  The approval of fabricators according to 501.03 will not apply.  Hot-dip galvanize steel structural members according to 711.02.  Galvanize steel hardware according to 730.08.

Tighten threaded fasteners, except anchor bolt nuts, by the “turn of the nut” method according to 513.20.

Furnish anchor bolts with a leveling nut, plain washer, and anchor nut conforming to 730.02.  Use anchor nuts with a plain washer against the base plate upper surface.

Tighten anchor bolt nuts according to 513.20, except that under Table 513.20-3, use the “nut rotation from snug tight condition” from 1/12 to 1/6 turn instead of 1/3 turn.

Apply anaerobic adhesive complying with Federal Standard MIL S 46163, Type II, Grade N to anchor bolts and other threaded connections 1/2-inch (13 mm) diameter or larger, according to the manufacturer’s recommendations.

A.      Ground Mounted Supports.  Ground mounted supports consist of structural sections of the material and weights required.  Drive the ground mounted supports into the earth or embed them in concrete, as specified.  Install supports in exposed locations in accordance with the performance requirements of NCHRP 350.  The support lengths shown on the plans are approximate.  Determine the exact length of supports before fabrication.

1.             Post Supports.  Mark each driven post with a line of paint 6 inches (150 mm) above the specified driving depth.  Drive posts to the specified depth without bending, distortion, or end mutilation.  Do not splice posts.     

Do not place posts in drainage ditches.  If unable to install the post at the specified location, relocate the post with the Engineer’s approval.

Install posts located in paved areas through a hole provided by sleeving or core drilling.  After the post is in position, patch the hole with asphalt concrete or an approved asphalt material.

For groupings of flat sheet signs in multiple arrangements mounted on posts, provide sign backing assemblies.

For one-way and street name sign supports, use square posts for mounting signs at right angles to other signs on the post.

For temporary sign supports and their placement, conform to the OMUTCD.

2.      Structural Beam Supports.  Furnish ground mounted structural beam supports from rolled steel sections.  Furnish slip base connections when specified.  Bolt the pieces of each beam together, and preload the assembly bolts before delivery to the project.  Carefully handle assembled breakaway beams during transportation and erection.  Upon erection, perform the final specified torquing on all threaded fasteners.

At least 4 weeks after erecting signs on breakaway beams, inspect the breakaway feature for evidence of shifting or loose fasteners.  Re-torque all loose fasteners to specified values.  Loosen and re-torque slip base plate fasteners even if no shifting or looseness is detected.  Apply anaerobic adhesive to the re-torqued  nuts.

3.      Pipe Supports.  Furnish ground mounted pipe supports from structural steel pipe and tubing.  Furnish bolt down anchor installations in existing concrete.  Furnish triangular slip base connection when specified.

4.      Wooden Box Beam Supports.  Furnish wooden box beam supports from laminated veneers pressure treated with wood preservative.  Install breakaway feature after installation for supports in exposed locations.

B.      Rigid Overhead Supports.  Rigid overhead supports consist of single poles with cantilevered arms, or span types supported between end frames.  Furnish anchor bolts and conduit ells [at least one 2-inch (50 mm) minimum diameter] for installation in the foundation.  Upon erection, set support poles and end frames on their foundations, and plumb using the leveling nuts followed by secure tightening of all leveling and anchor nuts on the anchor bolts.  Plumb poles supporting cantilevered signs following erection of signs as required.  Ensure that a minimum of one full thread remains on each anchor bolt above the top of the anchor nut after final tightening.  Do not use concrete grouting in the space between the foundation surface and support base.

Do not provide cover bases or individual anchor bolt covers on support anchor bases regardless of support location.

Furnish overhead sign supports with sign attachment assemblies for attaching extrusheet signs and/or sign hanger assemblies for mounting flat sheet signs to the support chords. 

When specified, furnish sign support identification stickers of Type F reflective sheeting listing the support type, design number, span/arm length, county, route, and section number (example:  TC-7.65, design 6, 80 ft span, CUY-90-17.58).  Apply stickers only when the ambient temperature is above 40 °F (4 °C).  Locate the sticker approximately 8 feet (2.4 m) above groundline on the quadrant of the sign support facing approaching traffic.  Identify sign supports spanning opposing directions of traffic with two stickers, each on a support member facing traffic.

Rigid span supports consist of a box truss supported by single plane truss end frames.  Fabricate box trusses from aluminum or steel tubular members with built-in camber, and mark each section “TOP”.  Do not erect box trusses unless at least one sign or damping device approved by the Engineer is installed within 8 hours.  Provide for the attachment of a luminaire bracket arm on combination overhead sign supports.

C.      Span Wire Supports.  Furnish span wire sign supports with sign hanger and messenger wire assemblies.  Furnish anchor bolts and conduit ells [at least one 2-inch (50 mm) minimum diameter] for installation in the foundation.

Achieve a span wire sag under load of 4 to 5 percent of the span.  Adjust poles to be essentially vertical after span wire tensioning.  Securely tighten all leveling and anchor nuts on the anchor bolts.  Ensure that a minimum of one full thread remains on each anchor bolt above the top of the anchor nut after final tightening.

Do not provide cover bases or individual anchor base covers on support anchor bases regardless of support location.

When specified, furnish sign support identification stickers as described in 630.06.B.

D.      Overpass Structure Mounted Supports.  Mount the supports on the overpass structure so the bottom of the signs are in a level position, regardless of bridge slope.

E.      Sign Attachments.  Use sign attachment assemblies to attach extrusheet signs to rigid overhead supports.  Use sign hanger assemblies to attach flat sheet signs to span wire or rigid overhead supports.  Use sign support assemblies to attach flat sheet or extrusheet signs to poles or bridge parapets.  Use sign backing assemblies for groups of signs attached to a sign post, and to attach exit number or supplemental panels to an extrusheet sign.

630.07  Sign Erection.  Erect signs on ground mounted or overhead supports according to the schematic signing layout.  Mount overhead signs so that the bottom of the signs are in a level position regardless of the sag of supporting messenger wire, mast arm rise, chord member or overpass slope.  Do not remove an existing sign until the replacement sign is either erected or available for immediate erection.  Do not erect a replacement sign on a new support more than 24 hours before the removal of the existing sign.

A.      Flat Sheet Sign Erection.

Use steel bolts, wide washers, lock washers and nuts.  Use bearing plates between the sign and U-channel post at each bolt.  Field drill signs mounted on messenger wire or mast arms to match holes in brackets.

B.      Extrusheet Sign Erection.

Use self-aligning aluminum mounting clips, aluminum or stainless steel rectangular head bolts, aluminum or stainless steel washers, and stainless steel elastic stop nuts, to attach extrusheet signs to beam or U-channel post supports, and for U-channel post sections used to attach exit number and supplemental panels to extrusheet signs.  Use aluminum bolts, washers, lock washers, and nuts to assemble extrusheet signs shipped in two pieces.

630.08  Sign Shipment and Storage.  Package and ship finished flat sheet signs to assure adequate protection of the sign face, using methods and materials as recommended by the reflective sheeting manufacturer.

Ship extrusheet signs up to 8 feet (2.4 m) high completely assembled.  Extrusheet signs over 8 feet (2.4 m) high may be shipped in two pieces for field assembly.  Keep extrusheet signs rigid by back bracing or crating.

Store signs, whether provided by the Contractor or furnished by the Department, off the ground in a vertical position with adequate covering or shelter to prevent packing material from getting wet.  Immediately remove packing material that does become wet from contact with sign faces to prevent damage to the reflective sheeting.

Identify extrusheet signs on a detachable form on the sign back giving the project number and year, sign reference number, sign legend sketch, and station location.  Identify the underlying sign for signs shipped with an attached temporary overlay sign.

630.09  Specific Service and Tourist-Oriented Directional Signs.  Maintain existing Specific Service (logo) signs and Tourist-Oriented Directional Signs (TODS) in accordance with 614.07 unless indicated in the plans.

630.10  Covering of Signs.  Install temporary covers, and subsequently remove and dispose of them as shown on the plans or as directed by the Engineer.  For the covering material, use a sturdy opaque material and obtain the Engineer’s approval of the proposed method of covering and attachment.

630.12  Removal and Delivery, Storage, Reerection, or Disposal of Signs and Supports.  Carefully dismantle signs and sign supports indicated for removal.  Either deliver to the Department facility as designated by the plan , store on the project, re-erect, or dispose of removed signs and sign supports.  To ensure maintenance of adequate traffic control at all times, remove signs only with the Engineer’s approval.

Remove sign supports in a manner to avoid damage.  Remove sign service to the support by disconnecting and removing cables at the service pull-box.  Ensure that connection of remaining cables conforms to 625.18.  Remove support foundations to at least 1 foot (0.3 m) below subgrade or finished groundline.  Backfill and  restore surfaces to a condition equal to that existing before the work started and dispose of surplus material according to 105.16, 105.17 and 611.15 at no cost to the Department.

Furnish mounting hardware for signs to be re-erected.  Field drill as necessary.  Furnish anchor bolts and conduit ells for installation in the foundation for overhead sign supports to be re-erected.

Remove temporary overlay signs so as not to damage the underlying sign.

630.13  Inspection.  After erection, the Engineer will inspect signs under both day and night conditions.  Correct deficiencies in lateral position or visibility to the Engineer’s satisfaction.

630.14  Method of Measurement.  The Department will measure Ground Mounted Post Support by the number of feet (meters) measured from the bottom of the support to the top of the support, and will include driving, hardware for anchor base installation, and furnishing and placing of patching materials for excavations in paved areas.  The Department will not measure the overlap length of post for the anchor base installation.

The Department will measure Foundations for ground mounted pipe supports, ground mounted structural beam supports, rigid overhead sign supports and span wire sign supports by the number of each for one pipe, structural beam, pole, end frame or strain pole, and will include excavation, reinforcing steel, concrete, backfilling raceways, and when required the 10 foot (3m) foundation section of concrete barrier, and the disposal of surplus excavation.  Sealing of the 10 foot foundation section of concrete barrier shall be paid for under Item 512 when specified in the plans.

The Department will measure Ground Mounted Structural Beam Support by the number of feet (meters) measured from the bottom of the foundation to the top of the sign, and will include furnishing and placing of patching materials for excavations in paved areas.

The Department will measure Ground Mounted Pipe Support by the number of feet (meters) measured from the bottom of the foundation to the top of the sign and will include u-bracket, tubing, posts and hardware for sign attachment, bolt-down anchor and furnishing and placing of patching materials for excavations in paved areas.

The Department will measure Ground Mounted Wooden Box Beam Support by the number of feet (meters), and will include excavation, backfilling, disposal of surplus material, and installation of breakaway feature.

The Department will measure One Way Support and Street Name Sign Support by the number of feet (meters) measured from the bottom of the support to the top of the support, and will include driving, hardware for anchor base installation, and furnishing and placing of patching materials for excavations in paved areas.  The Department will not measure the overlap length of post for the anchor base installation.

The Department will measure Temporary Sign Support by the number of feet (meters) or the number of each furnished, erected, maintained, and removed.

The Department will measure Breakaway Structural Beam Connection by the number of each set of connection parts with necessary welding and drilling of holes as required for the breakaway function in one beam, and will include base plates, fuse plate, hinge plate, bolt retainer plate, and bolts assembled to specified torques.

The Department will measure Triangular Slip Base Connection by the number of each set of connection parts with the necessary welding and drilling of holes as required for the breakaway function in one pipe and will include slip plate, slip base casting, locking collar, bolt retainer plate, coiled pin and bolts assembled to specified torques.

The Department will measure Overhead Sign Support by the number of each, and will include anchor bolts and conduit ells furnished for the foundation, sign attachment assemblies, sign hanger assemblies and identification stickers when specified.

The Department will measure Combination Overhead Sign Support with light pole extension by the number of each, and will include anchor bolts and conduit ells furnished for the foundation, sign attachment assemblies, sign hanger assemblies and identification stickers when specified.  Bracket arms and roadway lighting luminaires are not included.

The Department will measure Sign Attachment Assembly by the number of separately itemized assemblies, and will include one overhead sign bracket, U-bolts, clamps, and miscellaneous hardware.

The Department will measure Luminaire Support Assembly by the number of separately itemized assemblies, and will include one support arm, other necessary structural members, and miscellaneous hardware.

The Department will measure Span Wire Sign Support by the number of each support, and will include two strain poles with span wire clamps and anchor shackles, anchor bolts and conduit ells furnished for foundations, messenger wire, clamps, thimbles, and sign hanger assemblies with hangers, braces, lengths of post, and miscellaneous hardware.

The Department will measure Overpass Structure Mounted Sign Support by the number of each support, and will include attachment work and hardware, to attach one individual sign.

The Department will measure Sign Hanger Assembly by the number of each, and will include all parts necessary to attach one individual sign.

For pole mounted sign supports, the Department will measure Sign Support Assembly by the number of each, and will include brackets, hardware, and posts sufficient to attach each sign or set of signs to an individual pole.

For bridge mounted sign supports, the Department will measure Sign Support Assembly by the number of each, and will include post, hardware, and attachment work.

The Department will measure Sign by the number of square feet (square meters) of signs, and will include the furnishing of identification stickers, sign backing assemblies, mounting bolts, washers, nuts, bearing plates, clips, and rivets.  For square, rectangular, circular, or irregular shaped signs, the Department will determine measurement by multiplying the largest dimensions of width and height.  For triangular shaped signs, the Department will determine measurement by multiplying the largest dimension of width and one-half the largest dimension of height.  The Department will include the area of the glare shields for lighted signs as an integral part of the sign.

The Department will measure Sign Post Reflector by the number of each, and will include the furnishing of mounting bolts, washers and nuts.

The Department will measure Sign, Double-Faced by the number of each, and will include mounting fittings and hardware.

The Department will measure Sign Erected by the number of square feet (square meters) of signs erected, and will include mounting hardware, the assembly of signs that are in more than one piece and the installation of required sign backing assemblies.  The Department will exclude the furnishing of signs.  For square, rectangular, circular, or irregular shaped signs, the Department will determine measurement by multiplying the largest dimensions of width and height.  For triangular shaped signs, the Department will determine measurement by multiplying the largest dimension of width and one-half the largest dimension of height.  The Department will include the area of the glare shields for lighted signs as an integral part of the sign.

The Department will measure Sign Backing Assembly by the number of separately itemized assemblies, and will include back bracing for each group of flat sheet signs attached to a post or posts, or a single assembly for backing posts used to attach an exit or supplemental panel to a guide sign.

The Department will measure Covering of Sign by the number of square feet (square meters) of sign face covered, and will include the subsequent removal and disposal of the covering.

The Department will measure Removal and Delivery, Storage, Reerection, or Disposal of Sign by the number of each sign removed and delivered, stored, re-erected or disposed of.  Major signs are defined for measurement as being 40 square feet (3.7 m²) or larger.

The Department will measure Removal and Delivery, Storage, Reerection, or Disposal of Support by the number of each support removed and delivered, stored, re-erected or disposed of, and will include removal of foundations and restoration of surfaces.  With reerection, the Department will include furnishing of anchor bolts, conduit ells, necessary field drilling, and hardware.

630.15  Basis of Payment.  The Department will not pay for relocating posts from their planned location without prior approval by the engineer.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

630             Each                                Ground Mounted Structural Beam Support

                                                               Foundation

630             Each                                Ground Mounted Pipe Support Foundation

630             Each                                Rigid Overhead Sign Support Foundation

630             Each                                Span Wire Sign Support Foundation

630             Foot (Meter)                    Ground Mounted Support, ___ Post

630             Foot (Meter)                    Ground Mounted Structural Beam Support,
                                                               ___ Beam

630             Foot (Meter)                    Ground Mounted Support, Pipe

630             Foot (Meter)                    Ground Mounted Wooden Box Beam

                                                                Support,_____Beam

630             Foot (Meter)                    One-Way Support, ___ Post

630             Foot (Meter)                    Street Name Sign Support, ___ Post

630             Foot (Meter)                    Temporary Sign Support, ___ Post
                       or Each                           

630             Each                                Breakaway Structural Beam Connection

630             Each                                Triangular Slip Base Connection

630             Each                                Overhead Sign Support,

                                                               Type TC-___, Design___

630             Each                                Combination Overhead Sign
                                                               Support, Type TC-___, Design___

630             Each                                Sign Attachment Assembly

630             Each                                Luminaire Support Assembly

630             Each                                Span Wire Sign Support,
                                                               Type TC-17.10,   Design ___

630             Each                                Overpass Structure Mounted Sign
                                                               Support, Type TC-___, Design___

630             Each                                Sign Hanger Assembly,
                                                               (Span Wire, Mast Arm)

630             Each                                Sign Support Assembly,
                                                               (Pole or Bridge Mounted)

630             Square Foot                     Sign, (Flat Sheet, Ground

                       (Square Meter)                Mounted Extrusheet,

                                                               Overhead Extrusheet,  Temporary Overlay)

630             Each                                Sign, Double-Faced, (Street
                                                               Name, Mile Marker)

630             Square Foot                     Sign Erected, (Flat Sheet,
                       (Square Meter)                Extrusheet, Temporary Overlay)

630             Each                                Sign Backing Assembly

630             Each                                Sign Post Reflector

630             Square Foot                     Covering of Sign
                       (Square Meter)

630             Each                                Removal of Ground Mounted (Major) Sign
                                                               and (Delivery, Storage, Reerection, or
                                                               Disposal)

630             Each                                Removal of Ground Mounted (Structural
                                                               Beam, Post, Pipe, Wooden Box Beam)
                                                               Support and (Delivery, Storage or Disposal)

630             Each                                Removal of Overhead Mounted Sign and
                                                               (Delivery, Storage, Reerection, or Disposal)

630             Each                                Removal of Overhead Sign Support and
                                                                (Delivery, Storage, Reerection, or Disposal),
                                                               Type TC-___

630             Each                                Removal of Overlay Sign

ITEM 631  SIGN LIGHTING AND ELECTRICAL SIGNS

631.01  Description

631.02  General

631.03  Materials and Equipment

631.04  Sign Service

631.05  Signs Wired

631.06  Disconnect Switch

631.07  Luminaire

631.08  Controls

631.09  Electrical Signs

631.10  Removal

631.11  Inspection and Testing

631.12  Method of Measurement

631.13  Basis of Payment

631.01  Description.  This work consists of furnishing and installing sign lighting or electrical sign equipment, complete, tested, and ready for service.

631.02  General.  Perform installations according to the National Electrical Safety Code, the National Electrical Code and local codes for the area of installation.  Furnish overhead sign lighting and integrate electric power with roadway lighting circuits.

Furnish certified drawings according to 625.06.

Conform to the requirements of Supplement 1063 for the installation or testing of electrical items installed under 631.08 and 631.09.

Protect wire and cable by installing entirely within support structure interiors, enclosures, junction boxes, and rigid or flexible conduit.  Ensure that the methods, materials, and locations of splicing and the methods of connecting and identifying wire and cable conform to Item 625, Item 725, and the plans.  Furnish grounding systems according to 625.16.

Power service is furnished under Item 625.

631.03  Materials and Equipment.  Furnish materials and equipment that are new, of first quality, of current design, and free from defects. 

Use electrical parts, wire, switches, and other elements of the installations that are of ample capacity to carry the required current without excessive heating or drop of potential.

Ensure that each item of equipment bears a nameplate, indelible marking, or brand that identifies the type, model, catalog number, and manufacturer.

Furnish materials conforming to the following:

Ground rod.............................................................. 625.16

Sealing, conduit....................................................... 625.12

Cable and wire, 600-volt.......................................... 725.02

Conduit, rigid........................................................... 725.04

Ballast...................................................................... 725.11

Power service.......................................................... 725.19

Disconnect Switch .................................................. 725.19

Switch Enclosure..................................................... 725.19

Changeable message sign, electric type.................... 731.03

Internally illuminated fixed message sign................ 731.05

Sign flasher assembly.............................................. 731.06

School speed limit sign assembly............................ 731.07

Conduit, flexible...................................................... 731.08

Timer with enclosure............................................... 731.10

631.04  Sign Service.  Sign service consists of all cable and other equipment to provide a complete electrical service from either an underground or overhead source to the disconnect switch.

Route sign service cable from a pull box to the switch enclosure for overhead supported signs by means of underground conduit, foundation conduit ell, and the interior of the structural member supporting the enclosure.

Route sign service for overpass structure mounted signs through underground and structure attached conduit terminating at a switch enclosure.  Attach the conduit by 0.02-inch (0.5 mm) thick by 3/4-inch (19 mm) wide passivated stainless steel straps spaced at intervals of not more than 5 feet (1.5 m). 

Route sign service cable from a distribution system direct drop to the switch enclosure by means of a conduit riser with weatherhead.  Form a drip loop into the cable.  Use either a cast aluminum or galvanized ferrous metal weatherhead of a threaded design.  Attach the conduit by straps as described in the previous paragraph.

For sign service, use single conductor stranded copper.  When the connection is to highway lighting distribution and circuit cable, use the same cable for sign service.  In other applications, use sign service cable rated at 600 volts minimum and not smaller than 4 AWG.

631.05  Signs Wired.  Ensure that signs wired complete the electrical system from the disconnect switch to the luminaires.

Furnish continuous wiring from the disconnect switch to a junction box mounted on the sign support or overpass structure.  Install junction box in a manner that allows sign removal as a unit by the disconnection of the wires and the removal of sign attachment hardware.  Install a junction box for each sign.

Furnish continuous wiring from the junction box to the first luminaire and between additional luminaires.

Use wire rated at 600 volts, single conductor and not smaller than 10 AWG.

Route wire on overhead sign supports from the disconnect switch enclosure through structural member interiors.  Support wire hanging within the interior of steel vertical members by looping over the J-hook provided.  After wiring in the disconnect switch enclosure, seal the nipple in the enclosure back with self-fusing high-dielectric insulating compound.

Assemble flexible or rigid conduit on the sign structure or lighting support arms with condulets, and attach them to the structure by clamps located within 6 inches (150 mm) of each conduit end and separated by not more than 24 inches (0.6 m).

631.06  Disconnect Switch.  Install lighted signs with a disconnect switch within a lockable, weatherproof enclosure.  For the switch, use a two-pole (minimum), single-throw, fused safety disconnect type, rated at 600 volts, 30 amperes with the fuse size as specified.  Furnish a solid neutral bar.

For the enclosure, use stainless steel NEMA 250, Type 4.  Furnish space for a chase nipple in the enclosure back.  Field drill a hole through the enclosure and install the nipple.  Ensure that enclosures also have a screened 1/4-inch (6 mm) diameter weep hole located in the bottom surface.

Furnish each enclosure with at least one padlock.  Use padlocks with a bronze or brass lock body and a corrosion protected steel shackle.  Key all padlocks for a project alike, and obtain the appropriate master key number from the maintaining agency.

When specified, furnish and install bracket assemblies on existing overhead sign supports or on concrete structures.  Use bracket assemblies made of steel, galvanized according to 711.02, or aluminum.

631.07  Luminaire.  Include a lamp of the wattage specified.

Locate ballasts integral with the luminaire.  Furnish weatherproof ballast housings made from corrosion resistant materials.

631.08  Controls.  When specified, furnish photoelectric controls when sign lighting is fed by uncontrolled circuits.

When specified, furnish and install the timer with enclosure to provide automatic school speed limit sign operation.

631.09  Electrical Signs.  Furnish changeable message signs that conform to the Contract Documents.  The pay item will specify if the display capabilities are limited message or unlimited message.  The Contractor may use line units of these types as inserts in a panel sign, singly or grouped to provide a multiline sign.  Hardware and software shall be complete to operate and maintain the sign.

Furnish internally illuminated signs consisting of the single or double face type.  The sign support is furnished under another pay item.  Furnish suspended signs that hang plumb, are properly oriented, and locked in place.

Furnish sign flasher assemblies consisting of a pair of flashing beacons.  The sign, support, and foundation are furnished under other pay items.

 Furnish school speed limit sign assemblies that conform to the Contract Documents. School speed limit sign assemblies consist of a reflectorized SCHOOL SPEED LIMIT 20 DURING RESTRICTED HOURS (S5-H1) sign fitted with a pair of flashing beacons arranged above and below.

631.10  Removal.  Carefully remove sign lighting equipment (such as luminaires, disconnect switches, or ballasts) and electrical signs.  Removed items become the property of the Contractor.

631.11  Inspection and Testing.  Ensure that the sign lighting systems and electrical signs meet all requirements of the ground, cable insulation, and performance tests specified in 625.19.  Correct lamps, ballasts, and transformers that failed during the performance test by replacing the faulty component; the entire test period will not require restarting.

During the performance test, make final adjustments to sign lateral position and aiming angles of luminaires to eliminate excessive brightness and glare, and to obtain optimum sign face reflected brightness, uniformity of illumination, visibility, and legibility, to the satisfaction of the Engineer.

631.12  Method of Measurement.  All of the following methods of measurement include all hardware necessary to securely mount the associated item including angles, plates, tubes and channels.

The Department will measure Sign Service by the number of complete units for each support, and will include conduit, conduit riser, weatherhead, fittings, cables, trenching, and backfilling.

The Department will measure Sign Wired and Sign Wired, Overpass Structure by the number of complete units of wiring for each individual sign, and will include junction boxes, rigid or flexible conduit, condulets, clamps, wires, and connectors.

The Department will measure Disconnect Switch with Enclosure by the number of each, and will include field drilling and padlocks.

The Department will measure Switch Enclosure Mounting Bracket Assembly by the number of each, and will include two brackets and field drilling.

The Department will measure Ballast and Photoelectric Control by the number of each separate item.

The Department will measure Luminaire by the number of each, and will include lamps and luminaire attachment hardware.

The Department will measure Changeable Message Sign by the number of each, and will include cabinet, external enclosures, conduit, electrical, electronic and auxiliary components, and remote control units to provide a fully functional unit.

The Department will measure Internally Illuminated Fixed Message Sign by the number of each, and will include lamps and ballasts.

The Department will measure Sign Flasher Assembly by the number of each, and will include beacons, flasher control unit with enclosure, and lamps.

The Department will measure School Speed Limit Sign Assembly by the number of each, and will include sign, beacons, flasher control unit with enclosure, and lamps.

The Department will measure Timer with Enclosure by the number of each, and will include field drilling and padlocks.

The Department will measure Removal of sign lighting equipment or electrical signs by the number of each like items removed.

631.13  Basis of Payment.  The Department will pay for grounding systems under Item 625.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

631             Each                        Sign Service

631             Each                        Sign Wired

631             Each                        Sign Wired, Overpass Structure

631             Each                        Disconnect Switch with Enclosure, Type ___

631             Each                        Switch Enclosure Mounting Bracket Assembly

631             Each                        Ballast, Type ___

631             Each                        Photoelectric Control

631             Each                        Luminaire,
                                                       Type ___, with ___-watt Lamp

631             Each                        Changeable Message Sign,
                                                       (Limited, Unlimited) Message

631             Each                        Internally Illuminated Fixed
                                                       Message Sign, Type ___

631             Each                        Sign Flasher Assembly

631             Each                        School Speed Limit Sign Assembly,
                                                       ___ inches ´ ___ inches
                                                       (___ mm ´ ___ mm)

631             Each                        Timer with Enclosure

631             Each                        Removal of (Luminaire, Disconnect Switch,
                                                       Ballast, etc.)

ITEM 632  TRAFFIC SIGNAL EQUIPMENT

632.01  Description

632.02  Contractor Personnel Requirements

632.03  Materials and Equipment

632.04  Certified Drawings

632.05  General

632.06  Vehicular Signal Head, Conventional

632.07  Vehicular Signal Head, Optically Programmed

632.08  Pedestrian Signal Head

632.09  Pedestrian Pushbutton

632.10  Loop Detector Unit

632.11  Detector Loop

632.14  Foundations

632.15  Signal Support

632.16  Strain Pole

632.17  Wood Pole

632.18  Down Guy Assembly

632.19  Pedestal

632.20  Conduit Riser

632.21  Cable Support Assembly

632.22  Messenger Wire

632.23  Cable and Wire

632.24  Power Service

632.25  Covering of Vehicular and Pedestrian Signal Heads

632.26  Removal of Traffic Signal Installation

632.27  Reuse of Traffic Signal Equipment

632.28  Testing

632.29  Method of Measurement

632.30  Basis of Payment

632.01  Description.  This work consists of furnishing and installing traffic signal equipment, complete and ready for service.  This work also includes necessary excavation and backfill, disposal of discarded materials, restoration of disturbed facilities, and surfaces to a condition equal to that existing before the Work started, and electrical testing as specified.

Pull boxes, conduits, ground rods, and cable splicing kits required for traffic signal equipment installations are specified in Item 625.

632.02  Contractor Personnel Requirements.  Conform to the requirements of Supplement 1063 for the installation or testing of traffic signal equipment.

632.03  Materials and Equipment.  Furnish new materials and equipment of first quality, of current design, and free from defects.

Use electrical parts, wire, switches, and other elements of the installations capable of carrying the required current without excessive heating or drop of potential.

Ensure that major items or assemblies of equipment bear a nameplate, indelible marking, or brand that identifies the type, model, catalog number, and manufacturer.

Furnish materials and equipment conforming to:

Concrete, Class QC Misc or QC 1....................... 499, 511

Steel*:

.... Poles, supports, arms, appurtenances

.... and anchor bases...................... 730.02, 730.03, 730.04,

...................................................... 730.05, 730.06, 730.07,

.................................................................... 732.12, 732.11

.... Pedestals............................................................. 732.15

.... Backplates........................................................... 732.22

.... Hardware............................................................ 730.08

.... Stainless steel hardware...................................... 730.10

Other Items:

.... Conduit, rigid........................ 725.04, 725.051, 725.052

.... Ground rod......................................................... 725.16

.... Pull boxes.................... 725.06, 725.07, 725.08, 725.12.........

.... Identifying tags or bands..................................... 725.02

.... Signal heads................. 732.01, 732.02, 732.03, 732.05

.... Lamps................................................................. 732.04

.... Pushbuttons........................................................ 732.06

.... Detectors................................................ 732.07, 732.08.........

.... Wood poles......................................................... 732.13

.... Down guys......................................................... 732.14

.... Conduit risers...................................................... 732.16

.... Cable supports.................................................... 732.17

.... Messenger wire................................................... 732.18

.... Cable and wire.................................................... 732.19

.... Power service...................................................... 732.20

.... Disconnect Switch with enclosure...................... 732.21

     Backplates........................................................... 732.22

.... Tether Wire....................................................... 732.185

*   Acceptance of materials and products is based on certified test data, furnished in triplicate, or on test results of samples according 106.04, as required by the Laboratory.

632.04  Certified Drawings.  Furnish certified drawings according to 625.06.

632.05     General.  Ensure that major items of traffic signal control equipment used in combination are compatible, interchangeable and, whenever feasible, provided by the same manufacturer or supplier.  Perform work in compliance with applicable local laws and codes, the National Electrical Code, the National Electrical Safety Code, the Standard for Electrical Safety in the Workplace and OSHA

Ensure that the traffic control equipment installed in controller cabinets are shop prewired according to a wiring diagram that conforms to plan and specification requirements of the specific project and intersection, and show all wire harness and field connections required, with abbreviations according to Table 632.05-1.  Furnish a neat and legibly drawn wiring diagram, reproduced on durable paper, and place two copies in a plastic envelope fastened to the inside of the controller cabinet.

Identify cable and wire by tags or bands at pull boxes and controller cabinets, with size, material, and method of marking that conform to 725.02, except ensure that the identification on the tags or bands conforms to the wiring diagram with abbreviations according to Table 632.05-1.  The Contractor may identify field wiring using an indelible pen on a plastic tag instead of embossed letters.  Tags shall be a minimum of 1-inch diameter if round and 1-inch by ½-inch if rectangular.  Letters shall be clearly legible.  

Use spade terminals for wiring connected at signal heads and the wiring connected at terminal blocks within controller cabinets.  However, for incoming power wiring, use either spade terminals or bared conductor wire connected to terminal points utilizing screw or spring applied clamping surfaces compatible with both cooper and aluminum wire and providing a positive grip.  Neatly lash and fasten completed wiring to interiors with clamps and/or ties.

Table 632.05-1  Table and Wire Identification

Cable

Tag

Ground

GND

Power (2 wire)1Æ 120 volt

AC +AC- or ACN

Power (3 wire) 1Æ 120/240 volt
 Neutral wire

AC + 1, AC + 2
AC- or ACN

Phase A
Phase 1
Phase 1 northbound left turn lanes

Æ A
Æ 1
Æ 1 NBLT

Phase A, pedestrian signal

Æ A PD

Overlap, phase A + C
Overlap, phase 1 + 6

Æ A + C
Æ 1 + 6

Detector lead-in, phase A
Detector lead-in, phase 1
Detector lead-in, phase 1 northbound left turn lanes

DET A
DET 1
DET 1 NBLT

Detector lead-in, phase A (call type)
Detector lead-in, phase 1
(call type) northbound thru lanes

DET A CALL
DET 1 CALL
NB-THRU

Detector harness[1]

DET A

Interconnect

IC

Pre-emption, fire

PE FIRE

Pre-emption, railroad

PE RR

[1]  Place the tag next to the MS plug at the detector amplifier.

When constructing the traffic control system, cooperate with the agency supplying the electric service.  Supply 120/240 volt, single-phase, three-wire (grounded neutral) power to the disconnect switch.

After completion of the 10-day performance test in compliance with 632.28 and until acceptance, the Contractor is responsible for the care and maintenance of traffic control equipment installed or reused as part of the Contract.

Upon acceptance of the project, transfer to the Department all manufacturers’ guarantees or warranties covering installed electrical or mechanical equipment.  Furnish two copies of wiring diagrams, service manuals, and instructions on installation and maintenance for each different type, model, or system of equipment used on the project.

632.06  Vehicular Signal Head, Conventional.  Furnish heads in arrangements such that from one to a maximum of five sections assembled with the specified lens size, color, and circular or arrow configuration form a specific signal face.  Mount signal faces alone as a one-way head when backplates are used. 

Furnish multi-way heads with top and bottom brackets for mounting purposes.  Fit faces of lesser height in multi-way heads with pipe spacers.  Close openings unused for mounting purposes with weatherproof caps.   Before closing serrations, apply a bead of Room-Temperature Vulcanizing (RTV) silicone to all serrated surfaces and then tighten. RTV silicone shall be white to facilitate visual inspection. On heads with dual concentric serrated rings, completely fill the space between the rings with RTV silicone.

Install signals in a plumb condition, using a balance adjuster only if approved by the engineer.  Fit heads mounted on mast arms, except those intended to be rigidly mounted, with a universal hanger allowing the head to swing in both longitudinal and transverse directions.  Use drop pipes/extenders of suitable length only when necessary to bring the bottom of the signal heads to a proper roadway clearance. Drop pipes/extenders shall be kept as short as necessary on backplated signals. Use of drop pipes/extenders greater than 1.5 feet in length must be approved by the Engineer. Use disconnect hangers for suspended heads only when specified.

Orient each signal face to its traffic approach, and lock faces in place by the serrated or other type device incorporated in signal housing and support hardware.

Install LED lamps in each section. 

Furnish backplates unless specified otherwise.

632.07  Vehicular Signal Head, Optically Programmed.  Furnish heads of this type consisting totally of optically programmed sections unless an intermix of optically programmed and conventional sections is specified.  Install approved LED light sources or lamps in each optically programmed section.

Program each signal section according to the plan requirements. Upon completion of the project, deliver all programming tools and devices to the maintaining agency.

Furnish backplates unless specified otherwise.

632.08  Pedestrian Signal Head.  Furnish heads with the type of light source and symbol height specified.  Orient each signal head to its crosswalk, and lock heads in place by the serrated or other type device incorporated in signal housing and support hardware.  Close openings unused for mounting purposes with weatherproof caps.

632.09  Pedestrian Pushbutton.  Properly orient and install pushbuttons on poles or pedestals.  Service pushbuttons mounted on steel poles by wiring inside the poles.  Furnish 3/4-inch (19 mm) diameter holes through the back of the housing and the pole wall, install a rubber grommet, and route wiring through until no external wiring is visible.  Plug any unused conduit attachment holes.  Attach the housing by machine or self-tapping screws in the housing back wall.  Service pushbutton mounted on wooden poles through conduit.  Furnish pedestrian pushbutton signs of the legend and size required.

632.10  Loop Detector Unit.  Install and tune detector units to their loops with the sensitivity set for optimum operation and any interference or cross talk eliminated between other detector units in the cabinet.  Perform a field check to ensure that no extraneous detections are occurring by observing each detector unit’s operation to determine that a signal occurs only when a vehicle enters its associated loop.  If actuations are observed when there is no vehicle in the loop, eliminate the extraneous detections. 

632.11  Detector Loop.  Saw slots in the pavement for installation of vehicle detector loop wire in the configuration, dimensions, and combinations required.  Cut an extension from the loop to the pavement edge to allow wire routing to an adjacent pull box.

Furnish slots 1/16 to 1/8-inch (1.6 to 3 mm) wider than the outside diameter of the loop wire or tubing.  Ensure that the slot depth provides a covering of not less than 3/4-inch (19 mm) above the uppermost detector wire tubing after the loop installation is completed.  Before installing loop detector wire, brush and blow all slots clean of loose material and completely dry.  Install loop detector wire according to 632.23.  Conform to all applicable state and local nuisance dust regulations, and OAC 3745-17-08 while saw cutting. 

Fill the slots completely with a flexible embedding sealant, listed on the ODOT QPL.  Do not disturb slots until sealant has cured.  Cured sealant shall be level with or higher than the pavement surface.

For loop detector wire installations in new asphalt, the Contractor may saw slots and embed sealant in a subsurface course with subsequent covering by the surface course, subject to the Engineer’s approval.

632.14  Foundations.  Locate support foundations, and stake with the proper elevation.  If underground or overhead obstacles are encountered during stakeout, or to correct slope and subsurface difficulties, change foundation location and orientation with the approval of the Engineer.  Ensure that the approved location provides a safe clearance from overhead power lines for construction operations, in compliance with applicable Codes.  The Contractor is responsible for the correct location, elevation, and orientation for all poles and pedestals installed on the foundations.

Excavate for foundations using an earth auger to specified dimensions according to 503.04.  Exercise caution when excavating in areas of underground installations to avoid their disturbance or damage.  When a cave-in occurs, excavate using casing, sleeving, or other methods, with the Engineer’s approval.  If subsurface obstructions are encountered, remove the obstructions, or replace the excavated material and relocate the foundation, with the Engineer’s approval.  If bedrock is encountered, the Contractor may reduce that portion of the specified foundation depth within the bedrock up to 50 percent.  Perform all necessary dewatering of the excavation.

Perform foundation concrete work according to Item 511, except that the loading restrictions in 511.14 are modified by this subsection.  Place the concrete against undisturbed soil or compacted embankment.  Form the top of the foundations to a nominal depth of 6 inches (150 mm) below the groundline.  Place  the concrete foundation, including formed top, in one continuous concrete pour.

For foundations for anchor base type supports, provide the required reinforcing rods, and have anchor bolts and conduit ells accurately held by a template.

Remove forms and templates once the concrete has hardened sufficiently so as not to be susceptible to damage.  After 14 days, erect and load supports on anchor base foundations.  The Contractor may erect and load supports after 7 days if the tests of two beam specimens of concrete yield an average modulus of rupture of not less than 650 pounds per square inch (4.5 MPa).

632.15  Signal Support.  Furnish supports with mast arms with the required pole and arm length, anchor bolt circle diameter, and anchor bolt size.

Ensure that the combination signal supports with light pole extension provide for the attachment of a luminaire bracket arm.

For support designs not specifically shown on the plans, demonstrate, to the Director’s satisfaction, that supports are structurally equivalent to the specified design.

Do not use concrete grouting in the space between the foundation surface and support base.

Conform to the requirements of 630.06 for threaded fasteners, anchor bolts, anchor bolt nuts, and anaerobic adhesive.  Anaerobic adhesive is not required at the mast arm attachment.

Do not erect signal supports unless at least one signal, sign or damping device approved by the Engineer is installed within 24 hours.

632.16  Strain Pole.  Furnish strain poles for the attachment of messenger wire with the required pole length.  Use anchor base type strain poles. Adjust anchor base type poles with the initial rake so that when loaded the poles assume an essentially vertical position.

Ensure that the combination strain poles with light pole extension provide for the attachment of a luminaire bracket arm.

Conform to the requirements of 630.06 for threaded fasteners, anchor bolts, anchor bolt nuts, and anaerobic adhesive.

632.17  Wood Pole.  Set wood poles in holes excavated by an earth auger to a minimum depth of 6 feet (1.8 m).  Use an auger with a diameter approximately 4 inches (100 mm) greater than the pole butt.  Hold poles with initial rake, up to a maximum of 12 inches (0.3 m), while tamping backfill into place, so that under messenger wire tensioning conforming to 632.22, the poles assume an essentially vertical position.  Furnish backfill material no greater than 1 inch (25 mm) in size, and thoroughly tamp material in lifts not exceeding 6 inches (150 mm), to the satisfaction of the Engineer.  If concrete embedment is specified, brace the poles until the concrete has set.

Liberally coat field holes bored for the attachment of messenger or guy wire with approved creosote base paint and fitted with 5/8-inch (16 mm) thimble-eye through-bolts and 3-inch (75 mm) washers.  Securely attach and protect ground wire furnished as part of another work item with a wood or plastic molding for a minimum distance of 10 feet (3 m) above groundline.

632.18  Down Guy Assembly.  Install and tension guy assemblies before erecting signals such that they will resist the major portion of the horizontal loading caused by loading of the messenger wire.

632.19  Pedestal.  Furnish pedestals for the support of traffic control equipment with a cast or plate steel base, unless a transformer type base is specified.

632.20  Conduit Riser.  Attach risers to poles to provide a wiring raceway and include a weatherhead, conduit, necessary fittings, and pole attached clamps.  Attach risers to poles by clamps spaced at intervals not exceeding 5 feet (1.5 m).  Paint conduit risers mounted on painted poles to match the poles.

632.21  Cable Support Assembly.  Use cable support assemblies to eliminate strain on cables, or groups of cables up to a maximum of four, entering the interior of poles through a weatherhead or mast arm.  If required, include a length of messenger wire forming a sling with ends formed of lapped wire, thimbles, and clamps as part of the assembly.

632.22  Messenger Wire.  Arrange messenger wire with accessories between two or more poles to provide support and attachment for traffic control equipment.  Accessories used with messenger wire include bullrings, thimbles, preformed guy grip dead ends, and three bolt clamps.  Furnish bullrings at messenger wire network corners.  Use thimbles to attach messenger wire to the shackles of strain pole clamps and bullrings.

Adjust the length of the messenger wire under the load of traffic control equipment so the sag at the lowest point is not greater than 5 percent or less than 3 percent of the span.  Attach signal cable to messenger wire with lengths of preformed helical lashing rod that are of a proper internal diameter to tightly secure the cable to the messenger wire.  Attach interconnect cable with preformed lashing rod or spinning wire.

632.225         Tether Wire.  Arrange tether wire with accessories to stabilize signal heads and prevent excessive swinging and twisting. Install shim washers on hanger pin adjacent to wire entry to prevent any twisting of the head on the hanger. Accessories included with tether wire shall be those shown in the appropriate Plan Insert Sheet or Standard Construction Drawing and include pole clamps, anchor shackles, S-hooks yielding element, thimbles, turnbuckles, guy grips, wire rope clips, backup ties, lock wire, safety tie wires, and signal head tether anchors and extenders.

Adjust the tether span to be horizontal on simple spans. On all spans, install tether horizontally and tighten with turnbuckles. Bull Rings will be used at all internal corners of the tether span. Safety ties shall be installed at all yielding (S-hook) locations to prevent the span end from dropping into the roadway if the S-hook opens. No electrical or communication cables of any kind shall be attached to the tether wire. No signs or other devices shall be suspended from or attached to the tether wire.  Turnbuckles shall be tightened by hand to achieve the tether wire tension shown in appropriate Plan Insert Sheet or Standard Construction Drawing.  Measure tether tension with Loos & Co., Inc. Model PT-2 or approved equal.  Record tension test results and present written copy to the Engineer. 

632.23  Cable and Wire.  Fashion cable at traffic signal equipment weatherhead entrance fittings into a drip loop that extends at least 6 inches (150 mm) below the entrance.  Do not allow the cable to chafe on the equipment.  Support cables installed in strain poles and signal supports with cable support assemblies according to 632.21.

Do not use splices in any cable or wire, except at the following locations:

A.      At the junction of detector wire and lead-in cable.

B.      At the junction of power cable and the power supply source or service cable.

C.      On long lengths of interconnect or service cable.

For splices allowed in aerial installations, accomplish splicing in weather tight splice enclosures.  For splices allowed in underground installations, accomplish splicing in pull boxes or poles where the splice is encapsulated with poured waterproof epoxy insulation according to 725.15.

Install signal cable between signal heads and controller cabinets. Signal cables shall not be stripped beyond a length necessary to attach individual conductors within the signal head . The jacket shall extend into the signal head enclosure. Install interconnect cable between controller cabinets of different intersections. Route signal and interconnect cable by aerial installation supported by messenger wire or within underground conduit. If specified, use aerial self-supporting integral messenger type interconnect cable with a figure “8” cross-section and include pole clamps and splice enclosures. Ground the supporting messenger wire of interconnect cable.

Provide loop detector wire consisting of detector wire inserted into flexible plastic tubing.  Ensure that the tubing encases the wire continuously from the splice at the lead-in cable, through the entire loop turns, and back to the splice.  Install loop detector wire in sawn roadway slots forming loops according to 632.11.  Furnish the required number of turns of wire installed for each loop, and push the wire carefully into the slots with a blunt tool to avoid damaging the tubing.  Run the wire continuously around the loop perimeter and through a slot leading to the pavement edge and by underground conduit to a roadside pull box or pole with 5 feet (1.5 m) at each end for slack and splice.  Uniformly twist wires and tubing installed in the conduit to the splice with lead-in cable at 3 to 5 turns per foot (10 to 16 turns per meter).  Splice the loop ends to lead-in cable, which is connected to the controller cabinet.  Join the wires by a mutually twisted in-line splice, rosin core soldered, and wrapped in vinyl or equivalent electrical tape, and encapsulate wires with an approved poured waterproof epoxy insulated splice according to 725.15.  Extend and seal the tubing ends into the poured epoxy splice.  Also, solder crimped terminals to the conductors and the shield for connections inside the cabinet.

Install power cable from the power supply source to the controller cabinet.  If multi-conductor power cable is specified, the Contractor may substitute multiple single conductors.

Install service cable aerially from a remote power source to the vicinity of the controller cabinet with the support cable functioning as the electrical neutral.  Furnish connections used with aluminum power or service cable of an approved type for aluminum to aluminum or aluminum to copper connections, and insulate connections with an approved vinyl mastic pad.

632.24  Power Service.  Furnish and install all equipment necessary to provide complete electrical service to each signal installation as shown on the plans.  Make all necessary arrangements with the local electrical power company for connections to establish electrical service.  Charges made by the power company for establishing of the account, extension of company facilities, connection of customer equipment to the power company facilities and energy will be borne by the maintaining agency.

Power service consists of equipment to provide a pole attached wiring raceway and disconnect switch for use with power cable routed from the service entrance to the controller cabinet.  The power service installation includes a weatherhead, conduit and fittings, a disconnect switch with enclosure, meter base and attachment clamps.

Furnish each enclosure with at least one padlock.  Use padlocks with a bronze or brass lock body and a corrosion protected steel shackle.  Obtain the appropriate master key number from the maintaining agency.

Bend the conduit away from the pole at the top and bottom of the riser to allow the conduit to enter straight into the enclosure or meter base hub, and to provide space for the weatherhead when the riser is pulled tight against the pole.  Furnish watertight conduit connections between the meter base and enclosure by using conduit hubs listed on the enclosure UL label.

Paint conduit risers mounted on painted poles to match the poles.

632.25  Covering of Vehicular and Pedestrian Signal Heads.  Cover vehicular signal heads if erected at intersections where traffic is maintained before energizing the signals.  Cover pedestrian signal heads when specified in the plans.  Use a sturdy opaque covering material specifically made for use with traffic signals, and ensure that the color of the cover is different than the signal head, tan or beige, so that it is clear to drivers and pedestrians the heads are covered, not dark, Use a method of covering and cover attachment and materials as approved by the Engineer. Covers are to be free of text, pictures, or any type of advertising. .  Maintain covers, and remove them when directed by the Engineer.

632.26  Removal of Traffic Signal Installation.  Remove signal heads, cable, messenger wire, strain poles, cabinet, controller, or other incidental items required by the Engineer.  Remove support foundations to at least 1-foot (0.3 m) below subgrade or finished groundline.  Backfill, restore surfaces, and dispose of surplus material according to 105.16, 105.17 and 611.15.  Store removed items on the project for salvage by the maintaining agency, or reuse removed items as part of a new installation on the project under another item of work.  Dispose of all items not designated for salvage or reuse.  As specified in 614.03, do not remove signals until a new signal system or a temporary traffic control method approved by the Engineer is in operation.  Suitably protect stored equipment.

632.27  Reuse of Traffic Signal Equipment.  Reinstall or re-erect specified traffic equipment, removed from existing signal installations within the project.  Clean and restore reused equipment to an operating condition, and relamp signals with the proper type and size lamp.  Furnish all additional hardware and incidentals necessary to allow reuse of the equipment.

632.28  Testing.

A.      General.  Furnish all personnel and equipment required to successfully perform the following tests, and furnish to the Engineer six certified copies of complete test records, test reporting forms supplied by the Engineer, or alternate certification approved by the Engineer.

B.      Ground Test.  Measure each ground rod for earth resistance according to 625.19, except that measurements are not necessary immediately after installation.

C.      Short-Circuit Test.  Before performing any cable insulation tests or performance test, perform a short-circuit test with a volt-ohmmeter or other approved instrument.  Conduct short-circuit tests with electrical loads, power sources, equipment grounds, and earth grounds disconnected.  Test signal cable routed to signal heads with connections made to lamp sockets without lamps installed.  Measure each conductor against every other conductor and ground to ensure that no short-circuits, cross-circuits, or other improper connections exist.  Ensure that continuity does not exist between any conductor and another conductor including ground.

D.      Circuit Continuity Test.  Temporarily jumper each circuit branch at its termination and the temporarily looped circuit measured for continuity to ensure that no open circuits exist, that the circuit branch is according to plan, that no high resistance connections exist, and that each circuit is properly identified.  Test the lead-in cable for loop detector wire before and after splicing the cable to the loop wire.  As an alternative, perform the circuit continuity testing of signal head cable by applying 120 volts to each outgoing circuit and observing that only the proper lamps are lighted.

E.      Cable Insulation Test.  Ensure that the insulation resistance measured to ground is not less than 10 megohms for each conductor of cable or wire terminating at the controller cabinet.  Perform insulation testing with all conductors disconnected from their points on the terminal blocks.  Measure insulation resistance for the wire of roadway loops after the embedding of the wire with sealant in slots.  Include a list of the resistance readings for each conductor in the test results.  After completing the cable insulation test, connect all cabinet wiring according to the wiring diagram.  Demonstrate to the satisfaction of the Engineer that all circuits are continuous and operating correctly with freedom from shorts, crosses, and unintentional grounds.

F.      Functional Test.   Before the 10-day performance test begins, make the following checks and demonstrate to the Engineer that the system is ready for the performance test.  Ensure that the incoming AC voltage is a nominal 120 volts.  If the supplied voltage under load is less than 100 or more than 130 VAC, contact the power company to arrange correction.  Ensure that the cabinet ventilating fan, fan thermostat, and convenience outlet with lamp is operational.  Verify correct timing settings on the controller as shown on the plans.  Check all cabinet switches including the power on/off switch and flash switch.  Check all controller functions to verify correct operation.  Check the detector units to determine which pavement loop is associated with which detector unit.  Check the visual call strength indication of detector units to determine that each vehicle class (truck, car, motorcycle, and bicycle) entering sensor areas is detected on the associated detector unit and that no extraneous calls occur when the sensor area is vacant.  Occasional extraneous calls may be permitted by the Engineer if necessary to assure detection of small vehicle targets (bicycles and motorcycles).  Check the flash switch to verify transfer of signal operation to flash and return to stop-and-go.  Check the conflict monitor to verify that it is not activated by normal signal operations or by the manipulation of cabinet switches.  If the monitor is activated, determine the cause of the problem and make appropriate changes and adjustments before beginning the performance test.  Test the conflict monitor by artificially causing a number of different conflicting indications, and verify that at each test the monitor causes the signals to begin flashing and places the controller in a “stop timing” mode.  Obtain artificial causation either by touching a jumper wire between two conflicting load switch outputs or by other methods approved by the Engineer.  Ensure that the signal flashes when the monitor is disconnected.

G.     Performance Test.  At least 7 days before the performance test begins, notify the Engineer of the starting date.  The Engineer will notify the maintaining agency.  Before acceptance, operate the traffic control system continuously for 10 consecutive days without major malfunction or failure.  Immediately replace or repair minor failures (such as lamps, a single detector unit, or an individual signal head, etc.) that do not cause restart of the test.  Major malfunctions or failures (such as a master or local controller, interconnect equipment, etc.) will cause termination of the test and, after replacement or repair, the beginning of a new 10-day test.  Monitor items that have been repaired or that are replacements for a 10-day period to provide assurance of their reliability.  Record, for inclusion in the test result, the method and date of correction of each fault, and the beginning and end of the test.

632.29  Method of Measurement.  The Department will measure Vehicular Signal Head and Pedestrian Signal Head by the number of complete units, and will include all support or mounting hardware, disconnect hangers, closure caps, dimmers, and lamps as required.  Optically programmed heads shall include programming.  For programming purposes, 8-inch (200 mm) programmed heads shall include one extender tool per project.

The Department will measure Pedestrian Pushbutton by the number of individual units, and will include pedestrian pushbutton signs.

The Department will measure Loop Detector Unit by the number of individual units, adjusted and tuned, and will include a wiring harness.  If multi-channel detector units are used, the Department will consider each channel as an individual detector unit up to the number of units specified.

The Department will measure tether wire by the number of feet (meters) in place, and will include all necessary accessories such as pole clamps, safety tie clamps, anchor shackles, S-hooks yielding element, thimbles, turnbuckles, guy grips, wire rope clips, lock wire, safety tie wire, lead sheet, and signal head tether anchors and extenders in accordance with the applicable Plan Insert Sheet or Standard Construction Drawing. The Department will measure from pole center to pole center, or pole center to bullring, or bullring to bullring. The Department will not measure any length of tether wire for attachment to poles or bullrings by bending, lapping or wrapping.

The Department will measure Detector Loop by the number of           complete detector loops installed in the pavement, and will include pavement cutting, loop detector wire with tubing in place, application of sealant, conduit, trenching, backfilling, and surface restoration from the edge of pavement to the pull box.

The Department will measure Strain Pole Foundation, Signal Support Foundation, and Pedestal Foundation by the number of complete units, and will include excavation, dewatering, sleeving, casing, reinforcing steel, concrete, backfilling, disposal of surplus excavation, and installation only of anchor bolts and conduit ells.

The Department will measure Signal Support, Combination Signal Support, Strain Pole, Combination Strain Pole, Wood Pole, and Pedestal by the number of complete units of each, and will include pole arms, weather-heads and blind half couplings, anchor bolts and conduit ells furnished for foundations.

The Department will measure Down Guy by the number of individual units, and will include messenger wire, pole clamp or thru-bolt, washer, clamps, guy grips, insulator, guy guard, and anchor.

The Department will measure Conduit Riser by the number of complete units, and will include weatherhead, conduit, fittings, clamps, and hardware.

The Department will measure Messenger Wire by the number of feet (meters) in place, and will include all necessary accessories such as, grips, thimbles, clamps, bullrings, and lashing rod.  The Department will measure from pole center to pole center, or pole center to bullring, or bullring to bullring.  The Department will not measure any length of messenger wire for attachment to poles, or bullrings by bending, lapping, or wrapping.

The Department will measure Signal Cable, Interconnect Cable, Loop Detector Lead-In Cable, Power Cable, and Service Cable by the number of feet (meters) in place.  Cable inside of poles shall include cable support assemblies.  Aerial cable shall include pole attachment hardware, splices, splice enclosures, and ground connection.  Lead-in cable shall include poured epoxy insulated splices.  The Department will measure:  (1) horizontally from center-to-center of pull boxes, poles, cabinets, power sources, and signal heads with an additional allowance of 5 feet (1.5 m) at each pull box and terminating points for slack and connections; and (2) vertically between pole or conduit outlets.  If single-conductor power cable is substituted for multi-conductor cable, the Department will measure required length of multi-conductor cable.

The Department will measure Power Service by the number of complete units, and will include weatherhead, conduit, fittings, clamps and other necessary hardware, installation of meter base, ground wire connection, and disconnect switch with enclosure and padlock.

The Department will measure Covering of Vehicular Signal Head and Covering of Pedestrian Signal Head by the number of individual signal heads covered, and will include materials and labor to erect, maintain, and remove the covering.

The Department will measure Removal of Traffic Signal Installation by the number of installations removed, and will include storage when required.

The Department will measure Removal of (Item) and (Storage or Reerection) by the number of specific traffic signal installation parts (such as a signal head, controller unit, or pole) removed, and will include storage when required.

The Department will measure Reuse of (Item) by the number of traffic signal equipment items reused, and will include cleaning, restoring, and relamping.

632.30  Basis of Payment.  The costs to arrange service by the supply agency are included under Power Cable.

The costs of personnel, materials, equipment, electrical energy, and incidentals required to conduct performance tests are included under the contract unit price for the respective items tested.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

632             Each                                 Vehicular Signal Head, (Yellow or Black),

                                                           (Aluminum or     Polycarbonate), ___-Section

                                                           ___ inch (___ mm) Lens ___-Way (with

                                                           Backplate)

632             Each                                 Vehicular Signal Head, Optically Programmed,

                                                           (Yellow or Black), (Aluminum or

                                                           Polycarbonate),  ___-Section, ___ inch  (___

                                                           mm) Lens, ___-Way (with Backplate)

632             Each                                Pedestrian Signal Head,

                                                               (Countdown),  Type ___

632             Each                                Pedestrian Pushbutton

632             Each                                Loop Detector Unit

632             Each                                Detector Loop

632             Each                                Strain Pole Foundation

632             Each                                Signal Support Foundation

632             Each                                Pedestal Foundation

632             Each                                Signal Support, Type TC-___, Design ___

632             Each                                Combination Signal
                                                               Support, Type TC-___, Design ___

632             Each                                Strain Pole, Type TC-___, Design ___

632             Each                                Combination Strain Pole,
                                                               Type TC-___, Design ___

632             Each                                Wood Pole, Class ___,
                                                               (Length)___ feet (___ m)

632             Each                                Down Guy

632             Each                                Pedestal, (Length) ___ feet (___ m)

632             Each                                Pedestal, (Length) ___ feet
                                                               (___m),Transformer Base

632             Each                                Conduit Riser, ___ inch (___ mm) Dia.

632             Foot (Meter)                    Messenger Wire, (No.)
                                                               Strand ___ inch (___ mm)
                                                               Dia., with Accessories

632             Foot (Meter)                    Signal Cable, ___-   Conductor, ___ AWG

632             Foot (Meter)                    Interconnect Cable, ___-
                                                               Conductor, ___ AWG

632             Foot (Meter)                    Interconnect Cable, Integral Messenger Wire

                                                               Type, ___-Conductor, ___ AWG

632             Foot (Meter)                    Loop Detector Lead-In Cable

632             Foot (Meter)                    Power Cable, ___- Conductor, ___ AWG

632             Foot (Meter)                    Service Cable, ___-
                                                               Conductor, ___ AWG

632             Each                                Power Service

632             Each                                Covering of Vehicular Signal Head

632             Each                                Covering of Pedestrian Signal Head

632             Each                                Removal of Traffic Signal Installation

632             Each                                Removal of (Item) and
                                                               (Storage Or Reerection)

632             Each                                Reuse of (Item)

632             Foot (Meter)                    Tether Wire, with Accessories

ITEM 633  TRAFFIC SIGNAL CONTROLLERS

633.01  Description

633.02  Contractor Personnel Requirements

633.03  Materials and Equipment

633.04  Certified Drawings

633.05  General

633.06  Testing and Prequalification

633.07  Controllers

633.08  Cabinets

633.09  Cabinet Riser

633.10  Foundations

633.11  Controller Work Pad

633.12  Flasher Controller

633.13  Controller, Master, Traffic Responsive

633.14  Remote Monitoring Station

633.15  Communications

633.16  Training

633.17  System Analysis

633.18  Uninterruptible Power Supply

633.19  Method of Measurement

633.20  Basis of Payment

633.01  Description.  This work consists of furnishing and installing traffic signal control equipment, including controllers, cabinets, auxiliary equipment, and specified accessories, completely wired, at the locations shown on the plans and ready for service.

633.02  Contractor Personnel Requirements.  Conform to the requirements of Supplement 1063 for the installation or testing of traffic signal equipment.

633.03  Materials and Equipment.  .  Furnish new materials and equipment of first quality, of current design, and free from defects. For warranted items, “new” items shall have a manufacturing date (determined by serial number) within one (1) year of the date of shipment to the project as determined by the required warranty decal.

Use electrical parts, wire, switches, and other elements of the installation capable of carrying the required current without excessive heating or drop of potential.

Ensure that each item of equipment bears a nameplate, indelible marking, or brand that identifies the type, model, catalog number, and manufacturer.  Use equipment conforming to the types, models, and systems specified.

Furnish material and equipment conforming to:

Concrete

.... (cabinet foundations and work pads)

.... QC Misc or QC 1 ………………………….. 499, 511

Conduit...................................... 725.04, 725.051, 725.052

Controller unit.......................................................... 733.02

Cabinet and auxiliary equipment.............................. 733.03

Cabinet riser............................................................. 733.04

Flasher controller..................................................... 733.05

Controller, master, traffic responsive....................... 733.06

Remote monitoring station....................................... 733.07

Uninterruptible Power Supply……………………. 733.09

633.04  Certified Drawings.  Furnish certified drawings according to 625.06.

633.05  General.  Ensure that major items of traffic signal control equipment used in combination are compatible, interchangeable, and, whenever feasible, provided by the same manufacturer or supplier.

Ensure that controller cabinets are shop prewired according to 632.05.

Before starting installation, furnish to the Engineer, two copies of each cabinet wiring diagram, service manuals, and installation and maintenance instructions for each installation, including all components and interconnections.  Supply one additional copy of the cabinet wiring diagrams in a clear plastic pouch fastened to the inside of the controller door.  Before beginning the 10-day performance test, replace or modify these documents as necessary to reflect current conditions.  Upon completion of the work and before its acceptance, replace or modify the documents as necessary.

Transfer manufacturers’ guarantees or warranties on all installed traffic signal control equipment to the maintaining agency upon completion and acceptance of the project.

If required by the plans to install equipment furnished by others, store and care of the equipment upon receipt.

633.06  Testing and Prequalification.  For all traffic control equipment, perform functional tests and a 10-day performance test according to 632.28.  Do not clear conflict monitor logs during the 10-day test.  Ensure that logs note power-up to start the test and all events until the test is complete.  Restart the test upon correcting a noted event.  Notify the Engineer at least 3 days before beginning the 10-day performance test.  The Engineer will notify the maintaining agency of the beginning of the test.  Ensure that the following testing and prequalification requirements are met:

A.      For traffic control equipment required by this specification to meet NEMA Standards Publication TS-1 or TS-2, conform to the following:

1.      Furnish a certified test report indicating compliance to all requirements of NEMA Standards Publication TS-1 or TS-2 as applicable.

2.      Furnish the name and location of the laboratory testing facility as well as the identification of the principal personnel who conducted the equipment testing and a summary of their qualifications.

3.      Ensure that the laboratory provides Department representatives access to those parts of the laboratory where the testing was done.

4.      Upon request, furnish a copy of the actual test data results for review and analysis.

B.      For traffic control equipment required by this specification to meet CalTrans specifications, use a product or manufacturer as stated in this specification that is listed on the CalTrans Qualified Products List or applicable ODOT Qualified Product List.

C.      For Type 170/2070 controllers, use conflict monitors listed on the Department’s prequalified list as specified in Supplement 1076.

633.07  Controllers.  Install controller units, consisting of the timing unit, software, and signal timing, into the specified type of prewired cabinet.

Program controller units as shown on the plans unless otherwise directed by the Engineer.  If the plan timing data or the supplemental timing data supplied by the Engineer does not exactly fulfill the timing requirements of the installed equipment, notify, in writing, the Engineer of the problem and identify the discrepancies.  The Engineer will consult with the maintaining agency and notify the Contractor within 2 weeks.  After programming, briefly operate controllers, with the signals turned off by means of the signal shutdown switch, to ensure that operation is reasonable and conforms to the plans.

If the plans show two or more intersection controllers operated in a progressive signal system, coordinate signals by relating the various controller cycle start times to a zero time base, or other cycle start time at an adjacent signalized intersection.  Ensure that the controller unit software provides coordination capability to allow associated controllers to be operated within the progressive traffic system.  Coordination equipment shall supervise the operation of its associated controller by causing the end of certain phases and the beginning of the following phases to occur at set points.  Program coordination timing according to the coordination timing data shown on the plans or provided by the Engineer.

633.08  Cabinets.  Mount cabinets by attaching to pedestal or pole or by installing on a concrete foundation.  Arrange foundation mounted cabinets so that control equipment, terminal blocks, or shelves are no closer than 6 inches (150 mm) to the top of the foundation.  Attach pole or pedestal mounted controller cabinets at a height that allows convenient access to all controller components by service personnel.

Make field connections for the conductors of signal cable, power cable, interconnect cable, and detector lead-in cable.  Neatly arrange and route all field wiring to the appropriate terminal blocks.  Identify field wiring according to 725.02 except mark with either indelible pen or embossed letters.

Except for power wiring, fit field wiring entering the cabinet with spade terminals to ensure a good connection.  For incoming power wiring, either use spade terminals or connect the bare conductor wire to terminal points utilizing screw or spring applied clamping surfaces compatible with either copper or aluminum wire and providing a positive grip.  After completing field wiring, seal the conduit entering the cabinet in an approved manner with a removable sealing compound (no foam sealants), or a molded plastic or rubber device that is compatible with the cable jacket, the insulation, and the conduit material.

For foundation mounted cabinets, seal the joint between the controller cabinet and the foundation with a quality, clear silicone caulk.

When future phasing configurations are shown on the plans, furnish the cabinet and hardware to accommodate the future operation through only the future addition of load switches and detector units.

633.09  Cabinet Riser.  Cabinet risers provide an extension of the cabinet between the ground mounted cabinet and the foundation.  Bolt the riser to the foundation, and bolt the cabinet to the riser.

Use a type (size and shape) of cabinet riser compatible with the type of controller cabinets specified for the project.

Seal the joints between the controller cabinet and cabinet riser, and between the cabinet riser and foundation with a quality, clear silicone caulk.

633.10  Foundations.  Construct foundations for controller cabinets according to 632.14, except that excavation by earth auger is not required and the foundation does not require reinforcing steel.  Hold anchor bolts, conduit ells, and similar appurtenances in the proper position until the concrete has set.  Pour foundations separately from controller work pad.

633.11  Controller Work Pad.  Construct controller work pad according to 608.03, except that transverse joints are not required.  Provide the top of the pad nominally 1 inch (25 mm) above ground line.  If the controller cabinet has both front and back doors, the work pad shall encompass three sides of the cabinet foundation to include the non-hinged cabinet door side of the foundation.  Pour controller work pad separately from foundations.

633.12  Flasher Controller.  Furnish and install a flasher controller with cabinet and mounting hardware when indicated.  The flasher controller is for the operation of flashing beacons.

633.13  Controller, Master, Traffic Responsive.  The traffic responsive master controller supervises and controls the operation of an interconnected system of local controllers.  Ensure that the master controller is able to communicate with a remote monitoring station.  Locate this master controller in a local intersection controller cabinet unless otherwise shown on plans.  If the local controller cabinet size is not sufficient to accommodate the master controller and its associated wiring, furnish the proper size cabinet for the local intersection controller to house the local controller, master controller, modem, and all auxiliary devices.

633.14  Remote Monitoring Station.  Install, test, and operate the remote monitoring station, consisting of computer equipment, communications equipment, and software, in one or more locations in the maintaining agency’s facilities as shown on the plans.  The maintaining agency shall furnish telephone service at these stations.

633.15  Communications.  Furnish a broadband cellular modem from the Department’s approved products list.  The Maintaining Agency will arrange for the cellular service and device activation. 

Furnish all necessary cabling to interface with the traffic signal controller.  Furnish an antenna that provides RSSI (Received Signal Strength Indication) or no less than -95 dBm.  Provide all necessary cabling and surge suppression to connect the antenna to the modem. 

633.16  Training.  Furnish training for the traffic signal control equipment installed as part of the Contract.  Furnish all handouts, manuals, and product information.  For the training, use the same models of equipment furnished for the project.  The maintaining agency shall furnish the facilities in which the training will take place.  Furnish all media and test equipment needed to present the training.  Unless otherwise shown on the plans, the minimum training requirements are as follows:

A.      Sixteen hours on how to operate the system, analyze system performance, and revise critical operating parameters.

B.      Eight hours of field trouble-shooting and maintenance procedures.

C.      Eight hours of follow-up training after the maintaining agency has operated the system for a minimum period of 30 days.

D.      Four hours for preemption device training if emergency vehicle preemption is shown on the plans.

633.17  System Analysis.

A.      General.  Prepare signal timing and traffic progression programs, load the programs into the signal system, evaluate the performance of the system, and refine the programs as necessary to optimize traffic flow and operation.  Collect and evaluate traffic data, analyze traffic signal progression and timing, develop traffic adjusted pattern selection parameters, perform the system evaluation and refine the system operation, and prepare and submit a summary report for review and approval by the Engineer.

If a project contains individual sub-systems that are connected to the remote monitoring station, perform all work as outlined in this subsection for each sub-system.  If required, analyze signal “sub-systems” together and coordinate traffic progression programs to optimize the overall traffic flow between the various sub-systems.

Optimize only the cycle lengths, phase splits, permissives, and offsets without changing the actual controller phasing provided in the plan.

B.      Systems Engineer or Technician.  Employ a systems engineer or technician to perform the work required by this subsection and submit to the Engineer for approval three copies of a resume documenting the following qualifications:

1.      A minimum of 5 years experience in traffic engineering or traffic engineering technology.

2.      The systems engineer or technician’s education including training in traffic engineering technology and signal system design.

3.      The systems engineer or technician’s familiarity with the closed loop system installed and experience in setting up and fine tuning a system of that type.  Furnish a list of other closed loop systems that the systems engineer or technician has programmed into the traffic responsive mode for documentation purposes.

Also, submit to the Engineer for approval a brief description of proposed methodology of data collection and analysis of:

a.      System parameter usage in system evaluation.

b.      Frequency and measurement of travel time and delay.

c.      Comparison of actual versus system measurements of delays (level of service).

The systems engineer or technician, under authority of the Contractor, is responsible for the operation of the system from the completion of the signal system acceptance until completion and acceptance of the final summary report by the Engineer.  The systems engineer or technician shall provide a 24-hour emergency phone number and shall respond to system related problems as deemed necessary by the Engineer 24 hours a day, 7 days a week.  If there is a guarantee period, the Engineer reserves the right to request a systems analysis throughout the entire duration of this period, if new or continuing problems occur with the operation of the traffic responsive system.

The Engineer reserves the right to request that the Contractor furnish a new systems engineer or technician if the current systems engineer or technician fails to perform the required duties in a timely and professional manner or fails to have a firm understanding of the operation and programming of the closed loop system constructed.

C.      Traffic Programs.  The systems engineer or technician shall develop signal progression and timing programs from count and occupancy data obtained from the local intersection and system loop detectors, supplemented by field counts and measurements as required.  The systems engineer or technician shall develop the following signal progression programs and parameters:

1.      One (a.m. peak) with offsets for inbound preferential/balanced.

2.      One (p.m. peak) with offsets for outbound preferential/balanced.

3.      Two average (off peak/low volume).  The two average programs should utilize varying cycle lengths based on traffic volume, density, and occupancy to minimize overall intersection approach delay time.

4.      One average (weekend peak). One of the off peak/low volume plans plans should accommodate the off peak weekend timeframe.

5.      One special program for either high congestion or queue backup.

6.      A minimum of six timing plans for a backup time base coordinated system.  The systems engineer or technician shall program the timing plans into the system, to supplement the timing plans shown on the plans.

7.      Define system parameters that enable the system to automatically transfer into a “free operation” mode during light traffic volume periods and to automatically transfer to a computer selected coordinated mode during heavy traffic volume periods.  The systems engineer or technician shall establish the following system parameters:

a.      Volume, occupancy and directionality thresholds.

b.      Transition smoothing factors.

c.      System detector assignment.

d.      System detector weighting.

The systems engineer or technician may use the software provided with the remote monitoring station to help assist in the analysis of the operation of the closed loop system.

D.      System Travel Time Studies.  The systems engineer or technician shall conduct a series of travel time studies for each system or sub-system artery constructed as part of the project, to measure the time it takes to travel from 0.25 mile (0.4 km) in advance of the beginning of each system or sub-system to 0.25 mile (0.4 km) after the end of that system or sub-system, in each direction.  Ensure that the travel time study parameters are based on the posted speed limit; however, be aware that during peak periods it may not be possible to obtain the posted speed due to larger traffic volumes.

The systems engineer or technician shall conduct four separate sets of travel time studies for each of the following field conditions:

1.      Before beginning construction, with the existing signal system in operation (no lane closures shall be in effect during this analysis).

2.      Before implementing the traffic responsive mode, while the new traffic signal system is operating under the “time of day” mode (as is shown on the plans).

3.      After placing the system(s) in the traffic responsive mode.

4.      After the system operation meeting and making final system adjustments.

Each set of travel time studies shall include a minimum of five runs through the system per direction.  The systems engineer or technician shall conduct travel time studies during good weather conditions (i.e., no snow, rain, or fog).  The Engineer may omit the pre-construction travel time studies if the project includes substantial changes to the roadway geometrics (i.e., roadway widening, reconfiguring of pavement markings, etc.) that would affect the results of a comparison of the level of improvement over preexisting conditions.

The four separate sets of travel time studies shall include the following:

1.      Conduct the first set of travel time studies between the hours of 7:00 a.m. and 9:00 a.m. on weekdays.

2.      Conduct the second set of travel time studies between the hours of 11:30 a.m. and 1:00 p.m. weekdays.

3.      Conduct the third set of travel time studies between the hours of 4:00 p.m. and 6:00 p.m. weekdays.

4.      Conduct the fourth set of travel time studies during any of the following non-peak hour periods:

a.      9:00 a.m. to 11:00 a.m. Monday through Saturday.

b.      7:00 p.m. to 10:00 p.m. Monday through Saturday.

c.      7:00 a.m. to 10:00 p.m. Sunday.

The systems engineer or technician shall furnish a written report documenting, at a minimum, the date of travel time study, day of week, time of day, total time of travel, and total time the vehicle was stopped for each trip.

The systems engineer or technician shall use the reports furnished from each of the four field conditions for which system travel time studies are prepared as one means of measuring the efficiency of the new system.

E.      Draft System Summary Report.  The systems engineer or technician shall prepare a draft system summary report after travel time studies for the first three field conditions are performed.  Submit two copies each to the Engineer and the maintaining agency(s) of the signal system for the evaluation and review of the system programming, operation, and efficiency.

The report shall summarize the signal progression and timing programs that were entered into the system.  The report shall also include a copy of the systems log after operating in the traffic responsive mode to verify the number of programs used throughout the day as well as the frequency of program changes.  The systems engineer or technician shall provide a minimum of at least 4 days of systems logs.  The systems engineer or technician shall limit three of the four logs to the weekdays of Monday through Friday; the fourth log shall be on a Sunday.  The systems engineer or technician shall include copies of all data and analysis calculations for the system timing in the report.  The draft system summary report shall include an evaluation of the system operation, efficiency, and performance and copies of all travel time study data.

F.      System Operation Meeting and Final System Summary Report.  After the draft system summary report has been submitted, the Engineer will schedule a meeting that includes the systems engineer or technician, the Contractor, the Engineer, and representative(s) from the maintaining agency(s) to discuss the operation of the traffic responsive closed loop signal system.  This meeting shall occur within 4 weeks after the draft system summary report has been submitted to the Engineer and maintaining agency(s).

The purpose of this meeting is to discuss the operation of the traffic responsive closed loop signal system and to receive comments and recommendations from the Engineer and/or the maintaining agency(s) regarding potential modifications to the operation of the system.  The systems engineer or technician shall answer questions regarding the system summary report as well as the operation of the closed loop system.

The systems engineer or technician shall make final adjustments to the system as directed by the Engineer to address any concerns discussed at this meeting.  The systems engineer or technician shall perform the final travel time study before submitting the final report.  The systems engineer or technician shall submit one copy of a final system summary report to the Engineer and one additional copy for each maintaining agency for review and approval.  The final report shall include any revisions to the draft report that are required as a result of the system operation meeting.

633.18       Uninterruptible Power Supply (UPS).  Furnish and install a Battery Backup UPS system to provide uninterruptible, reliable, emergency power to a traffic signal intersection in the event of a power failure or interruption. The transfer from utility power to battery power shall not interfere with the normal operations of the traffic controller, conflict monitor or any other peripheral devices within the traffic control system.  The system shall be self-contained including all UPS hardware, the required number of batteries and its own separate ventilated enclosure.  A ground rod shall be provided for free-standing UPS cabinets.

633.19  Method of Measurement.  The Department will measure Controller Unit, Type ___, with Cabinet, Type ___ by the number of each complete unit, and will include controller unit with software, all required auxiliary equipment, loop detector units, and a prewired cabinet, with all items completely wired and tested.  Ground mounted cabinets will include anchor bolts and conduit ells for installation in the foundation.  Pole mounted cabinets will include pole mounting hardware.

The Department will measure Controller Unit, Type ___ by the number of each controller timing unit with software, and will include any signal timing programming or installation.  The Department will measure Controller Unit, Type ___, Furnish Only by the number of each controller timing unit with software, and will exclude any signal timing programming or installation.

The Department will measure Cabinet, Type ___ by the number of each complete prewired cabinet installed, and will include all required auxiliary equipment and loop detector units (excluding controller unit), with all items completely wired and tested.  Ground mounted cabinets will include anchor bolts and conduit ells for installation in the foundation.  Pole mounted cabinets will include pole mounting hardware.  The Department will measure Cabinet, Type ___, Furnish Only by the number of each complete prewired cabinet, and will include pole mounting hardware and anchor bolts, but will exclude installation, controller unit, and detector units.

The Department will measure Cabinet Riser by the number of each unit, and will include materials, mounting hardware, and installation.

The Department will measure Cabinet Foundation and Controller Work Pad by the number of each complete unit, in place, complete and accepted, and will include excavation, concrete, backfilling, and disposal of surplus excavation.  Cabinet foundation will include preformed joint filler between the foundation and adjacent paved areas.  One complete Controller Work Pad unit may encompass several sides of a controller cabinet installation.

The Department will measure Flasher Controller by the number of each complete flasher assembly with cabinet installed and tested.

The Department will measure Controller, Master, Traffic Responsive by the number of each unit, and will include installation, signal system software, programming, and any increase in cabinet size to house the master controller in the local intersection cabinet.  The Department will measure Controller, Master, Traffic Responsive, Furnish Only by the number of each unit, and will include software, but exclude any programming or installation.

The Department will measure Remote Monitoring Station by the number of each location shown on the plans, and will include all equipment, testing, and software.

The Department will measure Communication service by the number of each location shown on the plans for furnishing Communication service to an intersection controller, and will include the modem, conduit, trenching, and wiring.

The Department will measure Training on a lump sum basis, and will include providing the instruction materials, instructor travel expenses, and test or media equipment for presenting the training material.

The Department will measure System Analysis on a lump sum basis, and will include providing all materials, labor, software, printing reports, and incidentals to analyze all traffic responsive sub-systems included in the project.

The Department will measure Uninterruptible Power Supply by the number of each and will include all equipment, testing and certifications.

633.20  Basis of Payment.  If a project contains individual sub-systems that are connected to the remote monitoring station, the cost for performing work, as specified in 633.17 is incidental to the bid item price for System Analysis.

The costs to obtain and maintain telephone service of cellular by the supply agency are included under Communications.

The Department will pay for accepted quantities at the contract unit prices as follows:

Item           Unit                                Description

633             Each                                Controller Unit, Type ___,

                                                               with Cabinet, Type ___

633             Each                                Controller Unit, Type ___

633             Each                                Controller Unit, Type ___, Furnish Only

633             Each                                Cabinet, Type ___

633             Each                                Cabinet, Type ___, Furnish Only

633             Each                                Cabinet Riser

633             Each                                Cabinet Foundation

633             Each                                Controller Work Pad

633             Each                                Flasher Controller

633             Each                                Controller, Master, Traffic Responsive

633             Each                                Controller, Master, Traffic
                                                               Responsive, Furnish Only

633             Each                                Remote Monitoring Station

633             Each                                Communications

633             Lump Sum                      Training

633             Lump Sum                      System Analysis

633             Each                                Uninterruptible Power Supply

ITEM 638  WATER MAINS AND SERVICE BRANCHES

638.01  Description

638.02  Materials

638.03  Notification

638.04  Excavation

638.05  Pipe Bedding

638.06  Pipe Laying

638.07  Pipe Joints

638.08  Backfilling

638.09  Hydrostatic Tests

638.10  Disinfection of Completed Water Work

638.11  Steel Pipe Encasement

638.12  Polyethylene Encasement

638.13  Valves and Equipment

638.14  Fire Hydrant

638.15  Fire Hydrant Adjusted

638.16  Service Branches

638.17  Meter and Chamber Removed and Reset

638.18  Valve Box and Service Box Adjusted to Grade

638.19  Method of Measurement

638.20  Basis of Payment

638.01  Description.  This work consists of constructing water mains and service branches, including fire hydrants, water meters, corporation stops, service boxes, service stops, valves, fittings, and valve boxes, and includes:

A.      Excavation for items and preparation of the foundations, necessary for placing water mains and service branches, including fire hydrants, water meters, corporation stops, service boxes, service stops, valves, fittings, and valve boxes.

B.      Furnishing and placing bedding and backfill.

C.      Constructing and subsequently removing all necessary cofferdams, bracing, cribs and sheeting.

D.      Pumping and dewatering.

E.      Providing all joints as shown on the plans.

F.      Furnishing and installing all necessary bends and branches.

G.      Furnishing and installing all necessary tracer tape.

H.     Joining to existing and proposed appurtenances as required in the project plans.

I.       Performing all necessary test (leakage test, disinfections, hydrostatic).

J.       Restoration of disturbed underground facilities.

K.      Constructing all required blocking and wedging and/or thrust blocking.

L.      Furnishing and installing all necessary restraining of joints and fittings.

M.     Cutting and plugging as required existing water mains to be abandoned.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

638.02  Materials.  Furnish materials conforming to:

Pipe, joints, and fittings.

Ductile iron pipe, joints, and fittings........................ 748.01

Polyvinyl chloride (PVC) pipe,

.... joints, and fittings................................................ 748.02

Polyethylene (PE) service

.... branches and fittings........................................... 748.03

Copper service branches and fittings....................... 748.05

Steel pipe encasement.............................................. 748.06

Polyethylene encasement......................................... 748.07

Valves and equipment.

Gate valve and valve box......................................... 748.08

Inserting valve and valve box.................................. 748.09

Cutting-in sleeve, valve and valve box..................... 748.10

Tapping sleeve, valve and valve box........................ 748.11

Tapping saddle and corporation stop....................... 748.12

Service stop and service box.................................... 748.13

Meter, setting, stop and chamber............................. 748.14

Fire hydrant............................................................. 748.15

Miscellaneous.

Granular Material..................................................... 605.02

Disinfectant........................................................... AWWA

Pipe bedding ....................................................... 611.02 H

Concrete, Class QC-Misc............................... 499 and 511

Soil and granular embankment................................. 203.02

Structural backfill, Types 1, 2, and 3....................... 703.11

Mortar........................................................................... 602

The Engineer will allow Type 3 structural backfill, conforming to 703.11, to be used as bedding below the pipe only when pumping operations do not control severe ground water problems.  Place at least 12 inches (300 mm) of Type 1 structural backfill on top of the Type 3 structural backfill to prevent piping.

The metric equivalent pipe size may vary with material type for the same English size pipe.

638.03  Notification.  Notify the Engineer and maintaining agency of the following:

A.      The dates scheduled for testing and for disinfections of mains and branches.

B.      Any clearances less than 1 foot (0.3 m) between new mains and existing pipes, sewers, and structures.

638.04  Excavation.  Excavate according to Item 611 with the following additions:

A.      Excavate the trench a suitable distance in advance of pipe laying to ensure proper clearance between the waterline and any utility crossing or underground structure.  Suitably brace and support utilities and structures.

B.      Excavate the trench walls vertically up to the top of the pipe.  Ensure that the clearance on either side of a pipe is a minimum of 6 inches (150 mm) and a maximum of 12 inches (300 mm).  In paved areas, neatly line cut the pavement at the surface a distance of at least 12 inches (300 mm) beyond the trench side and remove paving material.

C.      Furnish cover over pipes of 5 feet (1.5 m) unless otherwise shown on the plans.

D.      Pile excavated material in a manner that will not endanger the work or obstruct sidewalks and driveways.  Keep gutters clear or make other satisfactory provisions for drainage.  Do not obstruct natural water-courses.

E.      Furnish holes for pipe bells at each joint, but make them no longer than necessary for joint assembly and assurance that the pipe barrel will be flat on the trench bottom.

F.      Furnish, place, and maintain such sheeting and bracing as may be required.  Immediately backfill and compact voids appearing outside of sheeting.  Notify the maintaining agency of sheeting and bracing left in place.  Do not remove sheeting and bracing until sufficient backfill has been placed to provide ample support to the sides of the excavation.  When sheeting is left in place, cut it off at least 2 feet (0.6 m) below the proposed finished surface or subgrade in paved areas.  The Department will pay for sheeting and bracing it orders to be left in place as a separate item of the work.

638.05  Pipe Bedding.  Where specified, provide structural backfill for bedding according to Item 611 except the bedding is 4 inches (100 mm) thick.

638.06  Pipe Laying.

A.      Inspection.  Inspect water mains and auxiliary equipment upon delivery in the field to ensure proper working order before installation.

B.      Trench Dewatering.  Where water is encountered in the trench, remove it during pipe-laying operations and maintain the trench water free until the ends of the pipe are sealed and provisions are made to prevent floating of the pipe.  Do not allow trench water or other deleterious materials to enter the pipe at any time.

C.      Pipe Clearance.  Lay pipe at least 12 inches (300 mm) from any structure or underground utility, and maintain a minimum 10-foot (3 m) horizontal separation from sanitary sewers.

D.      Existing Systems.  Do not operate any valve or other control on the existing system.  The maintaining agency will operate all valves, hydrants, air valves, and service stops.

E.      Pipe Handling.  Handle pipe in a manner that will prevent damage to the pipe, pipe lining, or coating.  Load, unload, and place pipe and fittings using hoists and slings in a manner that will avoid shock or damage.  Do not drop, skid, or roll pipe or fittings against other pipe.

F.      Pipe Cutting.  Whenever it becomes necessary to cut a length of pipe, make the pipe ends square with the longitudinal axis of the pipe and otherwise smooth so that good connections can be made.  Cut pipe using cutters recommended by the manufacturer.  Do not cut ductile iron pipe with an oxyacetylene torch.  File or grind field-cut pipe lengths to obtain a chamfer on the outside of the pipe, according to the manufacturer’s recommendations.  Remove rough or sharp edges from the cut end.

G.     Pipe Laying.  Ensure that pipe and fittings are clean when laid.  Take precautions to prevent floating.  Place the pipe on the trench bottom or bedding.  After the pipe has been aligned and jointed, and thrust blocking has been placed, secure the pipe in place with approved backfill material.  At times when pipe laying is not in progress, close the open ends of the pipe with a watertight plug.

H.     Pipe Laying on Curves.  If the pipe is shown curved on the plans, construct the curves by special fittings or by deflecting the joints according to the manufacturer’s recommendations.  Do not make joint deflections at valves.

When rubber-gasketed pipe is laid on a curve, joint the pipe in a straight alignment and then deflect it to the curved alignment.  Make trenches wider on curves for this purpose.

I.       Pipe Laying Where Earth Grading is Necessary.  Where a pipe is to be placed within an embankment or the top of the pipe is above the existing ground, construct the embankment to at least 6 inches (150 mm) above the top of the pipe before trenching for the pipe.  Excavate the trench to the minimum width necessary for the proper placing and backfilling of the pipe.

J.      Tracer Tape.  Install tracer tape over copper and non-metallic water lines, including service lines.  Place the tracer tape approximately 1 foot (0.3 m) above the top of the line and extend the tape for the line’s full length.  Use tracer tape that is a detectable type and is marked “WATER.”

K.     Blocking and Wedging.  Lay fire hydrants, valves, and fittings on hardwood blocks and hold them in position by hardwood wedges.  Bed blocks firmly in the bottom of the trench with uniform bearing and with the long dimension of the block perpendicular to the pipe barrel.  Ensure that the blocks are level across the trench and that the proper number of blocks are placed one upon the other to bring the fittings to the required grade for jointing.

L.      Thrust Blocking.  Furnish plugs, caps, tees, hydrants, and elbows or bends having a deflection of 11 1/4 degrees or greater with concrete thrust blocking, unless suitably restrained joints are provided.  Construct the thrust blocking by placing concrete Class QC - Misc between firm original undisturbed earth and the fitting to be anchored.  Place and shape the thrust blocking in a manner satisfactory to the Engineer with the thrust force contained by the blocking.  Place the hardwood blocks between the plugs, caps, and hydrants, and the thrust blocking.  Place the thrust blocking so that it allows for pipe and joint accessibility or repair.

M.     Restrained Joints and Fittings.  Where conditions at an elbow, tee, or bulkhead are not conducive to the use of thrust blocking, restrain push-on or mechanical joints and fittings by bent or straight tie-rods, straps, clamps, or other devices, with required hardware.  Protect the devices against corrosion by the application of an asphalt coating.  Restrain mechanical joints by a wedge action type joint restraint with twist-off nuts.  If polyethylene encasement is specified, ensure that the encasement covers the entire assembly.  The Contractor may use restraining devices instead of thrust blocking when approved by the Engineer.

638.07  Pipe Joints.  Furnish ductile iron pipe and cast iron or ductile iron fittings with push-on joints, mechanical joints, boltless-restrained joints, or ball-and-socket joints.  Furnish joints with all accessories and install them according to the manufacturer’s recommendations.  During any construction where the outside temperature is below 40 °F (4 °C), keep rubber gaskets and lubricants in a heated area to at least 40 °F (4 °C) until used.  Maintain gaskets in a flexible condition until placed in the bell or on the spigot of the pipe.

638.08  Backfilling.  Complete backfill from the pipe grade to the finished grade, or to the subgrade surface in paved areas.  Furnish and compact backfill material for water mains and appurtenances under pavements in the same manner as for 611 non-plastic Type B conduits.  Furnish and compact backfill material for water mains and appurtenances not under pavements in the same manner as for 611 non-plastic Type C conduits.

If hydrostatic testing is performed before the backfilling operation is completed, complete the portion of the backfill from pipe grade to the centerline of the pipe, fittings, or appurtenances and place sufficient backfill material over the pipe barrel between joints to prevent movement.

Place sand cushions at least 12 inches (0.3 m) thick between the pipe and existing pipelines or other conduits when encountered during construction and as directed by the Engineer.

Immediately after completion of the backfilling, restore the site according to Item 611.

638.09  Hydrostatic Tests.  Apply a hydrostatic test to the whole system or to all individual valved-off sections of the mains where work has been performed.  Perform the hydrostatic tests according to of AWWA, except make the test pressure greater than 150 pounds per square inch (1000 kPa).  Ensure that the quantity of water lost from the main does not exceed the number of gallons (liters) per hour as determined by in AWWA or by the following formula:

where:

                          L =  allowable leakage, in gallons (L) per hour

                          N =  number of joints in the length of pipe tested.

                          D =  nominal diameter of the pipe, in inches (mm)

                          P =  average test pressure during the leakage test, in pounds per square inch (kPa)

638.10  Disinfection of Completed Water Work.  After passing the hydrostatic testing, disinfect the completed water work according to AWWA.

Make all necessary taps and furnish all equipment and labor required for the disinfections.  Obtain the Engineer’s approval of the time and the section of line to be disinfected.

638.11  Steel Pipe Encasement.  Furnish and install a steel casing of the diameter and wall thickness shown in the plans.

Make any necessary excavation to install the steel casing.  Obtain the Engineer’s approval for the method of any boring or jacking operation.  If placing the steel casing in an open cut trench, place it according to 638.05 and 638.08.

Join the casing pipe together with a full-circumference weld conforming to 513.21.

Ensure that the inside diameter of the casing allows the water main to be removed without disturbing the casing or roadbed.  Ensure that the inside diameter of the casing is at least 2 inches (50 mm) greater than the largest outside diameter of the water main joints or couplings for carrier pipe that is less than 6 inches (150 mm).  Ensure that the inside diameter is at least 4 inches (100 mm) greater than the largest outside diameter for carrier pipe 6 inches (150 mm) in diameter and over.

Install the main in the casing on hardwood blocking or stainless steel chocks designed to remain fixed in position.  The Contractor may install polyvinyl chloride water main using casing insulators.  Close both ends of the casing with mortared 4-inch (100 mm) bricks or a concrete bulkhead.

638.12  Polyethylene Encasement.  Lay ductile iron pipe with a polyethylene encasement as shown on the plans.  Install pipe and polyethylene encasement according to ANSI/AWWA.  Any increased girth of wrapping over valves, tees, and any other irregular shaped items are included in this item without any additional payment.

638.13  Valves and Equipment.  Upon delivery at the work site, open valves to prevent the collection of water in the valve.  Clean the interiors of valves of all foreign matter, and inspect them in both the open and closed position before installation.

Set valves plumb and joint them to the pipe according to 638.07 and the ANSI/AWWA standards for the joint type used.

Install valve boxes on all buried valves.  Center the valve box and set it in a vertical position directly over the valve nut in such a manner that the box does not transmit shock or stress to the valve.  Set the base of the valve box first, and support it with a minimum backfill, hardwood blocks, or a Styrofoam collar at least 2 inches (50 mm) in thickness.  Do not allow the base to rest directly on the valve or main.  Use valve boxes that are two or three piece boxes with covers.  When necessary, furnish extension sections.  Carefully tamp backfill around the valve box to a distance of 3 feet (1 m) on all sides or to the undisturbed face of the trench if closer.  Set the valve box cover flush with the ground line or finished paved surface.

Installation methods for valves and equipment include the following.

A.      Gate Valve and Valve Box.  Install gate valves directly in new mains or by means of a cutting-in sleeve in existing mains where maintenance of a continuous supply of water is not mandatory.  Where it is mandatory not to interrupt the water supply, the Contractor may provide a branch to an existing main with a gate valve installed by means of a tapping sleeve.

B.      Inserting Valve and Valve Box.  Install inserting valves in existing water mains where it is mandatory not to interrupt the water supply.

Assemble the sleeve around the existing main through which water is flowing under pressure.  Bolt the equipment to the sleeve, drill a hole through the existing main walls, and insert the valve, according to the manufacturer’s recommendations.

C.      Cutting-In Sleeve, Valve, and Valve Box.  Use cutting-in sleeves to install a gate valve in an existing main, without breaking pipe joints, where it is permissible to interrupt the flow for a short period of time.  Install the valve by cutting an exact length of pipe from the existing main according to the manufacturer’s recommendation.

Assemble the cutting-in sleeve, its glands and gaskets, and the cutting-in valve over the cut ends of the existing pipe according to the manufacturer’s recommendations.

D.      Tapping Sleeve, Valve, and Valve Box.  Where it is mandatory not to interrupt the water supply in an existing main and the branch is 4-inch (100 mm) or larger provide tapping sleeves.

Bolt the tapping sleeve around the existing main, assemble the tapping valve, and drill a hole through the main wall, according to the manufacturer’s recommendations.

E.      Tapping Saddle and Corporation Stop.  Use corporation stops to provide individual service connections to mains.  Ensure that the stops permit a shut-off of the service flow.  Either assemble the stops directly to mains by means of a tap tool providing a tapped hole, or use a tapping saddle.  Fasten the saddle around the main and drill a hole into the main by an attached drilling machine, then remove the machine and screw the stop into the saddle.  Do not use corporation stops larger than 2 inches (51 mm) in size and locate them approximately 60 degrees from the top of the main.

F.      Service Stop and Service Box.  Install service stops in service lines to allow the shutting-off of individual services.  Locate the stop beyond the pavement and provide it with a service box centered vertically over the stop operating nut such that the box provides maximum protection for the stop.

When 2-inch (51 mm) service stops are used, provide service boxes with an enlarged base.  When necessary, provide extension sections for the service box to bring the box cover to finished grade.

G.     Meter, Setting, Stop, and Chamber.  This pay item is for meters that are to be installed in frost-proof chambers.  Set the chamber on hardwood blocks.  The maintaining agency shall furnish meters unless otherwise indicated by the plans.  Do not transmit shock or stress to the meter body.

638.14  Fire Hydrant.  The item includes excavation and furnishing and installing a new fire hydrant complete with proper jointing, blocking, and backfilling as outlined below and all other incidental work necessary to complete this item of work.  The Department will pay for all hydrant branches, gate valves, and valve boxes required to perform the work separately.

A.      Excavation and Drainage Pits.  Excavate according to 638.04.  Excavate a drainage pit 2 feet (0.6 m) in diameter and 3 feet (1 m) deep below the hydrant and fill it with granular material.

B.      Setting Fire Hydrants.  Provide a 3-foot (1 m) minimum radius unobstructed area around all hydrants.  Set the sidewalk flange 2 inches (50 mm) above finished grade.  Set hydrants on hardwood blocks according to 638.06.K.  Provide thrust blocking according to 638.06.L.

Cover any hydrant not in service with a burlap or sturdy opaque plastic bag.

C.      Fire Hydrant Connections.  Construct hydrant branches using a section of ductile iron pipe from the main to the hydrant, and include a gate valve and valve box set vertically and placed in the line as indicated.  Locate the valve a minimum of 3 feet (1 m) from the hydrant streamer connection.

D.      Gate Valve and Valve Box.  Provide gate valve and valve boxes for hydrant branches conforming to 638.13.

638.15  Fire Hydrant Adjusted.  This item includes installing fire hydrants as described below complete with proper jointing, blocking, backfilling as outlined and all other incidental work necessary to complete this item of work.  The Department will pay for all hydrant branches, gate valves, and valve boxes required to perform the work separately.

A.      Fire Hydrant Extended or Adjusted to Grade.  Where existing hydrants are to be adjusted to conform to new street alignment and grade, relocate the hydrant without disturbing the location of the hydrant lateral tee at the main.

Before excavating, close valves on hydrant branches to be cut.  Where the distance of the center of the existing hydrant to the center of the gate valve on the hydrant branch is less than 4 feet (1.2 m), extend the trench to the hydrant branch valve to permit removal of the pipe.  Adequately support the hydrant before being disconnected.  Extend the hydrant branch with new pipe of the same size as the existing pipe.  Thoroughly clean the removed hydrant of dirt, reset it, and connect it to the extended branch.  Provide drainage pits and thrust blocking according to 638.14.A, and 638.06.L.

After hydrants have been reset, open branch and hydrant valves until water flow expels all air and dirt.

B.      Fire Hydrant Removed and Reset.  Where existing hydrants are indicated for removal, provide adequate support for the hydrant before disconnecting it and resetting it in the new location.  Cap the existing branch line, and install adequate thrust blocking to brace the cap according to 638.06.L, unless the line is to be abandoned.  Construct a new main tee, a new pipe branch, a new gate valve with valve box, with thrust blocking, and a drainage pit for the reset hydrant items.  Adjust the valve box to the finished surface at the new location by raising or lowering the top portion and furnishing an extension section if needed.

C.      Fire Hydrant and Gate Valve Removed and Reset.  Conform to 638.15.B, except remove and reinstall the gate valve and valve box.  Furnish a new tee and new pipe branch using the existing valve and box.

D.      Fire Hydrant Removed and Disposed Of.  Remove and dispose of fire hydrants designated for removal.  Cap the existing line and place thrust blocking according to 638.06.L, unless the line is to be abandoned.

638.16  Service Branches.  Furnish and install service branches, either pipe or tubing and fittings, as necessary, or as shown on the plans including the removal of the existing service branches or service boxes, as required according to the following situations.  Tapping saddles, corporation stops, service stops, and service boxes, if required, are separate from this item:

A.      Where a service branch is disturbed for lowering, raising, or relocation between the water main at the corporation stop and the service stop, replace it with new materials within these limits unless the connections can be made outside the limits of the proposed pavement, paved shoulder, or curb.

B.      Where a service branch is disturbed for lowering, raising, extending, or shortening on the property side of the service stop, replace it with new materials from the existing service stop to the proposed service stop.  However, if the existing service branch encountered is found to be lead or galvanized pipe, replace it from the corporation stop to the service stop with new material.

638.17  Meter and Chamber Removed and Reset.  Remove and reset existing water meters and chambers as specified in 638.13.G.  Remove existing chambers.  Disconnect existing meters, and replace them with suitable connections if necessary.  Reconnect the meters at new locations.

638.18  Valve Box and Service Box Adjusted to Grade.  Raise or lower existing valve boxes and service boxes to grade or the reuse of existing service boxes.

The Contractor may reuse existing service boxes if they are in good condition, as determined by the Engineer then payment is per service box adjusted to grade.

Excavate around the valve box or service box to permit the raising or lowering of the valve box or service box.  The Contractor may adjust any screw-type boxes without the use of extensions provided that ample thread remains on the box to provide adequate rigidity to the box.  Provide extension sections for boxes that are not of the screw-type and boxes not having ample thread for rigidity to adjust the top to grade.  The Engineer will allow inserts or adapters.  Adequately secure new sections of box stem to the existing stems.  Backfill the hole after the box has been adjusted to grade.

638.19  Method of Measurement.  The Department will measure Water Main, Ductile Iron Pipe and Water Main, Polyvinyl Chloride Pipe and Fittings by the number of feet (meters) of each constructed.

The Department will measure Copper Service Branch, Polyethylene Service Branch, and Polybutylene Service Branch by the number of feet (meters) of each constructed.

The Department will measure Polyethylene Encasement by the number of feet (meters) of covered pipe.

The Department will measure Steel Pipe Encasement by the number of feet (meters) constructed, including the open cut or boring or jacking operation, encasement pipe, bedding and backfill, blocking to support the internal main, and end bulkheads.

The Department will measure Gate Valve and Valve Box; Inserting Valve and Valve Box; Cutting-In Sleeve, Valve and Valve Box; Tapping Sleeve, Valve and Valve Box; and Meter, Setting, Stop and Chamber separately as a complete item by the number of each.

The Department will measure Fire Hydrant, Fire Hydrant Extended and Adjusted to Grade, Fire Hydrant Adjusted to Grade, Fire Hydrant Removed and Reset, Fire Hydrant and Gate Valve Removed and Reset, and Fire Hydrant Removed and Disposed Of separately by the number of each.

The Department will measure Valve Box Adjusted to Grade and Service Box Adjusted to Grade separately by the number of each, including any extension sections of valve or service boxes required.

The Department will measure Meter and Chamber Removed and Reset by the number of each.

The Department will measure Sheeting and Bracing Ordered Left In Place in thousands of board feet, MBF (cubic meters).

638.20  Basis of Payment.  The Department will pay for accepted quantities at the contract unit prices as follows:

Item           Unit                                Description

638             Foot (Meter)                    ___ inch (___ mm) Water Main,
                                                               Ductile Iron Pipe, ANSI Class___,
                                                                (push-on, mechanical, boltless- restrained,
                                                               ball-and-socket) Joints and Fittings

638             Foot (Meter)                    ___ inch (___ mm) Water Main,

                                                               Polyvinyl Chloride Pipe and Fittings,
                                                               ASTM SAR ___ or AWWA Class ___

638             Foot (Meter)                    ___ inch (___ mm) Copper Service Branch

638             Foot (Meter)                    ___ inch (___ mm)

                                                               Polyethylene Service Branch

638             Foot (Meter)                    ___ inch (___ mm)
                                                               Polybutylene Service Branch

638             Foot (Meter)                    Polyethylene Encasement
638             Foot (Meter)                    ___ inch (___ mm) Steel Pipe Encasement,
                                                                (open cut, bored or jacked)

638             Each                                ___ inch (___ mm) Gate Valve and Valve Box

638             Each                                ___ inch (mm) Inserting Valve and Valve Box

638             Each                                ___ inch (mm) Cutting-In Sleeve,
                                                               Valve and Valve Box

638             Each                                ___ inch ´ ___ inch (___ mm ´ ___ mm)
                                                               Tapping Sleeve, Valve and Valve Box

638             Each                                Meter, Setting, Stop and Chamber

638             Each                                ___ inch (___ mm) Fire Hydrant

638             Each                                Fire Hydrant Extended and
                                                               Adjusted to Grade

638             Each                                Fire Hydrant Adjusted to Grade

638             Each                                Fire Hydrant Removed and Reset

638             Each                                Fire Hydrant and Gate Valve
                                                               Removed and Reset

638             Each                                Fire Hydrant Removed and Disposed Of

638             Each                                Valve Box Adjusted to Grade

638             Each                                Service Box Adjusted to Grade

638             Each                                Meter and Chamber Removed and Reset

638             MBF                               Sheeting and Bracing
                       (Cubic Meter)                  Ordered Left In Place

640  PAVEMENT MARKING

ITEM 641  PAVEMENT MARKING—GENERAL

641.01  Description

641.02  Materials

641.03  General

641.04  Equipment

641.05  Pavement Preparation

641.06  Layout and Premarking

641.07  Line Placement Tolerance

641.08  Marking Types

641.09  Two-Way Radio Communications

641.10  Removal of Pavement Markings

641.11  Deduction for Deficiency

641.12  Method of Measurement

641.13  Basis of Payment

641.01  Description.  This specification gives general requirements for various kinds of retroreflective pavement markings.  Deviations from these general requirements are covered in the specific requirements for each marking type.

Place all pavement markings according to the OMUTCD.

641.02  Materials.  Use marking materials that are a formulation, identified by a manufacturer’s code number, prequalified by the Laboratory and that have the same composition as the prequalified marking material.

Minimum material performance requirements and chemical and physical properties are stated in Item 740 and the Invitation for Samples for the service test performed according to Supplement 1047.

Any materials delivered without a TE-24 and applied without laboratory approval shall be removed. Laboratory tested materials not meeting specifications shall be removed from the project site.

Furnish a material safety data sheet (MSDS) for each material, including resin, catalyst, primer, adhesive, activator, glass beads, and cleaning solvent, to be used on the project to the Engineer before material delivery.  Inform workers of the location of all MSDS and allow workers an opportunity to review them.

Furnish the Engineer, prior to application, the paint manufacturer's printed application equipment requirements and application instructions.

641.03  General.  Apply lines as solid, broken, or dotted lines, either singly or in combination, as shown on the plans.  Apply broken lines in a 40-foot (12.0 m) cycle consisting of a 10-foot (3.0 m) dash and a 30-foot (9.0 m) gap between broken lines, unless otherwise shown on the plans.  Use an accurate striping mechanism that is capable of being easily adjusted to retrace existing broken markings or to apply new materials at the correct spacing.  Begin broken lines that are to be applied over plainly visible existing broken lines within 6 inches (150 mm) of the beginning of the existing broken line, unless otherwise directed by the Engineer.  Apply dotted lines in an 8-foot (2.4 m) cycle consisting of a 2-foot (0.6 m) dot and a 6-foot (1.8 m) gap between dots for line extensions and in a 12-foot (3.6 m) cycle consisting of a 3-foot (0.9 m) line segment and a 9-foot (2.7 m) gap for lane drop/add markings.

Fill gaps that were not marked as a result of template use for spray-applied auxiliary markings with marking material after the template is removed.  If applying extruded thermoplastic, the Contractor may leave small gaps in arrows or letters resulting from template use unfilled.

Ensure that pavement markings are free of uneven edges, overspray, or other readily visible defects that detract from the appearance or function of the pavement markings.

Ensure that lines are sharp, well defined, and uniformly retroreflective. Apply the lines to the width specified ±1/4 inch (6 mm). Fuzzy lines, excessive overspray, or non-uniform application are unacceptable. The Engineer will inspect lines at night to verify proper retroreflectivity. Correct pavement markings that are improperly applied, located, or reflectorized. Reapply lines applied with insufficient material quantities according to 641.11, 644.04 or 648.05. Remove improperly located lines according to 641.10, and apply new lines in the correct locations.

Reapply any lines applied with non-specification materials.

Obtain the Engineer’s approval for methods and equipment used for pavement preparation, marking, and marking removal.  Keep glass beads dry during storage and before use.

Furnish to the Engineer at least 3 days in advance of installation current copies of the manufacturer’s instructions and recommendations for application of any marking material, including primer, activator, catalyst, and adhesive, shown on the plans.  Schedule and perform other construction work, such as shoulder paving, seeding, and mulching in a manner to avoid damage to applied pavement markings.

Do not apply pavement marking materials to the reflector of a plowable raised pavement marker.  Interrupt the application of the pavement marking line at each raised pavement marker where marking material would otherwise be applied to the marker’s prismatic reflector.  Provide a maximum gap in the marked line of 18 inches (0.5 m) at each marker.  Remove pavement marking material applied to a prismatic reflector surface, or replace the reflector that same workday.  If material must be removed from the reflector, restore the reflector’s brightness to its prior condition.

641.04  Equipment.  Equip long line pavement marking equipment for traffic paint, polyester, epoxy and work zone marking Item 642 with a computerized Data Logging System (DLS), including a cab mounted display which shows the actual material application rate and film thickness.  For center line, lane line and edge line markings, when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent, document the following with the DLS:

1.    Measure and record application vehicle speed to nearest 0.1 MPH (0.16 km/h),

2.   Measure and record weight and/or volume amount of material used by color,

3.   Measure and record weight of glass beads,

4.   Measure and record pavement surface temperature,

5.   Measure and record air temperature,

6.   Measure and record dew point,

7.   Measure and record humidity,

8.   Calculate and record average material application rate and film thickness over the section painted.

Record as a separate DLS report line entry the above information for each route section painted, when the length of center line, lane line and edge line marking exceeds 0.5 miles (0.8 km) of continuous line equivalent. A route section is defined as one direction of a contiguous section of highway (without breaks) with the same route number designation.  DLS documentation is not required for center line, lane line and edge line markings of 0.5 miles (0.8 km) or less, and for channelizing lines of any length.

If the DLS equipment fails, finish that day’s work only and resume when the DLS equipment is working.

The Department will provide a standard DLS spreadsheet, which prescribes the correct DLS report format and content prior to beginning of work.

On the first working day following application of markings requiring documentation with the DLS or upon demand, furnish the Engineer a copy of the DLS report in ODOT standard DLS report format.  The DLS report can be provided in one of the following methods, which should be agreed upon at the preconstruction meeting:

1.  hand delivery of paper report

2.  fax delivery of paper report

3.  e-mail of Excel spreadsheet file

4.  disk or flash drive transfer of Excel spreadsheet file

Within two weeks of the date of application of markings requiring documentation with the DLS, furnish the Engineer the Excel spreadsheet file of the DLS report in ODOT standard DLS report format by e-mail at the e-mail address provided at the preconstruction meeting.

At the end of the project, furnish the Engineer all Excel spreadsheet files in ODOT standard DLS report format.

Each DLS shall have an annual calibration of all mechanical and electrical components and its software function and output confirmed by the DLS manufacturer or their designated representative. Evidence of the annual calibration shall be carried by a signed and dated stamp or seal affixed to the inside of the driver’s door of each striper.

641.05  Pavement Preparation.  Clean all visible loose or foreign material from the surface to be marked.  Equip the pavement marking equipment with an air jet to remove all debris from the pavement in advance of the applicator gun.  Operate the air jet when marking material is being applied, and synchronize it with marking material application.  Power-broom clean all surfaces where gore markings or edge lines are to be applied.  If required by the Engineer, also power-broom clean other surfaces.  Do not apply marking to portland cement concrete until the concrete in the areas to be marked is clean of membrane curing material and is dry.

641.06  Layout and Premarking.  Lay out the locations of all lines, words, and other symbols to ensure their proper placement.  Do not start marking operations until the Engineer or the Engineer’s representative has approved the layout and premarking lines  If applying longitudinal or transverse lines, use existing lines, construction joints, or premarking to guide this marking equipment.

On projects where resurfacing or other operations will result in obliteration of the existing pavement markings, establish reference points to ensure proper placement of restored markings.  If existing markings are to be retraced, verify any adjustment in the location with the Engineer.

Establish “T” marking of no-passing zones according to the plans or a no-passing zone log provided by the Engineer.

Locate premarking from survey data or reference points, and offset it so as to parallel the theoretical edge of the marking lines at a maximum distance of 1 inch (25 mm).  Use templates for the layout of arrows, words, and other symbols.  Place premarking for longitudinal lines at 40-foot (12 m) intervals, and do not exceed 2 inches (50 mm) in width or 12 inches (300 mm) in length.  Locate premarking for auxiliary markings from the plans or schematic forms provided by the Engineer.

641.07  Line Placement Tolerance.  Ensure that pavement marking lines are straight or smoothly curved, true to the alignment of the pavement, and do not deviate laterally from the proper location at a rate of more than 2 inches in 100 feet (50 mm in 30 m).  The Engineer will not allow any deviation greater than 3 inches (75 mm).  Remove improperly located lines according to 641.10 and apply new lines in the correct locations.

641.08  Marking Types.   Apply marking materials at the rate or thickness specified in 642.04, 643.04, 644.04, 645.03, 646.05, 647.04, or 648.05 and, except for parking lot stall markings, ensure that they are uniformly retroreflective. Ensure that portions of parking stalls that are adjacent to street traffic are retroreflective. Pavement markings consist of the following types:

A.      Edge Lines.   Place edge lines as continuous stripes using the width specified.  Locate the center of the stripe 6 inches (150 mm) from the edge of the pavement.

B.      Lane Lines.   Place lane lines using the width specified, as white stripes between contiguous lanes of pavement carrying traffic in the same direction.  Place them as broken lines unless specified solid.  Offset lane lines to the left of the longitudinal joint, if present, or the theoretical line lying between contiguous lanes, if a joint is not present.  Ensure that the nearer edge of the stripe is 2 inches (50 mm) to the left of the joint or line.  Do not place lane lines through intersections.

C.      Center Lines.  Place center lines as single or double yellow stripes between contiguous lanes of pavement carrying traffic in opposite directions.  Center line marking includes two-way left-turn lane striping and the outline of left-turn islands.  Make each stripe 4 inches (100 mm) wide, solid or broken as specified.

D.      Channelizing Lines.   Place channelizing lines as continuous white stripes, using the width specified.

E.      Stop and Crosswalk Lines.  Place stop lines as solid 24-inch (600 mm) wide white stripes.  Place crosswalk lines as solid 12-inch (300 mm) wide white stripes.

F.      Transverse/Diagonal Lines.  Place transverse/diagonal lines as solid 24-inch (600 mm) wide stripes, of the color specified, and at an angle to the direction of travel.

G.     Curb and Island Marking.  Prepare exposed surfaces and curbs and paved islands according to 641.05.  In addition, remove and dispose of all visible loose or foreign material, including vegetation, on and immediately contiguous to surfaces to be marked.

H.     Symbol Markings.  Place all railroad, school, bicycle and handicap symbol markings using white markings.  A railroad marking includes the 16-inch (400 mm) crossbuck, two 72-inch (1.8 m) “R”s, two 24-inch (600 mm) transverse lines, and a stop line.  A school marking includes the word “SCHOOL” and two 16-inch (400 mm) transverse lines.  A shared lane marking includes the bicycle symbol and two sharrows.

I.       Parking Lot Stall Marking.  Place parking lot stall marking lines as continuous 4-inch (100 mm) wide white stripes.

J.      Lane Arrows.  Place lane arrows using white markings.

K.     Words on Pavement.  Place words on pavement using white markings.

L.      Dotted Lines.  Place dotted lines using the width and color specified.

M.     Yield Lines.  Place yield lines as solid white 24-inch (600 mm) isosceles triangles pointing toward approaching traffic.

 The term long lines, when used in sections 642 through 648 includes edge lines, lane lines, center lines, and channelizing lines over 200 feet (60 m) long. The term auxiliary markings, when used in Items 642 through 648 includes channelizing lines 200 feet (60 m) or shorter, stop lines, yield lines, crosswalk lines, transverse lines, diagonal lines, curb markings, island markings, symbol markings, parking lot stall markings, lane arrows, and dotted lines.

641.09  Two-Way Radio Communications.  If two-way radio equipment is required, furnish and maintain radio equipment necessary for the voice communication between the striper and the inspector’s vehicle at all times during the pavement marking operation.  Use equipment capable of transmitting and receiving normal voice communications to at least 4 miles (6 km).

641.10  Removal of Pavement Markings.  If specified as a pay item, remove pavement markings as described in 614.11.G.    Take care during marking removal not to scar, discolor, or otherwise damage the pavement surface.  Do not overpaint or use other methods of covering markings instead of removal.

641.11  Deduction for Deficiency.   For traffic paint, polyester and epoxy, the Engineer will compute each day the amount of marking material (including all components) and glass beads applied for each route section on the DLS report for determining unsatisfactory sections.  The Department will reduce the contract price for each route section in direct proportion to the percent of deficiency of marking material or glass beads as specified in 642.04, 643.04 and 646.05, up to 20 percent for each material deficiency.  The Department will only use the greater deficiency of marking material or glass beads to compute the deduction.

If the deficiency of marking material or glass beads is 20 percent or more, the Department will consider the work unsatisfactory.  In addition, the Engineer will consider as unsatisfactory materials applied outside the temperature or application requirements in Items 642, 643 and 646 without written approval of the Engineer.  Replace pavement markings and glass beads in all sections determined to be unsatisfactory by retracing over the unsatisfactory markings at the full thickness specified in Items 642, 643 and 646.

641.12  Method of Measurement.  The Department will measure pavement markings complete in place in the units designated.  The Department will measure line quantities as the length of completed marking, including the gaps, intersections, and other sections of pavement not normally marked.  The Department will measure the removal of pavement markings using the same method of measurement as completed markings in the units designated.

641.13  Basis of Payment.  The Department will pay for accepted quantities of work performed under Items 642, 643, 644, 645, 646, 647 and 648.

The Department will not pay for costs associated with correcting improperly located lines, replacing reflectors coated with pavement marking material, or replacing unsatisfactory pavement markings.

The Department will not pay for lines placed using non-specification materials.

The Department will not pay for non-specification lines determined through field measurement.

The Department will pay for Two-Way Radio  Equipment at the lump sum bid price.

ITEM 642  TRAFFIC PAINT

642.01  Description

642.02  Materials

642.03  Equipment

642.04  Application

642.05  Basis of Payment

642.01  Description.  This work consists of furnishing and applying fast dry water-based traffic paint or fast dry water-based traffic paint for cold weather applications according to Item 641, 740.01, 740.02, 740.09, and the additional requirements specified below.

642.02  Materials.  Furnish materials  conforming to:

Traffic Paint............................................................. 740.02

Glass Beads, Type A............................................... 740.09

The Engineer may obtain random samples from the application equipment.  Furnish the manufacturer’s identification information for the sampled liquid materials.  The Department will test the quality assurance sample for conformance to the manufacturer’s production ranges.  Samples not meeting the manufacturer’s production ranges will require the Contactor to re-apply, at his expense, any markings using that sample.  All other untested batches will become not approved and will either require testing or re-application.

Do not apply paints that have exceeded the manufacturer’s shelf life.  Do not use glass beads that are wet.

642.03  Equipment.  Use equipment capable of applying the traffic paint as recommended by the manufacturer and applying glass beads at the time of line placement.  Furnish a calibrated measuring device acceptable to the Engineer to measure the traffic paint in the striper tanks.

Equip all striping equipment for center line, lane line and edge line markings with a computerized Data Logging System (DLS) conforming to 641.04 when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent.

Furnish written documentation to the Engineer for the equipment’s operational capabilities from the equipment manufacturer. 

642.04  Application.  Apply pavement markings only when the surface is clean and dry in accordance with the paint manufacturer’s written application instructions. 

If application is required when air and pavement temperatures are between 35 °F (2 °C) and 50 °F (10 °C)  obtain approval from the Engineer and apply only pre-qualified  Type 1A cold weather traffic paint materials.  Apply traffic paint according to the manufacturer’s recommendations and protect line from tracking.

Keep the paint thoroughly mixed during application.

Apply 20 mil (0.51 mm) thick traffic paint Type 1 at the following rates:

20 Mil Thickness

Line Width (inch)

4

6

8

12

24

Gallon per Mile of Line

Solid Line

22

33

44

66

132

Broken Line

5.5

8.25

11

16.5

33

Dotted Line

5.5

8.25

11

16.5

33

Areas, Symbols, Words

1.25 gallon per 100 square feet

0.51 mm Thickness

Line Width (mm)

100

150

200

300

600

Liter per Kilometer of Line

Solid Line

50

75

100

150

300

Broken Line

12.5

19

25

38

75

Dotted Line

12.5

19

25

38

75

Areas, Symbols, Words

0.51 L/m²

Apply 15 mil (0.38 mm) thick traffic paint Type 1A at the following rates:

15 Mil Thickness

Line Width (inch)

4

6

8

12

24

Gallon per Mile of Line

Solid Line

16

24

32

48

96

Broken Line

4

6

8

12

24

Dotted Line

4

6

8

12

24

Areas, Symbols, Words

0.94 gallon per 100 square feet

0.38 mm Thickness

Line Width (mm)

100

150

200

300

600

Liter per Kilometer of Line

Solid Line

37

56

74

111

222

Broken Line

9.3

14

18.6

28

56

Dotted Line

9.3

14

18.6

28

56

Areas, Symbols, Words

0.38 L/m²

Do not dilute the paint.  However, the Contractor may add spent traffic paint solvents, generated during performance of this work, to virgin traffic paint.  If adding spent solvents, add them in a maximum ratio of 1:50 of spent solvents to virgin paint.  Ensure that the maximum concentration of spent solvents in the striping equipment tanks is maximum 2 percent.  Add spent solvents during the loading of the striping equipment.

Apply glass beads to the wet paint so that the beads are embedded and retained in the paint and provide uniform retroreflectivity in the paint surface.  Apply glass beads at a minimum rate of 15 pounds per 100 square feet (7.3 kg per 10 m²) for Type 1 traffic paint.  Apply glass beads at a minimum rate of 8.0 pounds per 100 square feet (3.9 kg per 10 m²) for  Type 1A traffic paint. 

Ensure temperature of the paint at the discharge point is within the range recommended by paint manufacturer. 

Replace unsatisfactory markings according to 641.11.

Furnish the Engineer daily, biweekly and final DLS reports according to 641.04. 

Perform traffic control operations for all 642 pavement markings according to 614.12 and MT-99.20M, but provide for center line, edge line, lane line and channelizing line traffic control equipment according to MT-99.20M equipment requirements for center line, longer than 2 minute dry.

Payment for this work shall be included in the 642 price per mile for Center Line, Edge Line and Lane Line and the 642 price per foot for channelizing Line.

642.05  Basis of Payment.  The Department will pay for accepted quantities at the contract prices, or prices adjusted according to 641.11, measured according to 641.12, with the provisions specified in 641.13, and as follows:

Item           Unit                                Description

642             Mile (Kilometer)              Edge Line, ____ inch (_____ mm), Type ___

642             Mile (Kilometer)              Lane Line, ____ inch (_____ mm), Type __ 642    Mile (Kilometer)      Center Line, Type ___

642             Foot (Meter)                    Channelizing Line,  ____ inch (_____ mm), Type ___642     Foot (Meter)            Stop Line, Type ___

642             Foot (Meter)                    Yield Line, Type____

642             Foot (Meter)                    Crosswalk Line, Type ___

642             Foot (Meter)                    Transverse/Diagonal Line,   Type ____

642             Foot (Meter)                    Curb Marking, Type ___

642             Square Foot                     Island Marking, Type ___
                       (Square Meter)

642             Each                                Handicap Symbol Marking, Type ___

642             Each                                Railroad Symbol Marking, Type ___

642             Each                                School Symbol Marking, __ inch (___ mm),

                                                               Type ___

642             Each                                Bicycle Lane Symbol Marking, Type____

642             Each                                Shared Lane Marking, Type____

642             Foot (Meter)                    Parking Lot Stall Marking, Type ___

642             Each                                Lane Arrow, Type ___

642             Each                                Word on Pavement, ___ inch
                                                               (___ mm), Type ___

642             Foot (Meter)                    Dotted Line, ___ inch (___mm), Type ___

642             Foot or Square Foot        Removal of Pavement Marking
                       (Meter or Square            
                       Meter), or Each

642             Lump Sum                      Two-Way Radio Equipment

ITEM 643  POLYESTER PAVEMENT MARKING

643.01  Description

643.02  Materials

643.03  Equipment

643.04  Application

643.05  Basis of Payment

643.01  Description.  This work consists of furnishing and applying polyester pavement markings according to Item 641, 740.01, 740.03, 740.09, and the additional requirements specified below.

643.02  Materials.  Furnish materials  conforming to:

Polyester Pavement Marking................................... 740.03

Glass Beads, Type B............................................... 740.09

The Engineer may obtain random samples from the application equipment.  Furnish the manufacturer’s identification information for the sampled liquid materials.  The Department will test the quality assurance sample for conformance to the manufacturer’s production ranges.  Samples not meeting the manufacturer’s production ranges will require the Contractor to re-apply, at his expense, any markings using that sample.  All other untested batches will become not approved materials and will either require testing or re-application.

Do not apply material that have exceeded the manufacturer’s shelf life.  Do not use glass beads that are wet.

643.03  Equipment.  Use application equipment capable of mixing the polyester components in proportions recommended by the manufacturer and applying glass beads at the time of marking placement.  Use equipment (striper) capable of applying polyester long-lines at the thickness specified for solid and broken lines while moving on the highway at a speed of not less than 7 miles per hour (11 km/h).  Furnish a calibrated measuring device acceptable to the Engineer to measure the polyester resin in the striper tanks.

Equip all striping equipment for center line, lane line and edge line markings with a computerized Data Logging System (DLS) conforming to 641.04 when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent.  The DLS shall measure the polyester resin material component and glass beads only. Catalyst will be calculated as 2 percent of the resin used.

Furnish written documentation to the Engineer for the equipment’s operational capabilities from the equipment manufacturer. 

643.04  Application.  Apply polyester only when the pavement surface is clean and dry and the pavement and air temperature are above 50 °F (10 °C). 

If project safety requirements require marking application below 50°F (10°C), obtain approval from the Engineer and apply cold weather traffic paint, Type 1A, according to Item 642 instead of the polyester.

After sampling of resin is completed, transfer the entire contents of each material container to the striper tanks.  Ensure that the polyester is thoroughly mixed at all times during application.  Apply polyester (catalyst plus resin) uniformly to the pavement at the following rates:

15 Mil Thickness

Line Width (inch)

4

6

8

12

24

Gallon per Mile of Line

Solid Line

16

24

32

48

96

Broken Line

4

6

8

12

24

Dotted Line

4

6

8

12

24

Areas, Symbols, Words

0.94 gallon per 100 square feet

0.38 mm Thickness

Line Width (mm)

100

150

200

300

600

Liter per Kilometer of Line

Solid Line

37

56

74

111

222

Broken Line

9.3

14

18.6

28

56

Dotted Line

9.3

14

18.6

28

56

Areas, Symbols, Words

0.38 L/m²

Do not dilute the material.

Apply glass beads to the uncured polyester in sufficient quantity so that the beads completely fill the polyester film from the film-pavement interface to the top surface of the film to the extent that there are loose beads on the surface of the uncured line.  Apply glass beads at a minimum rate of 16.5 pounds per 100 square feet (8 kg per 10 m²) of polyester applied in a manner that provides uniformly retroreflective lines.

If the applied polyester becomes tacky and causes marking discoloration and darkening, cease marking application until the Engineer agrees that the problem is corrected.

If any marking is in a tracking condition 45 minutes after application, cease marking application until the Engineer agrees that the problem is corrected.

Do not apply polyester pavement markings to new asphalt concrete until at least 2 weeks after the pavement is placed.  Assure curing compound is removed from portland cement concrete pavements.

Replace unsatisfactory markings according to 641.11.

Furnish the Engineer daily, biweekly and final DLS reports according to 641.04.

643.05  Basis of Payment.  The Department will pay for accepted quantities at the contract prices, or prices adjusted according to 641.11, measured according to 641.12, with the provisions specified in 641.13, and as follows:

Item           Unit                                Description

643            Mile (Kilometer)           Edge Line, ____ inch (_____ mm),

643            Mile (Kilometer)           Lane Line, ____ inch (_____ mm),643          Mile (Kilometer)   Center Line

643            Foot (Meter)                 Channelizing Line, ____ inch (_____ mm),

643            Foot (Meter)                 Stop Line

643            Foot (Meter)                 Yield Line

643            Foot (Meter)                 Crosswalk Line

643            Foot (Meter)                 Transverse/Diagonal Line

643            Foot (Meter)                 Curb Marking

643            Square Foot                  Island Marking (Square Meter)

643            Each                               Handicap Symbol Marking

643            Each                               Railroad Symbol Marking

643            Each                               School Symbol Marking, ___ inch (___ mm)

643            Each                               Bicycle Lane Symbol Marking

643            Each                               Shared Lane Marking

643            Foot (Meter)                 Parking Lot Stall Marking

643            Each                               Lane Arrow

643            Each                               Word on Pavement, ___ inch (___ mm)

643            Foot (Meter)                 Dotted Line, ___ inch (___ mm)

643            Foot or Square Foot      Removal of Pavement Marking
                       (Meter or Square
                       Meter), or Each

643            Lump Sum                    Two-Way Radio Equipment

ITEM 644  THERMOPLASTIC PAVEMENT MARKING

644.01  Description

644.02  Materials

644.03  Equipment

644.04  Application

644.05  Layout and Premarking

644.06  Basis of Payment

644.01  Description.  This work consists of furnishing and applying screed extruded thermoplastic pavement markings according to Item 641, 740.01, 740.04, 740.09, and the additional requirements specified below.

644.02  Materials.  Furnish materials  conforming to:

Thermoplastic pavement marking............................ 740.04

Glass beads, Type C................................................ 740.09

The Engineer may obtain random samples from the application equipment.  Furnish the manufacturer’s identification information for the sampled liquid materials.  The Department will test the quality assurance sample for conformance to the manufacturer’s production ranges.  Samples not meeting the manufacturer’s production ranges will require the Contractor to re-apply, at his expense, any markings using that sample.  All other untested batches will become not approved materials and will either require testing or re-application.

Do not apply material that has exceeded the manufacturer’s shelf life.  Do not use glass beads that are wet.

644.03  Equipment.  Equip all thermoplastic pavement marking trucks for center line, lane line and edge line markings with a computerized Data Logging System (DLS), including a cab mounted display which shows the actual bead application rate.  A DLS is not required for markings applied with hand carts.  For center line, lane line and edge line markings applied with truck-mounted equipment, when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent, document the following with the DLS:

1.      Measure and record application vehicle speed to the nearest 0.1 MPH (0.16 km/h).

2.      Measure and record pavement surface temperature.

3.      Measure and record air temperature.

4.      Measure and record thermoplastic temperature in the kettle and at the point of application.

Record as a separate DLS report line entry the above information for each route section painted, when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent. A route section is defined as one direction of a contiguous section of highway (without breaks) with the same route number designation.

If the DLS equipment fails, finish that day’s work only and resume when the DLS equipment is working.

The Department will provide a standard DLS spreadsheet, which prescribes the correct DLS report format and content prior to beginning of work.

Each DLS shall have an annual calibration of all mechanical and electrical components and its software function and output confirmed by the DLS manufacturer or their designated representative. Evidence of the annual calibration shall be carried by a signed and dated stamp or seal affixed to the inside of the driver’s door of each striper.

Use application equipment that includes a kettle for melting the thermoplastic and maintaining it at the proper temperature.  Equip the kettle with a thermostat to control the temperature of the melted thermoplastic and to prevent overheating.  Use equipment that continuously mixes and agitates the molten thermoplastic.  Ensure that the parts of the equipment that convey the thermoplastic from the kettle to the application point maintains it at the required temperature.

Attach an automatic bead dispenser to the equipment so that the beads are immediately and uniformly dispensed over the marking surface.  Equip the bead dispenser with an automatic cut-off control synchronized with the cut-off of the thermoplastic material.

Ensure that the applicator portion of the equipment has a shoe that rides on the pavement and extrudes the thermoplastic.  Ensure that the application equipment applies lines with a square end and can apply broken lines.  Furnish application equipment for applying extruded markings that consists of dies of varying widths to produce different widths of lines.  Do not use pans, aprons, or similar devices that the die overruns.

Use equipment that ensures uniformity in the thickness and width of lines.  Use equipment that forms lines 12 inches (300 mm) wide or less by one application pass, and lines wider than 12 inches (300 mm) by no more than two passes.  Do not allow individual passes to overlap or to be separated by a gap greater than 1/4 inch (6 mm).

644.04  Application.  If applying thermoplastic to pavements that are less than six months old, ensure that both the pavement surface and the ambient air temperature at the time of application are not less than 50 °F (10 °C) and rising.  However, if applying thermoplastic to pavements that are older than six months, ensure that both the pavement surface and the ambient air temperature at the time of application are not less than 70 °F (21 °C) and rising.  Ensure that the temperature of thermoplastic at the point of application is at least 400 °F (204 °C) and not more than 440 °F (227 °C). 

Apply thermoplastic at a thickness of 125 mils (3.2 mm).  Thermoplastic for small quantities or auxiliary markings up to 100 feet (30 m) in length can be exchanged as equal in function and price with 125 mil (3.2 mm) thick heat-fused preformed thermoplastic (Item 647).

Apply thermoplastic at the following rates:

125 Mil Thickness

Line Width (inch)

4

6

8

12

24

Pounds per Mile of Line

Solid Line

2340

3510

4680

7020

14040

Broken Line

585

878

1170

1755

3510

Dotted Line

585

878

1170

1755

3510

Areas, Symbols, Words

133 pounds per 100 square feet

3.2 mm Thickness

Line Width (mm)

100

150

200

300

600

Kilograms per Kilometer of Line

Solid Line

650

975

1300

1950

3900

Broken Line

165

245

325

490

975

Dotted Line

165

245

325

490

975

Areas, Symbols, Words

6.5 kg/m²

Mechanically apply glass beads to the wet thermoplastic surface so that the beads are embedded and retained and provide uniform retroreflectivity in the surface.  Do not place beads by hand, except to symbols and words, and to complete the ends of lines.  Apply beads at a minimum rate of 12 pounds per 100 square feet (6 kg per 10 m²) of thermoplastic surface area.  The Contractor may leave small gaps unfilled in symbols and letters resulting from template use.

If required, furnish primer, and apply it according to the manufacturer’s recommendations.  Use primer except on new asphalt pavement.

For each route section on the DLS report, the Engineer will compute the amount of thermoplastic marking material and glass beads applied.  The Department will reduce the contract price in direct proportion to the percent of deficiency of thermoplastic marking material or glass beads as specified in 644.04, up to 20 percent for each material deficiency.  The Department will only use the greater deficiency of marking material or glass beads to compute the deduction.

If the deficiency of thermoplastic marking material or glass beads is 20 percent or more, the Department will consider the work unsatisfactory.  In addition, the Engineer will consider as unsatisfactory materials applied outside the temperature or application requirements in 644.04 without written approval of the Engineer.  Replace thermoplastic markings and glass beads in all sections determined to be unsatisfactory by entirely removing the unsatisfactory thermoplastic material by grinding as per 641.10 and then reapplying at the full thickness specified in 644.04.  Do not apply a layer of sprayed thermoplastic to sections determined to be unsatisfactory to achieve the required thickness.

Furnish the Engineer daily, biweekly and final DLS reports conforming to 644.03, and additional reports indicating material type and quantities in pounds (kilograms) of thermoplastic materials used, according to 641.04.

644.05  Layout and Premarking.  In addition to the requirements specified in 641.06, only place auxiliary markings on new pavement.  The Contractor may place initial thermoplastic markings over work zone traffic paint markings.

644.06  Basis of Payment.  The Department will not pay for any thermoplastic lines that do not meet the required thickness.  The Department will pay for accepted quantities at the contract prices, or prices adjusted according to 644.04, measured according to 641.12, with the provisions specified in 641.13, and as follows:

Item           Unit                                Description

644             Mile (Kilometer)              Edge Line, ____ inch (_____ mm),

644             Mile (Kilometer)              Lane Line, ____ inch (_____ mm),

644             Mile (Kilometer)              Center Line

644             Mile (Kilometer)              Channelizing Line, ____ inch (_____ mm),644      Foot (Meter)            Stop Line

644             Foot (Meter)                    Yield Line

644             Foot (Meter)                    Crosswalk Line

644             Foot (Meter)                    Transverse/Diagonal Line

644             Each                                Handicap Symbol Marking

644             Each                                Railroad Symbol Marking, __ inch (__ mm)

644             Each                                School Symbol Marking, __ inch (__ mm)

644             Each                                Bicycle Lane Marking Symbol

644             Each                                Shared Lane Marking

644             Foot (Meter)                    Parking Lot Stall Marking

644             Each                                Lane Arrow

644             Each                                Word on Pavement, ___ inch (___ mm)

644             Foot (Meter)                    Dotted Line, ___ inch (___ mm)

644             Foot or Square Foot        Removal of Pavement Marking
                       (Meter or Square            
                       Meter), or Each

644             Lump Sum                      Two-Way Radio Equipment

ITEM 645  PREFORMED PAVEMENT MARKING

645.01  Description

645.02  Materials

645.03  Application

645.04  Layout and Premarking

645.05  Basis of Payment

645.01  Description.  This work consists of furnishing and applying preformed pavement marking material according to Item 641, 740.01, 740.05, 740.06, and the additional requirements specified below.

645.02  Materials.  Furnish materials  conforming to the following:

Type A (permanent markings),

.... Type A1, A2, or A3............................................ 740.05

Type B (work zone markings),

.... Type II (non-removable)..................................... 740.06

Type C (work zone markings),

.... Type I (removable).............................................. 740.06

Do not apply materials that has exceeded the manufacturer’s shelf life.

645.03  Application.  Only apply on clean dry pavement surfaces.  If there is oil, salt or dust; power wash the pavement and allow the pavement to dry.

Furnish the Engineer with the manufacturer’s application instructions.  Record the surface temperature and date of application.  Furnish documentation to the Engineer.  Apply preformed markings to the pavement by means of a precoated adhesive on the back, or by an adhesive or activator furnished with the markings and used according to the manufacturer’s recommendations.  Form lines 12 inches (300 mm) wide or less by one piece; form lines wider than 12 inches (300 mm) by no more than two pieces.  Do not overlap individual pieces.  Do not allow a gap greater than 1/4 inch (6 mm) between pieces.

Do not use preformed markings that are subject to premature adhesion or contamination before placement.

Apply preformed markings according to the appropriate type of application as follows:

A.      Type A Marking Application.  Apply the preformed markings while the pavement surface temperature is at the manufacturer’s application recommendations.  Before any application, test and record the pavement surface temperature, air temperature and dew point.  Retest and record every 4 hours of operation.  Demonstrate to the Engineer the testing devices are accurate and operational.  Initially position the marking under light pressure, or use a hand operated light roller or mechanical applicator.  Once correctly located, hold the marking in position without delay by rolling.

If Type A preformed markings are specified to be inlaid on newly placed asphalt concrete, press the markings into the warm surface using a mechanical roller.  Proper application of inlaid markings requires that the asphalt concrete pavement surface have a temperature below the maximum temperature recommended for the preformed material or its adhesive backing.

B.      Type B and Type C Marking Application.  Apply the preformed markings according to the manufacturer’s recommendations.

645.04  Layout and Premarking.  In addition to the requirements specified in 641.06, place preformed auxiliary markings only on new pavement.

645.05  Basis of Payment.  The Department will not pay for under thickness lines or non-specification materials. The Department will pay for accepted quantities at the contract prices, or prices adjusted according to 641.11, measured according to 641.12, with the provisions specified in 641.13, and as follows:

Item           Unit                                Description

645             Mile (Kilometer)              Edge Line, ____ inch (_____ mm), Type ___

645             Mile (Kilometer)              Lane Line, ____ inch (_____ mm), Type __

645             Mile (Kilometer)              Center Line, Type ___

645             Foot (Meter)                    Channelizing Line, ____ inch (_____ mm),                                                           Type ___

645             Foot (Meter)                    Stop Line, Type ___

645             Foot (Meter)                    Yield Line, Type____

645             Foot (Meter)                    Crosswalk Line, Type ___

645             Foot (Meter)                    Transverse/Diagonal Line, Type ____

645             Each                                Handicap Symbol Marking, Type ___

645             Each                                Railroad Symbol Marking, Type ___

645             Each                                School Symbol Marking, ___ inch (___ mm),

                                                               Type ___

645             Each                                Bicycle Lane Symbol Marking, Type____

645             Each                                Shared Lane Marking

645             Foot (Meter)                    Parking Lot Stall Marking, Type ___

645             Each                                Lane Arrow, Type ___

645             Each                                Word on Pavement, ___ inch

                                                               (___ mm), Type ___

645             Foot (Meter)                    Dotted Line, ___ inch (___ mm), Type ___

645             Foot, Square Foot           Removal of Pavement Marking

                       (Meter, Square               
                       Meter), or Each

645             Lump Sum                      Two-Way Radio Equipment

item 646  EPOXY PAVEMENT MARKING

646.01  Description

646.02  Materials

646.03  Equipment

646.04  Cleaning and Surface Preparation

646.05  Application

646.07  Basis of Payment

646.01  Description.  This work consists of furnishing and applying epoxy pavement markings according to Item 641, 740.01, 740.07, 740.09, and the additional requirements specified below.

Store and handle epoxy material according to all the applicable EPA and local environmental regulations and the manufacturer’s recommendations.

646.02  Materials.  Furnish materials  conforming to:

Epoxy pavement markings....................................... 740.07

Glass beads, Type D................................................ 740.09

The Engineer may obtain random samples from the application equipment. 

Furnish the manufacturer’s identification information for the sampled liquid materials.  The Department will test the quality assurance sample for conformance to the manufacturer’s production ranges.  Samples not meeting the manufacturer’s production ranges will require the Contractor to re-apply, at his expense, any markings using that sample.  All other untested batches will become not approved materials and will either require testing or re-application.

Do not apply material that has exceeded the manufacturer’s shelf life.  Do not use glass beads that are wet.

646.03  Equipment.

A.      General.  Equip all striping equipment for center line, lane line and edge line markings with a computerized Data Logging System (DLS) conforming to 641.04 when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent.

Furnish written documentation to the Engineer for the equipment’s operational capabilities from the equipment manufacturer. 

Use equipment to apply epoxy pavement markings that has the following capabilities and features:

1.      Capable of mixing the epoxy components in proportions recommended by the manufacturer and applying glass beads simultaneously with line placement.

2.      Capable of applying epoxy at the specified thickness, width, and pattern.

3.      Individual material reservoirs, or space, for the storage of Part A and Part B of the epoxy.

4.      Heating equipment of sufficient capacity to maintain the epoxy components at the manufacturer’s recommended temperature, and to produce the required amount of heat at the mixing head and gun tip and maintain those temperatures with the tolerances recommended by the epoxy manufacturer for the spray application.

5.      Adequate individual tanks for the storage and dispensing of Size I and Size II glass beads.

6.      Individual dispensers for the simultaneous application of Size I and Size II glass beads at specified rates.

7.      Individual metering devices on the proportioning pumps (one indicator per pump) and stroke counters to monitor gallon (liter) usage.  Ensure that these devices are clearly visible.

8.      All the necessary spray equipment mixers, compressors, and other appurtenances to allow for the placement of reflectorized pavement marking systems in a simultaneous sequence of operations.

9.      A minimum 24-inch (600 mm) long static mixer unit or an equivalent system that produces properly mixed material.

10.    A completely enclosed flush and purge system to clean the lines and the guns without expelling any of the solution into the environment.

B.      Long Line Equipment.  Furnish a striper to apply long line epoxy markings that is:

1.      Truck-mounted and self-contained.

2.      Designed to spray the epoxy and glass beads in continuous and skip line.

3.      Maneuverable to the extent that straight lines can be followed and normal curves can be made in a true arc.

C.      Auxiliary Marking Equipment.  Furnish application equipment for auxiliary markings by either of the following two methods:

1.      Equip the striper with accessories for applying auxiliary markings.

2.      Use a portable applicator approved by the Engineer.

D.      Documentation Requirements  Furnish the Engineer documentation from the manufacturer that the equipment meets all requirements of 646.03.  Demonstrate the equipment has the capability to obtain the manufacturer’s required temperature for the mixed components and the required temperature at the lines and gun.

646.04  Cleaning and Surface Preparation.

A.      General.  Before applying epoxy, clean and prepare the pavement surface in the following sequence:

1.      Remove all debris, oil, and any other contaminants that may hinder the adhesion of the epoxy to the pavement.

2.      Use a power-broom to clean the pavement.

3.      Remove residue and debris with blasts of compressed air.

4.      Follow any additional manufacturer’s recommendations for surface preparation.

Perform operations in such a manner that the finished pavement surface is not damaged or unnecessarily scarred or left in a pattern that will mislead or misdirect the motorist and that minimizes airborne dust.  Avoid damage to transverse and longitudinal joint sealers.

B.      Asphalt Concrete Pavements.  In addition to the requirements of 646.04.A, the following apply.

Wait 48 hours after the placement of polymer modified asphalt-concrete pavement before preparing it for epoxy pavement markings.

For any other type of modified asphalt or for open graded friction course asphalts, contact the manufacturer for surface preparation recommendations.  Furnish the Engineer copies of the manufacturer’s recommendations.

Lightly abrade any new asphalt concrete pavement containing SBS, SBR latex or SMA latex polymer modifiers without scarring the area between the broken lines to the manufacturer’s recommendations to remove polymer surface film to assure proper bonding.  In no case shall the removal of the polymer surface film be less than that required for the epoxy to properly bond and adhere.

C.      Portland Cement Concrete Pavements.  On new portland cement concrete pavements, do not begin cleaning operations until a minimum of 30 days after the placement of concrete, unless otherwise directed by the Engineer.  In addition to the requirements of 646.04.A, the following apply.

Remove all curing compound and laitance on the concrete surface and in any textured pavement valleys.

Round the profiles of the peaks of textured pavement and remove sharp edges and irregularities.

Acceptable removal methods are:

1.      Sand blasting with containment.

2.      Lightly abrading the surface without scarring the surrounding surface.  This must be demonstrated before the application and approved by the Engineer.

3.      Blast track cleaning.

4.      High-pressure water blasting (greater than 5000 psi [34 450 kPa]) with or without abrasives and with sufficient time to allow the pavement to dry before applying epoxy markings.

5.      Other methods approved by the Engineer.

Contain and dispose of all the removal debris.

D.      Removal of Existing Markings.  When placing epoxy markings in the same place as existing pavement markings, remove at least 95 percent of the existing pavement markings.  Use a removal method that results in little or no color and texture changes in the surrounding pavement.

E.      Preparation Area.

1.      Lines.  Prepare an area that is the width of the new pavement marking, or existing line, plus 1-inch (25 mm) on each side and the length of broken lines plus 12 inches (300 mm) on each end.

2.      Arrows, Letters, and Symbols.  When cleaning for letters and symbols, prepare an area that is sufficiently large to accommodate the new marking, or to remove the existing marking.

646.05  Application.  Apply epoxy only when the surface is clean and dry and when the pavement and air temperature are above 50 ºF (10 ºC).  Transfer the entire contents of each material container to the striper tanks.  Keep the epoxy thoroughly mixed at all times during application.  Before any application, test and record the pavement surface temperature, air temperature.  Retest and record every 4 hours of operation.  Demonstrate to the Engineer the testing devices including DLS are accurate and operational.

Apply epoxy uniformly to the surface to be marked at a rate specified below.  To achieve the rate, ensure that the thickness of the applied epoxy is 20 mils (0.51 mm).

20 Mil Thickness

Line Width (inch)

4

6

8

12

24

Gallon per Mile of Line

Solid Line

22

33

44

66

132

Broken Line

5.5

8.25

11

16.5

33

Dotted Line

5.5

8.25

11

16.5

33

Areas, Symbols, Words

1.25 gallon per 100 square feet

0.51 mm Thickness

Line Width (mm)

100

150

200

300

600

Liter per Kilometer of Line

Solid Line

50

75

100

150

300

Broken Line

12.5

19

25

38

75

Dotted Line

12.5

19

25

38

75

Areas, Symbols, Words

0.51 L/m²

Do not dilute the epoxy.

Apply enough glass beads to the uncured epoxy so that the beads completely fill the epoxy film from the film-pavement interface to the top surface of the film to the extent that there are loose beads on the surface of the uncured line.  Apply glass beads at a minimum rate of 31 pounds per 100 square feet (15 kg per 10 m²) of epoxy to achieve uniform retroreflectivity.  Drop glass beads onto the epoxy in a double-drop system with the large gradation (Size I) first and the regular gradation (Size II) second in the same pass of the equipment.  Apply the beads in equal amounts by weight.

Cease operations when any of the following conditions are observed:

A.      The marking does not consistently dry to a no-track condition.

B.      The marking has cyclical soft spots.

Resume marking operations when the Inspector is satisfied the problem is corrected.

Replace unsatisfactory markings according to 641.11.

Furnish the Engineer daily, biweekly and final DLS reports according to 641.04.

646.07  Basis of Payment.  The cost of cleaning and surface preparation according to 646.04 is included in the unit bid cost for the various pavement markings.

The Department will make payment for accepted quantities at the contract prices, or prices adjusted according to 641.11, measured according to 641.12, with the provisions specified in 641.13, and as follows:

Item           Unit                                Description

646             Mile (Kilometer)              Edge Line, ____ inch (_____ mm),

646             Mile (Kilometer)              Lane Line, ____ inch (_____ mm),

646             Mile                                 (Kilometer)              Center Line

646             Foot (Meter)                    Channelizing Line, ____ inch (_____ mm),

646             Foot (Meter)                    Stop Line

646             Foot (Meter)                    Yield Line

646             Foot (Meter)                    Crosswalk Line

646             Foot (Meter)                    Transverse/Diagonal Line

646             Foot (Meter)                    Curb Marking

646             Square Foot                     Island Marking
                       (Square Meter)

646             Each                                Handicap Symbol Marking

646             Each                                Railroad Symbol Marking

646             Each                                School Symbol Marking, ___ inch (___ mm)

646             Each                                Bicycle Lane Symbol Marking

646             Each                                Shared Lane Marking

646             Foot (Meter)                    Parking Lot Stall Marking

646             Each                                Lane Arrow

646             Each                                Word on Pavement, ___ inch (___ mm)

646             Foot                                 Dotted Line, ____ inch (_____ mm),646                Each, Foot, (Meter) Removal of Pavement Marking
                       Square Foot                    
                       (Square Meter)

646             Lump Sum                      Two-Way Radio Equipment

Item 647  HEAT-FUSED PREFORMED THERMOPLASTIC PAVEMENT MARKING

647.01  Description

647.02  Materials

647.03  Equipment

647.04  Application

647.05  Basis of Payment

647.01  Description.  This work consists of furnishing and applying heat-fused preformed thermoplastic for use as auxiliary pavement markings according to Item 641, 740.01, 740.08 and the additional requirements specified below.

647.02  Materials.  Furnish materials  conforming to:

Heat fused preformed thermoplastic

.... pavement marking material.................................. 740.08

647.03  Equipment.  Use manufacturer recommended equipment to apply the heat-fused preformed thermoplastic  pavement marking material according to the appropriate type, as follows:

A.      Type A90 or Type A125 Material.

1.      Propane torch to heat the pavement and material according to 647.04.B.

2.      Infrared thermometer to assure that both the pavement and the material are properly heated and do not exceed the manufacturer’s specified application temperature.

B.      Type B90 or Type B125 Material.

1.      Propane torch for ensuring no moisture is present on the pavement and heating the material according to 647.04.C.

2.      A thermometer is not required.

647.04  Application.

A.      General.  Apply the heat-fused preformed thermoplastic pavement marking material to clean, dry pavement surfaces according to the appropriate type unless otherwise directed by the manufacturer's recommendation.  Apply primer sealer on portland cement concrete pavements for proper adhesion only if the manufacturer requires its use.

Form lines 12 inches (300 mm) wide or less by one piece; form lines wider than 12 inches (300 mm) by no more than two pieces.  Do not overlap individual pieces.  Do not allow a gap greater than 1/4-inch (6 mm) between pieces.

B.      Type A90 and Type A125 Material Application on Asphalt Concrete and Portland Cement Concrete Pavements.  Uniformly pre-heat the pavement to 300 °F (149 °C) with a propane torch.  Place the material on the warm surface as soon as practical, then uniformly post-heat to 400 °F (204 °C).  Begin the post-heating process of material application as quickly as possible.  The Contractor may have to extend post-heating on concrete having a high moisture content.  Allow the material to cool naturally and solidify before exposing it to traffic.

Type A90 and A125 materials shall contain intermix beads throughout.  Drop-on glass beads are not required unless using a non-surface beaded marking (i.e., for turn or combination arrows).

C.      Type B90 and Type B125 Material Application on Asphalt Concrete and Portland Cement Concrete Pavements.  Heat the pavement only to ensure no moisture is present.   Place the material on the dry surface and then uniformly heat the material until it bubbles and  changes color to off-white.  Material must be able to be applied with no preheating of the   pavement to a specified temperature and without the use of a thermometer.  Allow the material to cool naturally and solidify before exposing it to traffic.

Type B90 and B125 material shall contain intermix glass beads throughout.  Drop-on glass  beads are not required unless using a non-surface beaded marking (i.e., for turn or combination arrows).

647.05  Basis of Payment.  The Department will pay for accepted quantities at the contract prices, or prices adjusted according to 641.11, measured according to 641.12, with the provisions specified in 641.13, and as follows:

Item           Unit                                Description

647             Foot (Meter)                    Channelizing Line, ____ inch (_____ mm),                                                            Type ___

647             Foot (Meter)                    Stop Line, Type ___

647             Foot (Meter)                    Yield Line, Type____

647             Foot (Meter)                    Crosswalk Line, Type ___

647             Foot (Meter)                    Transverse/Diagonal Line, Type ____

647             Each                                Handicap Symbol Marking, Type ___

647             Each                                Railroad Symbol Marking, Type ___

647             Each                                School Symbol Marking, ___ inch (___ mm),
                                                               Type ___

647             Each                                Bicycle Lane Symbol Marking, Type____

647             Each                                Shared Lane Marking

647             Foot (Meter)                    Parking Lot Stall Marking, Type ___

647             Each                                Lane Arrow, Type ___

647             Each                                Word on a Pavement,

                                                                ___  inch (___ mm), Type ___

647             Foot (Meter)                    Dotted Line, ___ inch (___ mm), Type ___

647             Each, Foot,                      Removal of Pavement Marking

                       Square Foot                    
                       (Meter,

                       Square Meter)

ITEM 648 SPRAY THERMOPLASTIC PAVEMENT MARKING

648.01 Description

648.02 Materials

648.03 Equipment 

648.04 Surface Preparation

648.05 Application

648.06 Basis of Payment

648.01 Description. This work consists of furnishing and applying spray thermoplastic pavement markings according to Item 641, 740.01, 740.09, 740.10, and the additional requirements specified below.

648.02 Materials. Furnish materials conforming to:

Spray Thermoplastic Pavement Marking.......................... 740.10

Glass beads, Type C ..........................................................740.09

The Engineer may obtain random samples from the application equipment. Furnish the manufacturer’s identification information for the sampled materials. The Department will test the quality assurance sample for conformance to the manufacturer’s production ranges. Samples not meeting the manufacturer’s production ranges will require the Contractor to re-apply, at his expense, any markings using that sample. All other untested batches will become not approved materials and will either require testing or re-application.

Do not apply material that has exceeded the manufacturer’s shelf life. Do not use glass beads that are wet.

648.03 Equipment. Equip all spray thermoplastic pavement marking trucks for center line, lane line and edge line markings with a computerized Data Logging System (DLS), including a cab mounted display which shows the actual bead application rate. For center line, lane line and edge line markings applied with truck-mounted equipment, when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent, document the following with the DLS:

1. Measure and record application vehicle speed to the nearest 0.1 mph (0.16 km/h).

2. Measure and record pavement surface temperature.

3. Measure and record air temperature.

4. Measure and record spray thermoplastic temperature in the kettle and at the point of application.

Record as a separate DLS report line entry the above information for each route section painted, when the length of marking exceeds 0.5 miles (0.8 km) of continuous line equivalent. A route section is defined as one direction of a contiguous section of highway (without breaks) with the same route number designation.

If the DLS equipment fails finish that day’s work only and resume when the DLS equipment is working.

The Department will provide a standard DLS spreadsheet, which prescribes the correct DLS report format and content prior to beginning of work.

Each DLS shall have an annual calibration of all mechanical and electrical components and its software function and output confirmed by the DLS manufacturer or their designated representative. Evidence of the annual calibration is shown by carrying a signed and dated stamp or seal affixed to the inside of the driver’s door of each striper.

Use application equipment that includes a kettle for melting the spray thermoplastic and maintaining it at the proper temperature. Equip the kettle with a thermostat to control the temperature of the melted spray thermoplastic and to prevent overheating. Use equipment that continuously mixes and agitates the molten spray thermoplastic. Ensure that the parts of the equipment that convey the spray thermoplastic from the kettle to the application point maintain it at the required temperature.

Attach an automatic bead dispenser to the equipment so that the beads are immediately and uniformly dispensed over the marking surface. Equip the bead dispenser with an automatic cut-off control synchronized with the cut-off of the spray thermoplastic material.

Ensure that the application equipment applies lines with a square end and can apply broken lines. Furnish application equipment for applying spray thermoplastic markings that produces different widths of lines.

Use equipment that ensures uniformity in the thickness and width of lines. Use equipment that forms lines 8 inches (200 mm) wide or less by one application pass.

648.04 Surface Preparation. Before applying spray thermoplastic the pavement surfaces must be clean, dust free, and completely dry. Test for moisture using the following test procedures, if needed as directed by the Engineer:

Moisture Test

1. Tape a 12 inch (300 mm) square sheet of thin plastic to the road surface, sealing all edges.

2. After 15 minutes examine the side of the sheet facing the road surface.

3. If more than a sparse amount of moisture is present, do not apply spray thermoplastic.

Apply spray thermoplastic to new pavement, over existing thermoplastic, or over one application of paint. Do not apply spray thermoplastic over epoxy, polyester, or preformed markings. Remove poorly adhering, flaking and loose markings and curing compounds. Use an air blast, or manual or mechanical broom to prepare surfaces. When more effort is needed to obtain a surface free from adhering, flaking and loose markings and curing compounds, use water blasting or mechanical removal.

648.05 Application. If applying spray thermoplastic to pavements that are less than six months old, ensure that both the pavement surface and the ambient air temperature at the time of application are not less than 50 °F (10 °C) and rising. However, if applying spray thermoplastic to pavements that are older than six months, ensure that both the pavement surface and the ambient air temperature at the time of application are not less than 70 °F (21 °C) and rising. . Ensure that the temperature of spray thermoplastic at the point of application is at least 375 °F (191 °C) and not more than 425 °F (218 °C).

Apply spray thermoplastic at a thickness of 45 mil (1.15 mm) at the following rates:

45Mil Thickness

Line width (inch)

4

6

8

12

Pounds per Mile of Line

Solid Line

762-886

1143-1329

1524-1772

2286-2658

Broken or Dotted Line

191-222

286-332

381-443

572-666

1.15 mm Thickness

Line Width (mm)

100

150

200

300

Kilogram per Kilometer of Line

Solid Line

209-242

313-364

417-485

626-728

Broken or Dotted Line

52-61

79-92

104-121

158-184

Mechanically apply glass beads to the wet spray thermoplastic surface so that the beads are embedded and retained and provide uniform retroreflectivity in the surface. Apply beads at a minimum rate of 10 pounds per 100 square feet (4.9 kg per 10 m²) of spray thermoplastic surface area.

Use primer when required by the manufacturer. Apply primer according to the manufacturer’s recommendations.

For each route section on the DLS report, the Engineer will compute the amount of spray thermoplastic marking material and glass beads applied. The Department will reduce the contract price in direct proportion to the percent of deficiency of spray thermoplastic marking material or glass beads as specified in 648.05, up to 20 percent for each material deficiency. The Department will only use the greater deficiency of marking material or glass beads to compute the deduction.

If the deficiency of spray thermoplastic marking material or glass beads is 20 percent or more, the Department will consider the work unsatisfactory. In addition, the Engineer will consider as unsatisfactory materials applied outside the temperature or application requirements in 648.05 without written approval of the Engineer. Replace spray thermoplastic markings and glass beads in all sections determined to be unsatisfactory by entirely removing the unsatisfactory spray thermoplastic material by grinding as per 641.10 and then reapplying at the full thickness specified in 648.05.

Furnish the Engineer daily, biweekly and final DLS reports conforming to 648.03, and additional reports indicating material type and quantities in pounds (kilograms) of spray thermoplastic materials used, as per 641.04.

648.06 Basis of Payment. The Department will not pay for any spray thermoplastic lines that do not meet the required thickness. The Department will pay for accepted quantities at the contract prices, or prices adjusted according to 648.05, measured according to 641.12, with the provisions specified in 641.13, and as follows:

Item           Unit                                Description

648             Mile (Kilometer)                 Edge Line, ____ inch (_____ mm),

648             Mile (Kilometer)                 Lane Line, ____ inch (_____ mm),

648             Mile (Kilometer)                 Center Line

648             Foot (Meter)                       Channelizing Line, ____ inch (_____ mm),

648             Foot (Meter)                       Dotted Line, ___ inch (___ mm)

648             Foot or Square Foot           Removal of Pavement Marking

                      (Meter or Square Meter),

                      or Each

648             Lump Sum                          Two-Way Radio Equipment 

650  ROADSIDES

ITEM 651  TOPSOIL STOCKPILED

651.01  Description

651.02  Construction Requirements

651.03  Method of Measurement

651.04  Basis of Payment

651.01  Description.  This work consists of stripping topsoil from areas shown on the plans or from within the Right-of-Way limits, transporting, and stockpiling topsoil at locations shown on the plans or at locations selected by the Contractor with project approval.

651.02  Construction Requirements.  Remove all heavy grass, weeds, or other vegetation over the areas before stripping.  Keep the topsoil separate from other excavated materials.  Remove topsoil before beginning the regular excavation or embankment work in the area.  Strip the topsoil to the depth shown on the plans or as directed by the Engineer.

651.03  Method of Measurement.  The Department will measure Topsoil Stockpiled by the number of cubic yards (cubic meters) completed and accepted, measured from the removal areas.

651.04  Basis of Payment.  The Department will not pay for any removal of topsoil beyond the directed depth.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

651             Cubic Yard                      Topsoil Stockpiled
                       (Cubic Meter)

ITEM 652  PLACING STOCKPILED TOPSOIL

652.01  Description

652.02  Construction Requirements

652.03  Method of Measurement

652.04  Basis of Payment

652.01  Description.  This work consists of hauling and spreading topsoil from stockpiles and preparing the surface.

652.02  Construction Requirements.  Prepare the surface according to 653.03.  Place and spread the topsoil according to 653.03.

652.03  Method of Measurement.  The Department will measure Placing Stockpiled Topsoil by the number of cubic yards (cubic meters) completed and accepted in place.

652.04  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

652             Cubic Yard                      Placing Stockpiled Topsoil
                       (Cubic Meter)

ITEM 653  TOPSOIL FURNISHED AND PLACED

653.01  Description

653.02  Materials

653.03  Construction Requirements

653.04  Method of Measurement

653.05  Basis of Payment

653.01  Description.  This work consists of furnishing and spreading topsoil and preparing the subgrade.

653.02  Materials.  Furnish topsoil consisting of loose, friable, loamy material without admixture of subsoil or refuse.  For topsoil to be considered loamy, ensure that the fraction passing the No. 10 (2.00 mm) sieve does not contain more than 40 percent clay.  Furnish topsoil consisting of not less than 4 percent and not more than 20 percent organic matter as determined by loss on ignition of samples oven dried to constant weight at 212 °F (100 °C).  Furnish topsoil that is free of grass, brush, and, roots.

653.03  Construction Requirements.  Before placing any topsoil, prepare all areas to be covered with topsoil according to 659.10.  Place the topsoil according to 659.11.  When seeding is specified, open the topsoil up to receive the seed.

653.04  Method of Measurement.  The Department will measure compacted Topsoil Furnished and Placed by the number of cubic yards (cubic meters) accepted in place.

653.05  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

653             Cubic Yard                      Topsoil Furnished and Placed
                       (Cubic Meter)                 

ITEM 654  RENOVATING EXISTING SOIL

654.01  Description

654.02  Materials

654.03  Construction Requirements

654.04  Method of Measurement

654.05  Basis of Payment

654.01  Description.  This work consists of preparing a suitable seedbed by grading and renovating existing soil, and furnishing and placing commercial fertilizer, if specified.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

654.02  Materials.  Use commercial fertilizer conforming to 659.04.

654.03  Construction Requirements.  Prepare the surface area for seed according to 659.10.

If the Contract Documents require commercial fertilizer, place it according to 659.04.

654.04  Method of Measurement.  The Department will measure Renovating Existing Soil by the number of M square feet (square meters) completed and accepted.

The Department will measure Commercial Fertilizer by the number of tons (kilograms) completed and accepted.

654.05  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

654             M Square Feet                 Renovating Existing Soil
                       (Square Meter)

654             Ton (Kilogram)               Commercial Fertilizer

ITEM 656  ROADSIDE CLEANUP

656.01  Description

656.02  Intensity of Cleanup

656.03  Cleaning

656.04  Pruning

656.05  Disposal of Refuse

656.06  Method of Measurement

656.07  Basis of Payment

656.01  Description.  This work consists of cleaning up outside the excavated and filled areas and disposing of undesirable plants and other vegetative growth, prunings, rubbish, stumps, conspicuous stones, all down timber, dead brush, logs and timbers; felling and destroying of all snags and such dangerous trees; and pruning trees, native shrubs and similar vegetation but does not include work to be performed under Item 201.

656.02  Intensity of Cleanup.  Control the intensity of cleanup to effect a natural transition in cleanup treatment from the edge of the pavement outward to the limits of the Right-of-Way to avoid sharp demarcation between the artificial and the natural.

656.03  Cleaning.  After removal of large objects, clean the designated areas with grubbing rakes or wide-spaced tooth rakes.  Do not disturb or injure desirable grass, vines, or wild flowers.

656.04  Pruning.  Prune trees 6 inches (150 mm) or less in diameter and native shrubs and similar vegetation according to Item 666.  Consider the diameter of existing trees to be the diameter measured at 54 inches (1.4 m) above the ground.

656.05  Disposal of Refuse.   Use removed materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

656.06  Method of Measurement.  The Department will measure Roadside Cleanup by the number of M square feet (square meters) cleaned up and accepted.

The Department will determine the boundaries of the area to be cleaned up and the number of units.

656.07  Basis of Payment.  The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

656             M Square Feet                 Roadside Cleanup
                       (Square Meter)

ITEM 657  RIPRAP FOR TREE PROTECTION

657.01  Description

657.02  Materials

657.03  Tree Wells in Fill

657.04  Walls in Cut

657.05  Hand-Laid Stone Riprap

657.06  Earthwork

657.07  Pipe Drains

657.08  Method of Measurement

657.09  Basis of Payment

657.01  Description.  This work consists of furnishing and placing riprap for protecting selected trees or shrubs by tree wells and retaining walls.

657.02  Materials.  Furnish stone consisting of sandstone, limestone, or other natural rock with a maximum 30 percent single slab loss and a maximum 20 percent cumulative loss after testing to ASTM D 5240.  Use an 8-inch slab test sample.  The Department may waive testing when the stone source has a known durability history.  Furnish embankment according to Item 203.  Unless otherwise specified, use 4-inch (100 mm) pipe conforming to 611 Type E conduits.

657.03  Tree Wells in Fill.  Where a fill around a tree or shrub not marked for removal will be 12 inches (0.3 m) or more in depth over the feeding root area or ground surface lying within the periphery of the tree, construct a dry hand-laid stone riprap tree well.  Construct a wall, of the same height as the fill, circling the tree or shrub and 3 1/2 feet (1 m) from the tree trunk or as specified.  Construct the wall so that the top of the wall follows the contour on the finished grade in a neat line.

Construct tree wells before placing the fill over the root area.  However, the Contractor may bring up the fill with the wall after required aggregate for root aeration is in place according to Item 658.

657.04  Walls in Cut.  Where the top of the slope in cut is within 6 feet (2 m) of the trunk of a tree not marked for removal, construct a dry hand-laid stone riprap wall.  Toe the bottom of the wall into the ground 2 inches (50 mm) unless otherwise shown on the plans, and make the top of the wall even with the original ground line at the base of the tree.  Extend the length of the wall far enough from the tree to amply cover the roots, or according to the shape and size as shown on the plans.  Flare the ends of the wall back, and taper or fade them out into the finished grade of the slope in a neat line.

657.05  Hand-Laid Stone Riprap.  Construct the earth bed on which riprap is to be placed to a slope of 1 foot (300 mm) vertical to 2 inches (50 mm) horizontal.  Dress the earth bed to a true plane.  Where riprap is to rest against a fill, tamp the embankment against the back of the stone.

Construct riprap for walls or wells according to the arrangements and dimensions shown on the plans.  Lay each course with the long dimensions of each stone perpendicular to the slope or batter.

Use individual stones that are roughly rectangular in cross-section and are a minimum of 3 inches (75 mm) in the vertical depth with a horizontal dimension of not less than 15 inches (0.4 m).  Place the individual stones by hand, one upon the other so that they break joints with the stone in the course below.  Where it is necessary to use more than one stone to provide the specified thickness or depth of the wall, thereby resulting in joints parallel to the face of the wall, place such stones to break joints with the adjacent stones.

Fill the space between the larger stones with spalls rammed into place.  Ensure that the surface of the finished riprap does not vary more than 3 inches (75 mm) from that shown on the plans, and that it presents an even, tight surface, pleasing in appearance.

657.06  Earthwork.  Perform excavation and embankment, as necessary, according to Item 203.

657.07  Pipe Drains.  Drain tree wells with pipe starting on the original ground surface and lay to drain beyond the toe of the fill.  Install pipe for drains according to Item 611.

657.08  Method of Measurement.  The Department will measure Riprap for Tree Protection by the number of square yards (square meters) in place, completed and accepted.  The Department will measure parallel to the face of the wells or walls.

657.09  Basis of Payment.  The Department will pay for embankment and excavation under Item 203 and the pipe for drains under Item 611.

The Department will pay for accepted quantities at the contract price for as follows:

Item           Unit                                Description

657             Square Yard                    Riprap for Tree Protection
                       (Square Meter)

ITEM 658  TREE ROOT AERATION

658.01  Description

658.02  Materials

658.03  Preparation

658.04  Aeration for Trees Not Welled

658.05  Aeration with Tree Wells

658.06  Earth Embankment

658.07  Method of Measurement

658.08  Basis of Payment

658.01  Description.  This work consists of furnishing and placing the necessary aggregate and tile for the protection and aeration of the roots of trees and shrubs.

Use removed or excavated materials in the Work when the material conforms to the specifications; if not, then recycle or dispose of the material according to 105.16 and 105.17.

658.02  Materials.  Furnish aggregate for tree root aeration and protection consisting of No. 4 or 467 limestone or gravel with a maximum sodium soundness loss of 15 percent.

Furnish 4-inch (100 mm) pipe conforming to 611 Type E conduit.  Furnish embankment conforming to Item 203.

658.03  Preparation.  The feeding root area to be protected and aerated is the ground surface area lying within the periphery of the tree or shrub not marked for removal.  Prepare these areas by excavating all vegetation, wood, brush, and debris.

658.04  Aeration for Trees Not Welled.  Where the earth fill is less than 12 inches (300 mm) and more than 4 inches (100 mm) over the feeding root area, loosely spread an aggregate aeration course of one-half the height of fill, but not less than 3 inches (75 mm), over this area.  At the tree trunk, increase the thickness to the height of the fill and extend it outward from the tree trunk in collar form for a distance of 15 inches (0.4 m).  Place a 2-inch (50 mm) layer of straw or hay over the aggregate.

658.05  Aeration with Tree Wells.  Place an aeration course of aggregate while constructing the tree wells and before any other filling.  Do not place any aggregate inside the tree well (between the wall and the tree trunk).  Place the aggregate over the entire feeding root area outside of the tree wells to a total depth of 6 inches (150 mm) for each 12 inches (300 mm) of earth fill, or proportion thereof, but place a minimum depth of 6 inches (150 mm) regardless of depth of overlying fill.  Place a 2-inch (50 mm) layer of straw or hay over the aeration layer.

658.06  Earth Embankment.  Perform excavation and embankment, as necessary, according to Item 203.

658.07  Method of Measurement.  The Department will measure Tree Root Aeration by the number of cubic yards (cubic meters), measured in the carrier or truck according to 109, of the aggregate furnished, placed, completed, and accepted.

658.08  Basis of Payment.  The Department will pay for embankment and excavation under Item 203 and the pipe under Item 611.

The Department will pay for accepted quantities at the contract price as follows:

Item           Unit                                Description

658             Cubic Yard                      Tree Root Aeration
                       (Cubic Meter)

Item 659  SEEDING AND MULCHING

659.01  Description

659.02  Testing of Soil or Topsoil

659.03  Lime

659.04  Commercial Fertilizer

659.05  Topsoil

659.06  Compost

659.07  Seeds

659.08  Legumes

659.09  Native Grasses and Wildflowers

659.10  Site Preparation

659.11  Placing Topsoil

659.12  Seeding Methods

659.13  Mulching Operation

659.14  Straw Mulch

659.15  Wood Fiber Mulch

659.16  Compost Mulch

659.17  Watering

659.18  Maintenance

659.19  Mowing

659.20  Repair Seeding and Mulching

659.21  Inter-Seeding

659.22  Fertilization:  2nd Application

659.23  Performances

659.24  Method of Measurement

659.25  Basis of Payment

659.01  Description.   This work consists of placing topsoil, preparing the seed bed, and placing and incorporating seed, agricultural lime, commercial fertilizer, and placing mulching material used to achieve NPDES final stabilization.

Perform this work in areas shown on the plans for seeding and mulching.

Perform seeding and mulching after completing all work in the area and within 7 days of obtaining final grade. If it is anticipated that future work may disturb an area, place temporary NPDES compliant Best Management Practices as needed until final stabilization measures under this item can be installed. If the Contractor disturbs a final area, then the Contractor shall restore this area. With the Engineer’s approval, the Contractor may apply permanent seed between October 30 and March 1 on projects started and completed within the same calendar year.

Use all excavation material in the work.  Alternatively legally use, recycle, or dispose of all excavated materials according to 105.16 and 105.17.

659.02  Testing of Soil or Topsoil.  When a Soil Analysis Test of the soil or topsoil is required in the plans, use the following sampling frequency to determine the lime required:

A.      When an area is near final grade, perform Standard Soil Analysis Test to measure the soil acidity or alkalinity (pH) if no topsoil is to be placed.  This testing will determine the soil requirements for lime.  If the soil requirements are different than the standard lime mixture ratio application rates then the standard application rate shall be adjusted up or down such that the soil requirements are met.  If liquid lime is used then use the following application table to achieve a  pH of 6.5 or greater. Calculate the difference between the  soil pH and 6.5 pH.

pH Difference

0.25

0.50

0.75

1.0

Application rate in gals/ac (L/ha)

2.5  (4)

5  (8)

10  (15)

20  (30)

Example: Soil Analysis Test pH=5.75 required pH=6.5 difference= 0.75 required application rate is 10 gals/ac (15L/ha)

Only use liquid lime on the QPL list.  Provide the Engineer with the Liquid Lime manufacturers written application rate. The Engineer will only accept printed application rates.

There will be no change in the mixture ratio.  The sampling frequency is one sample every 10 acres (4.0 ha) per project side or one sample per project side whichever is greater.  A sample consist of 15 soil cores in a random pattern spaced at a minimum of 500 feet (153 m) apart.  Sample any change in soil.  Soil changes can be seen as color and/or texture changes.

B.      If placing topsoil, perform the Standard Soil Analysis Test from topsoil stockpiles to measure the topsoil acidity or alkalinity (pH).  This testing will determine the soil requirements for lime.  If the topsoil requirements are different than the standard lime mixture ratio application rates then the standard application rate shall be adjusted up or down such that the topsoil requirements are met. 

If liquid lime is used then use the following application table to achieve a  pH of 6.5 or greater. Calculate the difference between the  soil pH and 6.5 pH.

pH Difference

0.25

0.50

0.75

1.0

Application rate in gals/ac (L/ha)

2.5  (4)

5  (8)

10  (15)

20  (30)

Example: Soil Analysis Test pH=5.75 required pH=6.5 difference= 0.75 required application rate is 10 gals/ac (15L/ha)

Only use liquid lime on the QPL list.  Provide the Engineer with the Liquid Lime manufacturers written application rate. The Engineer will only accept printed application rates.

There will be no change in the mixture ratio.  The sampling frequency is one sample every 10,000 cubic yards (7600 m³) of a topsoil stockpile, or at least two samples per stock pile whichever is greater.  Test each stockpile.  A sample consisting of 15 soil cores in a random pattern spaced evenly throughout the stockpile.

Mix the 15 cores from each sample and then remove 1 pint (0.5 L) for testing.

The Ohio County Extension offices can provide the Contractor with a soil sample kit and testing laboratory locations.

The Department will review the sample test results and approve application rates for the standard mixture ratios provided by the Contractor.

If a Soil Analysis Test of the soil is not required by the plans, use the standard application rates for lime and commercial fertilizer.

659.03  Lime.  Obtain granular or liquid lime from a agricultural lime dealer or manufacturer whose brands are grades registered or licensed by the State of Ohio, Department of Agriculture.  The granular or liquid lime standard grade is Ag-ground 90+.  Ag-ground 90+ is defined as agricultural ground limestone, having a total neutralizing power (TNP) of 90 percent or more, at least 40 percent passing a No. 100 (150 mm) sieve and 95 percent passing a No. 8 (2.36 mm) sieve.  Test granular or liquid lime according to Supplement 1007.  Apply the granular or liquid lime standard grade Ag-ground 90+ at the standard application rate of 92 pounds per 1000 square feet (2 tons per acre) [0.45 kg/m² (9 metric tons/ha)].

The Contractor may provide other lime grade materials.  The lime grade materials provided will meet Table 7-10 “Equivalent Amounts of Liming Materials” found in Bulletin 472, Ohio Agronomy Guide, published by the Cooperative Extension Service, The Ohio State University.  Based on the type of lime grade material provided, determine the increase or decrease in the standard application rate from Table 7-10 “Equivalent Amounts of Liming Materials” found in Bulletin 472, “Ohio Agronomy Guide”, published by the Cooperative Extension Service, The Ohio State University.

If using liquid lime apply liquid lime at a rate of 5 gals/acre (8 L/ha) unless otherwise required per the soil or topsoil Soil Analysis Test. Provide the Engineer with the Liquid Lime manufacturers written application rate. The Engineer will only accept printed application rates. Only use Liquid lime on the QPL list.

If testing of the soil or topsoil was performed, the lime required will be such that a growing environment of slightly acidic (pH 6.5) can be reached.  The application rate of the standard grade lime Ag-ground 90+ will be adjusted up or down to achieve this condition and reported to the Department for approval.  No lime is required for the soil or topsoil if the test shows a slightly acidic condition.

659.04  Commercial Fertilizer.  Obtain commercial fertilizer from a dealer or manufacturer whose brands are grades registered or licensed by the State of Ohio, Department of Agriculture.

Commercial fertilizer may be dry or liquid.  Apply standard commercial fertilizer 10-20-10 evenly over the surface at a standard dry application rate of 20 pounds per 1000 square feet (0.1 kg/m²).  Furnish liquid application rates for approval by the Department.

The Contractor may provide other commercial fertilizer mixture ratios, however, ensure that the ratio meets or exceeds the standard commercial fertilizer ratio of 10-20-10 by providing an application rate specific for that ratio.  The Department will approve this application rate that is specific to that ratio provided by the Contractor.

For areas of inter-seeding apply commercial fertilizer 12-12-12 over the affected area at the above rate.

For commercial fertilizer second application the method, mixture, and rate is broadcast 12-12-12 evenly over the surface without incorporation into the soil at a rate of 10 pounds per 1000 square feet (0.05 kg/m²).

659.05  Topsoil.  If placing topsoil as specified in the plan, then stockpile off project site topsoil for testing and/or stockpile stripped topsoil from the project for testing.  Perform the Soil Analysis Test from these stockpiles to determine the percent of organic matter present.  The topsoil shall contain between 4 percent and 20 percent organic matter as determined by loss on ignition of samples oven dried to constant weight at 212 °F (100 °C) and consist of fertile, loose, friable, and loamy material that contains humus material.  For topsoil to be considered loamy, ensure that the fraction passing the No. 10 (200) sieve does not contain more than 40 percent clay. Test topsoil according to Supplement 1016.

The Department will review the sample test results and approve the stockpiles for use.  Stockpiles outside the above limits will not be used.

Stripped topsoil from the R/W limits will be from the upper most layers of the excavation areas.  Remove all heavy grass, weeds, and other vegetation before stripping topsoil from the excavation areas.

A mixture of 1 part compost and 2 parts topsoil will be treated as topsoil.

659.06  Compost.  Acceptable compost shall include Ohio EPA rated Class IV compost, EQS biosolids compost, or a Department approved equal.  Furnish compost with a nitrogen content of 1.4 percent or above.  Obtain compost from an Ohio EPA approved facility.  Before delivering compost, provide the Engineer with the facility name and location.

659.07  Seeds.  Furnish grass seed from a grass seed dealer or grower whose brands are grades registered or licensed by the State of Ohio, Department of Agriculture or from the approved list of grass seed dealers or growers on file with Department.  Furnish the kind and type of grass seed required that meets current specifications on file with the Department as to percentage purity, percentage weed seed, and percentage germination.

Turf grass germination rates specifications are shown below in Table 659.07-1 to provide an understanding of the specifications on file with the Department along with information to understand what is required.

Table 659.07-1  GERMINATION RATES

Species

Minimum Percent

High Quality Percent

Kentucky Bluegrass

80

85

Fine Fescue

85

90

Perennial Ryegrass

85

90

Annual Ryegrass

85

90

Tall Fescue

85

90

Creeping Red Fescue

85

90

If high quality is not shown on the plans, then the minimum germination rate is required.

Mark the test date on seed bags. Furnish seeds as separate species and cultivars, packaged together or bagged separately, and labeled, tagged, or marked according to ORC 907.03.  Sow seeds within 9 months of the testing date.  The Department reserves the right to test, reject, or approve all seed after delivery.

659.08  Legumes.  Inoculate or treat all leguminous seeds (crown vetch) with the proper amount of pure nitrogen-fixing bacteria and mix with sufficient water to thoroughly wet the seed.  The bacteria selected will be for maximum vitality and shall not be more than one-year old.  All culture records will be provided with the leguminous seeds.

If sown hydraulically, use 4 times the inoculant rate specified by the inoculant manufacturer.  If pre-inoculated seed is used then use 3 times the inoculant rate specified by the inoculant manufacturer.  Immediately before seeding, add inoculant and sticking agent directly into the slurry, and thoroughly mix the slurry.  Sow seed as soon as possible after inoculation.  If left standing for more than 24 hours, reinoculate seed before sowing.  Mix all seed on the project.  Sixty days before seeding, provide a written description for the Class 3C mixture showing the percentage by weight (mass) of each kind of seed for the Engineer’s approval.

Include the following with the description:

A.      Name and location of the seed supplier.

B.      Origin and date of harvest of each kind of seed.

C.      A statement of the purity and germination of each seed.

D.      Testing date for each seed.

E.      How and when seeds were mixed.

659.09  Native Grasses and Wildflowers.  Table 659.09-1 lists the seed quantities by weight per area.  Use Classes 4, 5, and 6 in the amounts of pure live seed (PLS) for each species listed.  If seed tests show that the seed has an actual pure live seed (PLS) yield less than the intended yield, adjust the specified quantity to provide the intended PLS yields.

For Class 4, 5, and 6 mixtures, provide seed specifically grown for the Ohio climate.

Use cool season turf Classes 1, 2, 3A, and 3B as listed in Table 659.09-1 composed of no less than two and no more than four cultivars of the same species.  Sixty days before seeding, provide a written description for the Class 1, 2, and 3A mixtures showing the percentage by weight (mass) of each kind of seed for the Engineer’s approval.  Mix all seed on the project.  Sixty days before seeding, provide a written description for the Classes 1, 2, 3A, 3B, 4, 5, and 6 mixtures showing the percentage by weight (mass) of each kind of seed for the Engineer’s approval.

Include the following with the description:

A.      Name and location of the seed supplier.

B.      Origin and date of harvest of each kind of seed.

C.      A statement of the purity and germination of each seed.

D.      Testing date for each seed.

E.      How and when seeds were mixed.

Table 659.09-1 Grass and Wildflower Seed Mixes

Class

Mix Type

Seeds

Weight per Area

lb

kg

1000 ft²

1000 m²

1

Lawn Mixture
Use for areas in front of residences, commercial properties, etc. between curb and sidewalk with slopes 3:1 or flatter.

Kentucky Bluegrass (Poa pratensis)

3

14.64

Creeping Red Fescue (Festuca rubra)

3

14.64

Annual Ryegrass (Lolium multiflorum)

2

9.76

Perennial Ryegrass, turf type (Lolium perenne)

2

9.76

2

Roadside Mixture

Kentucky Bluegrass (Poa pratensis)

1.5

7.32

Kentucky 31 Fescue
(Festuca arundinacea var. KY 31)

2

9.76

Perennial Ryegrass (Lolium perenne)

1.5

7.32

3A

Slope Mixtures
Use for slopes flatter than or equal to 3:1.

   Use Class 2, 3B, 3C, or 4B mixtures

3B

Low Growing Slope Mixture
Use for slopes steeper than 3:1 when low growing species are required

Hard Fescue (Festuca longifolia)

1.3

6.35

Creeping Red Fescue (Festuca rubra)

0.8

3.9

Annual Ryegrass (Lolium multiflorum)

0.23

1.12

3C

Crown Vetch Mixture
Use for slopes steeper than 3:1 and shale or rock slopes.

Crown Vetch (Coronilla varia)

0.9

4.39

Perennial Ryegrass (Lolium perenne)

1.8

8.79

Annual Ryegrass (Lolium multiflorum)

0.3

1.46

4A

Native Grass Mixture
Use for slopes flatter than 2:1 and seeding for wildlife habitat mitigation.

Big Bluestem (Andropogon gerardii)

0.07

0.34

Indiangrass (Sorghastrum nutans)

0.09

0.44

Switchgrass (Panicum virgatum)

0.02

0.09

Annual Ryegrass (Lolium multiflorum)     spring
                                                                fall

0.11

0.34

0.54

1.66

4B

Low Growing Native Grass Mixture
Use for slopes flatter than 2:1 and seeding for wildlife habitat mitigation when low growing species are required.

Little Bluestem (Schizachyrium scoparium)

0.18

0.88

Sideoats Grama (Bouteloua curtipendula)

0.04

0.19

Prairie Dropseed (Sporobolus heterolepis)

0.04

0.19

Annual Ryegrass (Lolium multiflorum)     spring
                                                                fall

0.11

0.34

0.54

1.66

5A

Annual and Perennial Wildflower Mixture
Use for slopes flatter than 2:1 and seeding for wildlife habitat mitigation.

Annual Mixture
Do not exceed 25% by weight of any one of the following species:

0.07

0.34

Corn Poppy (Papaver rhoeas)

Cosmos (Cosmos bipinnatus)

Yellow Cosmos (Cosmos sulphureus)

Cornflower (Centaurea cyanus)

Rocket Larkspur (Delphinium ajacis)

Indian Blanket (Gaillardia pulchella)

Perennial Wildflower Mixture
Do not exceed 50% by weight PLS of any one of the following species:

0.28

1.37

Black-eyed Susan (Rudbekia hirta)

Purple Coneflower (Echinacea purpurea)

Lance-leaved Coreopsis (Coreopsis lanceolata)

5B

Native Wildflower and Grass Mixture
Use for slopes flatter than 2:1 and seeding for wildlife habitat mitigation.

Native Wildflower Mixture
Do not exceed 10% by weight PLS of any one of the following species:

0.34

1.66

Butterfly-weed (Asclepias tuberosa)

New England Aster (Aster novae-angliae)

Partridge Pea (Cassia fasciculata)

Purple Coneflower (Echinacea purpurea)

Rattlesnake Master (Eryngium yuccifolium)

Ox-eye Sunflower (Heliopsis helianthoides)

Wild Bergamot (Monarda fistulosa)

Greyhead Coneflower (Ratibida pinnata)

Orange Coneflower (Rudbekia fulgida)

Prairie Dock (Silphium terebinthinaceum)

Whorled Rosinweed (Silphium trifoliatum)

Stiff Goldenrod (Solidago rigida)

Grass Mixture

Big Bluestem (Andropogon gerardii)

0.046

0.22

Little Bluestem (Schizachyrium scoparium)

0.069

0.34

Indiangrass (Sorghastrum nutans)

0.023

0.11

Annual Ryegrass (Lolium multiflorum)

0.92

4.49

6

Wildlife Mixture
Use for slopes flatter than 2:1 and seeding for wildlife habitat mitigation.

Big Bluestem (Andropogon gerardii)

0.13

0.63

Little Bluestem (Schizachyrium scoparium)

0.18

0.88

Indiangrass (Sorghastrum nutans)

0.13

0.63

Ox-eye Sunflower (Heliopsis helianthoides)

0.18

0.88

Prairie Dock (Silphium terebinthinaceum)

0.18

0.88

Purple Coneflower (Echinacea purpurea)

0.18

0.88

Whorled Rosinweed (Silphium trifoliatum)

0.11

0.54

Downy Sunflower (Helianthus mollis)

0.07

0.34

New England Aster (Aster novae-angliae)

0.07

0.34

Annual Ryegrass (Lolium multiflorum)     spring
                                                                fall

0.11

0.34

0.54

1.66

7

Temporary Erosion Control Mixture

Annual Ryegrass (Lolium multiflorum)

2.02

9.86

659.10  Site Preparation.  Before placing topsoil or seed remove rock or other foreign material of 3 inches (75 mm) or greater in any dimension, from all areas except as listed below.

A.      Remove stones 1-inch (25 mm) or greater in any dimension from all seed areas from in front of residences, commercial properties, etc.; between curb and sidewalks; or as shown on the plans.

B.      Remove nothing in shale cuts, but allow the shale to deteriorate to a soil type surface before seeding or placing topsoil.

Finish the area in such a manner that seeding, place sod, planting, or, placing topsoil can proceed without additional soil preparation.

Apply commercial fertilizer, lime, or other soil amendments including compost to the soil or topsoil surface in separate operations.  Incorporate the commercial fertilizer, granular lime, or other soil amendments, including compost either separately or together, into the soil or topsoil to a depth of 2 to 4 inches (50 to 100 mm). Do not mix Liquid lime into the soil or topsoil.  Only apply liquid lime to the top of the soil or topsoil. Furnish a smooth surface for the seed or topsoil by tracking with a dozer or by other methods.  If the site is inaccessible to a dozer and other methods do not provide results equivalent to hand raking, hand rake these areas.  Ensure that the surface is uniform, free of gullies, rivulets, crusting, and caking.  Finely grade the surface for seed or topsoil for slopes 4:1 or flatter, and grade all other slopes.  Rake or open the surface with a dozer cleats or otherwise loosen the surface of these areas to a depth of 1 inch (25 mm) immediately before covering with topsoil.  Remove raked up material from the area.

659.11  Placing Topsoil.  If shown on the plans, place topsoil in loose lifts that construct a 4-inch (100 mm) compacted depth.  The surface of the topsoil shall be such that the final grade as shown on the cross-sections is met.  Use the following methods or combination of any of the methods to produce the required space to place the topsoil.

A.      The 203 Items can be cut or placed to the final grade, which will match the plan quantities for Items 203, and then remove a 4-inch (100 mm) thickness for the topsoil.

B.      The 203 Items can be cut or placed to a 4-inch (100 mm) height below the final grade.  There will be no change from the plan quantities in the 203 Items for this method.

Track the area with a dozer to compact and provide good contact between the topsoil and the surface.

The Contractor may place topsoil by using pneumatic, or hydraulic methods.  If using pneumatic or hydraulic methods to place the topsoil, the Contractor may place the top 1-inch (25 mm) with a mix of seed, commercial fertilizer, lime, and other soils amendments.  This mixture will be 1 part compost and 2 parts topsoil.  Do not apply mulch to this surface.  The compost is the mulch.

659.12  Seeding Methods.  Apply seed to prepared areas.  If the prepared areas to be seeded become compacted before seeding, loosen the surface using disks, rakes, or other methods.

Thoroughly mix all seed, and evenly sow the seed over the prepared areas at the required rates.  Do not sow seed during high winds.  For slopes subject to windy conditions, seed using hydraulic methods only.  Operate equipment in a manner to ensure complete coverage of the entire area to be seeded.

If broadcast seeding, seed Classes 1, 2, 3A, and 3B between August 15 to October 30.  If necessary to seed Classes 1, 2, 3A, or 3B before August 15, but after March 1 increase the seeding rates by 5 percent.

Between March 1 and October 30, the Contractor may use hydro seeding, which applies the mulch, seed, water, and commercial fertilizer in the same operation, for Classes 1, 2, 3A, 3B, 3C, and 7.

Between October 30 and March 1, apply temporary seed according to Item 207.  With the Engineer’s approval, the Contractor may apply permanent seed between October 30 and March 1 on projects started and completed within the same calendar year.

Seed before or concurrently with all required erosion control items.

Do not apply crown vetch seed from September 1 to October 31.

Wildflower Classes 5 and 6 seed from September 1to October 30, unless the Engineer allows seeding from March 1 to May 31.

Seed Class 4 wildflowers from March 1 to May 31.

Seed native grasses and wildflowers in Classes 4, 5, and 6 with a rangeland type, slit seeder or native seed grass drill.  Seed native grasses with no less than two passes in different directions and by equally splitting the seed application rate to each pass.  Use broadcast seeding, along with cultipacking or rolling, only with the Engineer’s approval.

If broadcast seeding, perform the following, immediately after sowing, to provide good seed-soil contact:

A.      For flat surfaces, lightly rake the area then roll.

B.      For slopes, track the area with a dozer.

659.13  Mulching Operation.  Mulch materials consist of straw, compost, or wood fiber for 3:1 or flatter slopes.  The Contractor may specify which mulch to use, if it is not shown on the plans.  Use mulch that is reasonably free of weed seed, foreign materials, or other materials that would prohibit seed germination.  Do not mulch during high winds.  For slopes subject to windy conditions mulch using hydraulic methods only.  Within 24 hours after seeding an area, evenly place mulch.  Immediately replace mulch that becomes displaced..

659.14  Straw Mulch.  Straw mulch consists of straw.  Evenly place straw mulch over all seeded areas at the following rates:

Seeding Period

Rate

From March 15 to October 30

2 tons per acre (0.5 metric ton/1000 m²)

From October 31 to March 14

3 tons per acre (0.7 metric ton/1000 m²)

Keep straw mulching materials in place by applying an asphalt emulsion at a minimum rate of 60 gallons per ton (250 L/metric ton) of straw mulch or by applying tackifiers according to the manufacturer’s recommendations.  Apply an additional application at a rate of 30 gallons per ton (125 L/metric ton) of straw mulch to shoulder areas, starting at the berm edge and extending out for a distance of 10 feet (3 m).  Use an emulsion that is nontoxic to plants and prepared in a manner that will not change during transportation or storage.

659.15  Wood Fiber Mulch.  Wood fiber mulch consists of pure wood fibers manufactured expressly from clean wood chips.  Ensure that the chips do not contain lead paint, varnish, printing ink, and petroleum based compounds.  Do not use wood fiber mulch manufactured from recycled materials of unknown origin such as sawdust, paper, cardboard, or residue from chlorine-bleached pulp and paper mills.

Ensure that the wood fiber mulch maintains uniform suspension in water under agitation and blends with grass seed, commercial fertilizer, and other additives to form a homogeneous slurry.  Use manufacturer-approved tackifiers.

Using standard hydraulic mulching equipment, evenly apply the slurry over the soil surface in a one-step operation.  Apply slurry from March 1 to October 30 at the following rates:

Surface

Rate

Slopes 3:1 or flatter

46 pounds per 1000 square feet (225 kg/1000 m²)

659.16  Compost Mulch.  The Contractor may provide compost applied to a minimum depth of 1/4-inch (6 mm) over the prepared seed areas.  The Contractor may also mix the grass seed with the compost and using pneumatic equipment, place this mixture to a minimum depth of 1/4-inch (6 mm) over the prepared seed areas.  If using compost no tackifiers or asphalt emulsion are required.

659.17  Watering.  Thoroughly water all permanent seeded areas (Classes 1 to 6) after the seed has germinated.  Apply a total rate of 300 gallons per 1000 square feet (12.2 m³/1000 m²) in at least 2 applications spread over 7 days.  Apply the water using a hydro-seeder or a water tank under pressure with a nozzle that produces a spray that will not dislodge the mulch material.

Perform a secondary water application between 7 and 10 days after the primary applications.  If 1/2-inch (13 mm) or greater of rainfall has occurred within the first 7-day period, the Contractor may delay or omit the secondary application, depending on weather conditions.

659.18  Maintenance.  Maintain all seeded and mulched areas until final inspection.  Repair damaged areas to the original condition and grade.

659.19  Mowing.  The Engineer may require mowing before permanent seeding and during the growing season following permanent seeding.  The Engineer will notify the Contractor of when to begin each mowing.  Use suitable mowing equipment of the rotary, flail, disk, or sickle type.  Do not bunch or windrow mowed vegetation.  Mow to a final cutting height of no less than 6 inches (150 mm).  If necessary to achieve the cutting height, make more than one pass with the mower.

659.20  Repair Seeding and Mulching.  Repair all damage or erosion of the seeded and mulched areas before the completion of the project.

Rework or reshape slopes, and bring in additional material, as necessary, using whatever equipment is necessary to restore slopes to grade.  Seed and mulch repaired areas according to this specification.  As an alternative, the Contractor may apply compost to repair areas as specified in Item 659.

659.21  Inter-Seeding.  Inter-seeding is seeding existing thin and spotty growing turf using a slit or drill type seeder.  Perform inter-seeding only from March 15 to May 15 and from September 1 to October 15.  If necessary to achieve good seed-soil contact, mow before seeding according to Item 659.

For seeding steep slopes or inaccessible areas, the Contractor may use broadcast or hydraulic seeding methods.  Broadcast commercial fertilizer over affected areas as specified in Item 659.  Water affected areas at the rate specified in 659 to aid in seed-soil contact.

659.22  Fertilization:  2nd Application.  Once all repair seeding and mulching, and inter-seeding is complete and no earlier than 3 months after seeding, perform a Soil Analysis Test if shown on the plans to determine the need for a second application of commercial fertilizer.  Do not apply the second application of commercial fertilizer unless the grass has germinated.  Broadcast commercial fertilizer of 12-12-12 evenly over the surface without incorporation at a rate of 10 pounds per 1000 square feet (0.05 kg/m²).

659.23  Performance.  The Department will inspect all seeded areas no earlier than 6 months and no later than 12 months after final seeding.  For any area identified without a uniform density of at least 70 percent grass cover, repair seeding and mulching as specified in 659 or perform inter-seeding as specified in 659, and fertilize as specified in this subsection.

Also repair seeding and mulching or perform inter-seeding, and fertilize seeded areas damaged by traffic or erosion, due to no fault or negligence of the Contractor.

659.24  Method of Measurement.  The Department will measure Soil Analysis Test by the number of tests submitted to the Engineer.

The Department will measure the compacted topsoil by the number of cubic yards (cubic meters). 

The Department will measure Commercial Fertilizer by the number of tons (kilograms) of each quantity of furnished, spread, and incorporated into the soil or topsoil.  This measure will be converted to the standard application rate for the standard mixture ratio. 

The Department will measure lime or liquid lime by the number of acres (ha) furnished, spread, and incorporated into the soil or topsoil.  The measure will be converted to the standard application rate for the standard mixture ratio.

The Department will measure Seeding and Mulching by the number of square yards (square meters).

The Department will measure Repair Seeding and Mulching by the number of square yards (square meters) of damaged or eroded areas reshaped, seeded, and mulched.  If compost is substituted for mulch to repair areas, the Department will include such work under Repair Seeding and Mulching.

The Department will measure Water by the number of M gallons or 1000 gallon units (cubic meters) applied.  The Department will measure water in tanks, tank wagons, or trucks of predetermined capacity, or by means of meters of a type satisfactory to the Engineer and furnished and installed by the Contractor at expense to the Department, or determined by weight conversion.

The Department will measure Inter-Seeding by the number of square yards (square meters) of the seeded area.

The Department will measure mowing by the number of M square feet (square meters) satisfactorily mowed.

If seeded areas are damaged by traffic or erosion, due to no fault or negligence of the Contractor, the Department will measure for such work and mobilization by Supplemental Agreement.

The Department will not measure for repairs to seeding and mulching if damage or erosion of the areas occurs as a result of fault or negligence of the Contractor.

659.25  Basis of Payment. 

The Department will pay the plan quantity for compacted topsoil. The Department will not adjust topsoil quantities when the volume between two consecutive cross-sections differs by less than 5 percent from the plan quantity, unless the difference between the actual quantity and plan quantity is greater than 1000 cubic yards (1000 m³). For quantity differences greater than 5 percent or greater than 1000 cubic yards (1000 m³), submit supporting documentation to the Engineer.

The Department will pay the plan quantity for Seeding and Mulching. The Department will not adjust Seeding and Mulching quantities when the area between two consecutive cross-sections differs by less than 5 percent from the plan quantity, unless the difference between the actual quantity and plan quantity is greater than 20,000 square yards (20,000 m²) for all Seeding and Mulching pay items, combined. For quantity differences greater than 5 percent or greater than 20,000 square yards (20,000 m²), submit supporting documentation to the Engineer.

The Department will pay for accepted quantities at the contract prices as follows (M=1000):

Item           Unit                                Description

659             Each                                Soil Analysis Test

659             Cubic Yard                      Topsoil
                       (Cubic Meter)

659             Ton (Kilogram)               Commercial Fertilizer

659             Acres (ha)                       Lime

659             Square Yard                    Seeding and Mulching
                       (Square Meter)

659             Square Yard                    Seeding and Mulching for Wildlife
                       (Square Meter)               

659             Square Yard                    Seeding and Mulching Class ___
                       (Square Meter)               

659             Square Yard                    Repair Seeding and Mulching
                       (Square Meter)               

659             M Gallons                       Water
                       (Cubic Meters)

659             Square Yard                    Inter-Seeding
                       (Square Meter)

659             M Square Feet                 Mowing
                       (Square Meter)

ITEM 660  SODDING

660.01  Description

660.02  Materials

660.03  Lifting Sod

660.04  Preparation of Areas to be Sodded

660.05  Placing Sod on Slopes 3 to 1 or Flatter

660.06  Placing Sod on Slopes Steeper Than 3 to 1 But Flatter Than 2 to 1

660.07  Placing Sod in Ditches

660.08  Placing Reinforced Sod On Slopes 2 to 1 or Steeper

660.09  Watering

660.10  Method of Measurement

660.11  Basis of Payment

660.01  Description.  This work consists of furnishing, hauling, excavating for and preparing the bed, and placing sod.

660.02  Materials.  Furnish sod consisting of well-rooted Kentucky Blue Grass (Poa pratensis) or Canadian Blue Grass (Poa compressa) containing a growth of not more than 30 percent of other grasses and clovers, and free from all noxious weeds such as wild mustard, thistles, quack grass, and Johnson grass, and reasonably free from dandelions and crab grass.

Ensure that all sod is certified by the sod supplier that it complies with this item.  Ensure that the sod was recently mowed to a height of not more than 3 inches (75 mm).  Furnish a certificate with each shipment, and furnish the following additional information from the sod supplier:

A.      The name of the producer.

B.      The amount of sod shipped in square yards (square meters).

C.      The location of sod field.

D.      The location of job site.

E.      The date sod was cut.

F.      The thickness the sod was cut.

Furnish wood stakes that are at least 1/2 ´ 3/4 ´ 12 inches (13 ´ 19 ´ 300 mm).

Furnish T-pins that are 18-inch (450 mm) in length and ¼ inch (6 mm) in diameter and have a 3-inch (75 mm) tee.

Furnish round pins that are 18-inch (450 mm) in length and ¼ inch (6 mm) in diameter and have a 1.5-inch (38 mm) washer.

Furnish galvanized poultry netting 50 inches (1200 mm) wide with 2-inch (50 mm) mesh and No. 20 gage minimum wire.

Furnish fertilizer and lime according to Item 659.

Furnish sod materials according to the Department’s Qualified Product List (QPL).

660.03  Lifting Sod.  Furnish sod strips that are not less than 3 feet (0.9 m) and not over 6 feet (1.8 m) in length with a uniform width of not over 24 inches (0.6 m). Furnish sod strips that lay flat on skids. The Contractor may elect to deliver sod rolls of up to 25 feet (7.6 m) in length.  Furnish sod rolls that are pre-rolled on skids. Furnish sod cut to a depth equal to the growth of the fibrous roots but in no case less than 1 inch (25 mm).

Deliver sod to the job within 24 hours after being cut, and install it within 48 hours after being cut.

During wet weather, allow the sod to dry sufficiently to prevent tearing during handling and placing.  During dry weather, water the sod before lifting to ensure its vitality and to prevent the dropping off of the soil in handling.

660.04  Preparation of Areas to be Sodded.  Before placing the sod, excavate the sod bed to a depth that when the sod is in place the top of the sod is flush with the surrounding grade and conforms to the typical cross-section.  If specified, place the topsoil according to Item 659.  If specified under Item 659, apply commercial fertilizer and agricultural liming material.  Incorporate these materials in the areas to be sodded at the rate specified in 659.03 and 659.04 to a depth of not less than 1 inch (25 mm).  Incorporate these materials within 48 hours prior to placing the sod.  Immediately before placing the sod, rake the area or otherwise bring it to an even surface forming a proper sod bed.  If the area is dry, thoroughly water the sod bed.

660.05  Placing Sod On Slopes 3 to 1 or Flatter.  Do not place any sod when the temperature is below 32 °F (0 °C).  Do not place any frozen sod, and do not place any sod upon frozen soil.  When placing sod between June 1 and October 15, cover it immediately with straw mulch 1 inch (25 mm) thick, loose measurement.

Lift sod from trucks or storage piles, and place it by hand with close joints and no overlapping.  Plug all gaps between sections of sod and openings at angles with sod.  After laying, thoroughly water the sod, and tamp the sod with approved sod tampers sufficiently to bring the sod into close contact with the sod-bed and to ensure tight joints between the sections or strips.  Upon placing the sod, ensure that the surface of the sodded areas coincides with the finished grade.

660.06  Placing Sod on Slopes Steeper Than 3 to 1 But Flatter Than 2 to 1.  Place sod on slopes steeper than 3 to 1 but flatter than 2 to 1 according to 660.05, with the following modifications.

Lay sod with the long edges of the strip parallel to the contour starting at the bottom of the slope.  Neatly match successive strips, and stagger all joints by at least 12 inches (300mm).

For  sod placed 6 feet (1.8 m) or greater in height (measured along the slope), stake each strip or roll  securely along all sides with stakes not more than 2 feet (0.6 m) apart with the flat side against the slope or with pins not more than 2 feet (0.6 m) apart.   Drive the wooden stakes so that the last 1 inch (25 mm) remains above the top of the sod. Drive pins 1 inch (25  mm) below the top of the grass.

After laying, thoroughly water the sod, and tamp the sod with approved tampers sufficiently to bring the sod into close contact with the sod-bed and to ensure tight joints between the sections or strips.

660.07  Placing Sod in Ditches. Place sod in ditches according to 660.05, with the following modifications.

 Place sod in ditches with joints staggered at least 12 inches (300 mm). Stake each strip or roll securely along all sides with wooden stakes not more than 2 feet (0.6 m) apart with the flat side against the slope. Drive the wooden stakes so that the last 1 inch (25 mm) remains above the top of the sod.

660.08  Placing Reinforced Sod On Slopes 2 to 1 or Steeper. Place reinforced sod on slopes 2 to 1 or steeper or as specified in the plans according to 660.05, with the following modifications. Before placing the sod, place the galvanized poultry netting or equivalent.  Stake the galvanized poultry netting or equivalent securely to the subgrade by using pins or wood stakes. Place the pins or wooden stakes at 4 foot (1.2m) intervals. Fasten the netting to the wooden stakes with staples.  Where the sod width is from 8 to 10 feet (2.4 to 3 m) wide, the Engineer will allow two strands of netting for a total width of 8 feet (2.4 m). For sod, stake each strip or roll  securely along all sides with wooden stakes not more than 2 feet (0.6 m) apart with the flat side against the slope or with pins not more than 2 feet (0.6 m) apart. Drive the wooden stakes so that the last 1 inch (25 mm) remains above the top of the sod. Drive pins 1 inch (25mm) below the top of the grass.

660.09  Watering.  Keep all sodded areas thoroughly moist for 30 days after sodding.  Repair any areas damaged following installation.  Ensure that sod is in place for at least 30 days before final acceptance.

660.10  Method of Measurement.  The Department will measure Sodding Unstaked, Sodding Staked, and Sodding Reinforced by the actual number of square yards (square meters) of area sodded, completed and accepted.

660.11  Basis of Payment.  If required, the Department will pay for topsoil liming and fertilizing under Item 659.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

660             Square Yard                    Sodding Unstaked
                       (Square Meter)

660             Square Yard                    Sodding Staked
                       (Square Meter)

660             Square Yard                    Sodding Reinforced
                       (Square Meter)

ITEM 661 PLANTING TREES, SHRUBS, Perennials AND VINES

661.01  Description

661.02  Plant Materials

661.03  Location and Source of Supply

661.04  Transportation, Storage and Handling

661.05  Labeling

661.06  Acceptance

661.07  Scheduling

661.08  Layout of Plant Materials

661.09  Backfill Mix

661.10  Planting

661.11  Mulch

661.12  Wrapping

661.13  Bracing

661.14  Period of Establishment

661.15  Final Acceptance

661.16  Removal of Stakes and Wrapping

661.17  Method of Measurement

661.18  Basis of Payment

661.01  Description.  This work consists of furnishing, planting and maintaining trees, shrubs, perennials, and vines, described in the plans.  Additionally, provide landscape watering according to Item 662.

661.02  Plant Materials.  Plant materials include all trees, shrubs, perennial and vines, and plants required as part of the Work.  Provide plant materials that are healthy specimens, typical of their species or variety, and that exhibit a normal habit of growth as set forth in the most current edition of the American Standard for Nursery Stock (ANSI Z60).

661.03  Location and Source of Supply.  Supply the Engineer with complete and detailed information concerning the source of supply for each item of required plant material within 15 days after receiving the notice of award of the Contract.

Ensure that all plant materials have been grown in the same hardiness zone or 1 zone colder than the project.

661.04  Transportation, Storage, and Handling.  Transport all plants from nursery sources to the project site with the entire load completely covered for protection from drying winds.  Thoroughly water all plants that cannot be immediately planted so as to keep the roots in a continually moist and protected condition.  The Engineer may reject plants that are not adequately protected during transportation and storage.  Immediately remove all rejected plant materials from the project site.  Handle all plant materials by the root ball or container.

661.05  Labeling.  Attach legible labels to all specimens, or boxes, bundles, and other containers, indicating detailed information including, but not limited to, the botanical genus and the species name, the common name, the size or age of each species or variety and the quantity contained in the individual bundles or boxes.  Remove all labels no more than two weeks prior to the completion of the establishment period.  Notify the Engineer prior to removing the plant material labels.

661.06  Acceptance.  Prior to acceptance by the Engineer, notify the Engineer when plant materials are delivered to the project site. Ensure that the plant species delivered are as described in the plans and are healthy, vigorous, and free from harmful plant diseases, and insect pests.  Species substitutions must have written approval from the project engineer prior to delivery to the project.

Do not install any plant materials until the Engineer provides the contractor with notification that the plant materials have been accepted.

661.07  Scheduling.  Install all plant materials after March 15 and before June 1 or after September 15 and before November 30.  Do not install plant materials in frozen or saturated soil conditions.  Ensure a sufficient water supply is available to satisfy the requirements of the plant materials and Item 662.

661.08  Layout of Plant Materials.  Before installation, use suitable staking to lay out the locations of all planting holes and beds.  Provide the Engineer with a scaled drawing that indicates the location, species, and size of plant materials required in the plan.  Obtain the Engineer’s approval of these locations before installation.

661.09  Backfill Mix.  For all plantings, use backfill mix consisting of the following:

A.      One part soil.

B.      One part sphagnum peat moss, shredded pine bark, or EPA rated Class IV compost.

C.      One part sand.

Do not use backfill mix that is frozen or muddy.

661.10  Planting.

A.      Planting Holes:  Dig planting holes that have sloping side walls and are ‘bowl shaped’.  Slope the side walls to approximately 45 degrees.  Dig the planting hole so that the diameter at the top is at least two times the diameter of the root ball.  Dig the planting hole to the same depth as the root ball structure. 

Dig planting holes for vines and perennials to a minimum depth and diameter of 6 inches (150 mm).  Make planting holes for rooted cuttings and tree seedlings large enough to accommodate the root system.

B.      Planting Beds:  One month before cultivation, treat all planting beds that are to be developed in areas of existing turf with pre-emergent and post-emergent type herbicides.  Use a State-licensed pesticide applicator to apply the herbicide according to the manufacturer’s instructions.

Before planting, top dress all planting beds with a minimum of 2 inches (50 mm) of backfill mix, then cultivate it to a depth of 6 inches (150 mm) using a plow, disc, or roto-tiller.

C.      Planting Trees & Shrubs: Set each plant in the center of the planting hole, plumb, and straight at a level such that the top of the root structure (i.e., trunk flare or root collar) is 1 inch (25 mm) above the surrounding soil.  Set the root ball on compacted or unexcavated soil to prevent settlement.  Prior to backfilling the hole, remove all twine, bags, and roping.  For trees shipped with wire baskets supporting the root structure, remove the top two-third of the wire basket from root balls.  Remove all rot-proof burlap.  Remove or fold down the top one-third of standard (biodegradable) burlap.  Take care not to separate the soil of the root ball from the plant’s root system.  Cut or remove circling roots before planting.

Backfill the planting hole with the backfill mix.  Fill the hole gradually and settle the backfill with water to the top of the root structure.  Do not place backfill mix in direct contact with the trunks or stems.  Add backfill mix around the root structure up to the plant’s root collar is at the soil surface.

Do not plant groundcovers, vines, or perennials closer than 12 inches (300 mm) to tree trunks and shrub stems or within 6 inches (150 mm) of the edge of planting beds.

D.      Planting Seedlings, Groundcovers, Vines or Perennials: For seedlings, groundcovers, vines, or perennials that are not in a planting bed, , remove all grass and weeds by scalping an area that has a minimum diameter of 12 inches (300 mm).  Plant seedlings or perennials in the center of the scalped area using a spade or planting bar.

661.11  Landscape Mulch. Provide Landscape Mulch that consists of shredded bark and shredded wood.  The length of any individual component cannot exceed 2 inches (50 mm).  Ensure that at least 75 percent of the mulch can pass a 1-inch (25 mm) screen.  Landscape Mulch may contain up to 50 percent shredded wood.  Wood chips are not acceptable.  Provide mulch that is free of soil, rocks, and weeds, and that has been aged at least one year before installation.

Smooth and shape the backfill mix to form a shallow basin slightly larger than the planting hole.  Mulch these areas with a 4-inch (100 mm) layer of Landscape Mulch uniform in texture and size.  Do not place mulch in direct contact with the trunks of any trees. Rake and smooth all planting beds upon completion of the work.

661.12  Wrapping.  Wrap all single deciduous tree trunks of 1-inch (25 mm) caliper and larger.  Before wrapping, inspect for insect infestation and take corrective measures.  Wrap trees within 48 hours after planting, using a double-layered, bituminous-cemented, waterproof, crinkled paper.  Start at the ground and wrap the trunk neatly and snugly to the height of the first branches, then attach securely.  With each turn of the wrapping, overlap the previous turn by half the width of the paper.

661.13  Bracing.  Use only flexible, biodegradable ties when bracing trees.  Use bracing only in areas where mower damage, vandalism, or windy conditions are a concern or as directed by the Engineer.  Install loose fitting ties that will not girdle the trunk.  Ensure that the tie will allow trunk movement and growth.  Install all bracing as shown on the standard construction drawing.

661.14  Period of Establishment.  Before final inspection, install all plants and care for them for a period of establishment.  The period of establishment begins immediately upon completion of the planting operations and continues until October 1.  The minimum period of establishment is one complete growing season, beginning June 1 and ending the following October 1.

During the period of establishment, follow standard horticultural practices to ensure the vigor and growth of the transplanted material including watering (according to Item 662), re-mulching, re-staking, and cultivating as necessary.  Prune branches of deciduous plants to preserve the natural characteristics of the species according to ANSI Pruning Standards (ANSI A300).  Remove broken, damaged, and dead branches.  Do not trim the central leader of trees.

Completely remove weeds and grasses from the planted and mulched areas by weeding and mowing (around trees, shrubs, and bed edges) at least two times during the growing season. Weed and mow the first time on or about June 15 and again approximately 8 weeks later.

661.15  Final Acceptance.  On or about October 1 at the end of the establishment period, the Engineer, in coordination with the Department’s Office of Environmental Services, will inspect the plantings and supply the Contractor with a list of plant materials that do not comply with the contract requirements.  Install all replacement plantings in accordance with the contract requirements.  Replacement plants are subject to a new establishment period.  Care for, water and maintain the replacement plant materials throughout the new establishment period at no additional cost to the State.

661.16  Removal of Stakes and Wrapping.  After receiving notification from the Department of the date of the final inspection, remove all stakes and wrapping material from all plants not more than 14 days before the final inspection, with the exception of the replacement plantings that have not been in place for a full growing season.

661.17  Method of Measurement.  The Department will measure the number of healthy plant materials that exhibit typical growth habit for the species and variety.

The Department will measure each species and size, completed and accepted in place.

The cost associated with wrapping, bracing, mulching and staking is included in the unit price bid for Item 661 Planting Trees, Shrubs, Perennials and Vines.

If the Contract does not include an estimated quantity for Item 662 Landscape Watering, the Department will not pay for landscape watering separately. In this case, include the cost of landscape watering in the unit price bid for Item 661 Planting Trees, Shrubs, Perennials and Vines.

661.18  Basis of Payment.  The Department will pay 40 percent of the bid price for plant materials delivered and accepted at the project site.  The Department will pay 40 percent of the bid price when the plant materials have been installed.  The Department will pay the remaining 20 percent of the bid price at the end of the establishment period following final acceptance. 

If for each pay item, less than or equal to 5% of the installed plants require replacement at the time of Project Completion, the Engineer may waive the establishment period for the replacement plantings, provided that the replacement plantings are installed in accordance with this specification and in the presence of the Engineer or Inspector.

If for each pay item, more than 5% of the installed plants require replacement at the time of Project Completion, the contractor is required to install the replacement plantings in accordance with this specification.  The Department will pay the remaining percentage of the bid price at the time of Project Completion.  The replacement plantings are subject to the one year establishment period regardless of the Project Completion date.  After the replacement plantings complete the one year establishment period, the Department will inspect the replacement plantings and notify the contractor of the Departments’ findings.  As final remedy under the contract, the Contractor is required to install replacement plants for all plantings that did not survive the establishment period at no additional cost to the State.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

661             Each                                Tree Seedling, (Size), (Species)

661             Each                                Perennials, (Size), (Species)

661             Each                                Groundcover and Vines, (Size), (Species)

661             Each                                Deciduous Shrub, (Size), (Species)

661             Each                                Evergreen Shrub, (Size), (Species)

661             Each                                Deciduous Tree, (Size), (Species)

661             Each                                Evergreen Tree, (Size), (Species)

ITEM 662  Landscape Watering

662.01  Description

662.02  Watering

662.03  Method of Measurement

662.04  Basis of Payment

662.01  Description.  This work consists of furnishing, delivering, applying, measuring, and scheduling a sufficient amount of water necessary to keep each plant included in Item 661 in a healthy growing condition throughout the period of establishment and the Contract.

662.02  Watering.  Furnish the water used in watering landscape plants.  Thoroughly water all plant material at the time of planting regardless of soil moisture content.  Continue to water throughout the period of establishment.

Saturate the root zone and mulched area of each plant without causing run-off according to Table 662.03-1.  During fall planting, continue to water until the ground is frozen and recommence watering after the spring thaw.  Furnish a rain gauge approved by the Engineer.

662.03  Method of Measurement.  The Department will measure Landscape Watering by the number of gallons (liters) delivered to plants from approved metered tanks or individually measured containers as follows:

Table 662.03-1  Watering Table

Plant Description

Gallons (L)

Shrubs:

   12 to 36 inches (300 to 900 mm), height

4 (15)

   36 inches to 5 feet (900 mm to 1.5 m), height

7 (25)

Trees:

   5 to 8 feet (1.5 to 2.5 m), height

15 (55)

   2 to 3 inches (50 to 75 mm), caliper

25 (95)

   3 to 4 inches (75 to 100 mm), caliper

30 (115)

   Greater than 4 inches (100 mm), caliper

35 (115)

662.04  Basis of Payment.  The Department will pay for the accepted quantities at the contract price as follows:

Item           Unit                                Description

662             Gallon (Liter)                  Landscape Watering

ITEM 666  PRUNING EXISTING TREES

666.01  Description

666.02  Wound Dressing

666.03  Pruning

666.04  Painting

666.05  Removal of Foreign Materials from Trees

666.06  Removal of Rubbish

666.07  Method of Measurement

666.08  Basis of Payment

666.01  Description.  This work consists of pruning trees.

666.02  Wound Dressing.  Use approved material specifically manufactured for tree wound dressing.

666.03  Pruning.  Prune all trees to make them shapely, typical of the species, using standard drawings on the plans as a guide.  Use approved pruning tools and methods.

Remove all dead wood and dead branches 1 inch (25 mm) or more in diameter.  Remove all branches interfering with or hindering the healthy growth of the tree with a good clean cut made flush with the parent trunk.  Remove all diseased branches.  For branches that may be partly dead, yet have a good healthy lateral branch between the dead part and the base, cut off the branch with a good clean slanting cut close to and beyond the healthy lateral branch.

Remove low hanging, unsound, or unsightly branches on trees or shrubs designated to remain.  Remove all branches or growth interfering with the free traffic movement on the highway.  Trim branches of trees extending over the roadbed to provide a clear height of 20 feet (6 m) above the roadbed surface.

Cut off all stubs or improper cuts resulting from former pruning or limbs that have been broken flush with the trunk or limb of the tree in order to ensure proper healing.

666.04  Painting.  Paint all cuts or wounds measuring 1 inch (25 mm) or more in diameter and all exposed wood and scars resulting from previous work or damage with approved tree wound dressing.

666.05  Removal or Foreign Materials from Trees.  Remove all nails, spikes, bolts, wire, or other foreign materials driven into or fastened to the trunk or branches of the tree, or, if directed by the Engineer, cut them flush with the bark of cambium layer to ensure complete healing over.

666.06  Removal of Rubbish.  Legally use, burn, or dispose of all material according to 105.16 and 105.17.

666.07  Method of Measurement.  The Department will measure Pruning Existing Trees by the number of each size, completed and accepted.

666.08  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

666             Each                                Pruning Existing Trees,
                                                               3 to 8-inch (80 to 200 mm) Diameter

666             Each                                Pruning Existing Trees,
                                                               8 to 16-inch (200 to 400 mm) Diameter

666             Each                                Pruning Existing Trees,
                                                               16 to 24-inch (400 to 600 mm) Diameter

666             Each                                Pruning Existing Trees,
                                                               24 to 36-inch (600 to 900 mm) Diameter

666             Each                                Pruning Existing Trees,
                                                               36 inches (900 mm) and Over

ITEM 670  EROSION PROTECTION

670.01  Description

670.02  Materials

670.03  Construction

670.04  Maintenance

670.05  Method of Measurement

670.06  Basis of Payment

670.01  Description.  This work consists of furnishing, placing, and maintaining slope, ditch, and vegetated swale erosion protection as shown on the plans.

670.02  Materials.  Furnish materials conforming to:

Sodding................................................................... 660.02

Erosion Control Mats.............................................. 712.11

For slope erosion protection, the Contractor may use any of the above materials.  For ditch erosion protection, use only Item 660 Sodding or Item 671 Erosion Control Mat Type B, C, E, or G or as specified in the plans.  For vegetated swale erosion protection, use only Item 671 Erosion Control Mat Type B or as specified in the plans.

670.03  Construction.  Install sodding according to Item 660.  Install erosion control mats according to Item 671.

670.04  Maintenance.  Maintain sodded areas as specified in Item 660.  Maintain erosion control mats as specified in Item 671.

670.05  Method of Measurement.  The Department will measure Slope Erosion Protection, Ditch Erosion Protection, and Vegetated Swale Erosion Protection by the number of square yards (square meters) completed and accepted.  The Department will determine the area based on the surface area covered by the slope, ditch, or swale erosion protection.

670.06  Basis of Payment.  The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

670             Square Yard                    Slope Erosion Protection
                       (Square Meter)

670             Square Yard                    Ditch Erosion Protection
                       (Square Meter)

670             Square Yard                    Vegetated Swale Erosion Protection

                       (Square Meter)            

670             Square Yard                    Slope Erosion Protection Mat Type __

                       (Square Meter)            

670             Square Yard                    Ditch Erosion Protection Mat Type __

                       (Square Meter)            

670             Square Yard                    Vegetated Swale Erosion Protection

                       (Square Meter)                Mat Type ____

ITEM 671  erosion control Mats

671.01  Description

671.02  Materials

671.03  Construction

671.04  Maintenance

671.05  Method of Measurement

671.06  Basis of Payment

671.01  Description.  This work consists of furnishing, placing, and maintaining Types A through I erosion control mats.  This work also consists of furnishing, placing, and maintaining seeding and mulching when the seeding and mulching is to be held in place with erosion control mats.

671.02  Materials.  Furnish materials conforming to:

Seed and Mulch............................................................ 659

Lime and Fertilizer........................................................ 659

Erosion Control Mats.............................................. 712.11

If the mat type is not specifically itemized, furnish any mat type listed in 712.11.

Furnish staples consisting of 12-inch (0.3 m) No. 11 gage steel wire bent into narrow U-shape with the ends of the staples approximately 1 inch (25 mm) apart producing a 6 inch staple or furnish pins conforming 18 inch (450 mm) long, 1/4 inch (4.5 mm) in diameter, with attached 1 1/2 inch (38 mm) washer. Drive staples until the staple is flush with the ground surface.  Drive pins until the attached washer is flush with the ground surface.

For clay, shale, and other heavy soils, furnish 3-inch (75 mm) steel staples, No. 9 gage or thicker with points approximately 1 inch (25 mm) apart, as required by the Engineer.

671.03  Construction.  Before placing any type of temporary erosion control mats, prepare the surface, apply the fertilizer and lime if specified, and seed as specified in Item 659 or as shown on the plans.  Place the temporary erosion control mat in the locations shown on the plans.

A.      Types A, B, C, E, F, and I.  Construct erosion control mat Types A, B, C, E, F, and I as follows:

1.      Within 48 hours after seeding and before placing the mat, evenly place mulch over the specified area at the following rates:

a.      For straw mulch, use 30 percent of the rate specified in 659.14.

b.      For wood fiber mulch, use 30 percent of the rate specified in 659.15.

c.      For compost, use the same rate as specified in 659.16.

d.      Asphalt emulsion tack or tackifier is not required.

2.      Immediately after mulching, lay the mat strips flat, loose, parallel to the flow of water, and with the mat contacting the ground at all points.  For mats placed in ditches, start the construction at the downstream end.

3.      Where more than one strip is required to cover the area, overlap the strips at least 4 inches (100 mm).  Overlap the ends at least 6 inches (150 mm) with the upgrade strip on top.

4.      Place upgrade slots at the upgrade end of each strip of mat by placing a tight fold of the mat at least 6 inches (150 mm) vertically into the soil. Firmly tamp the soil against the end and staple the mat.  If directed by the Engineer, bury other edges exposed to more than normal flow in a similar manner.

5.      Place end slots between the ends of strips by placing a tight fold of the mat at least 6 inches (150 mm) vertically into the soil.  Firmly tamp the soil and staple the mat. 

6.      Place check slots by placing a tight fold of the mat at least 6 inches (150 mm) vertically into the soil. Firmly tamp the soil and staple the mat.  Space check slots so that one check slot or an end slot occurs within each 50 feet (15 m) of slope for slopes 3 to 1 or steeper.

7.      Bury the edges of the mat where the mat abuts catch basins and other structures.

8.      Secure the mat in place with staples driven vertically into the soil.  Do not stretch or draw the mat taut during the stapling operation.  Install three rows of staples for each strip of mat, with one row along each edge and one row alternately spaced in the middle.  Space staples not more than 3 feet (1 m) apart in each row.  Staple all upgrade slots, end slots and check slots across the width, with staples spaced not more than 6 inches (150 mm) apart.

9.      After completing the mat installation, seed over top of the mat in areas that the Engineer identifies as disturbed.  Use a seed mixture conforming to Item 659 at the rate of 1 pound per 1000 square feet (5 g/m²) or with a mixture or rate shown on the plans.

B.      Type G.  Construct erosion control mat Type G according to 671.03.A, with the following exceptions.

1.      Do not use mulch under the mat.

2.      Overlap edges and ends by 1 1/2 inches (40 mm).

3.      Do not bury the upgrade end or top edge of each strip unless required by the Engineer due to special conditions in the field.

4.      The Contractor may elect not to provide check slots. However upgrade slots and end slots will be furnished.

5.      Place the mat in contact with the soil.

671.04  Maintenance.  Maintain the specified areas until all work in the Contract has been completed and the Engineer issues the final acceptance.  Restore damaged areas to the condition and grade existing just before placing the mat.  Relime, refertilize, and reseed restored areas according to Item 659.  Replace all damaged mats.

671.05  Method of Measurement.  The Department will measure Erosion Control Mat, Type ___ by the number of square yards (square meters) completed and accepted.  The Department will determine the area based on the surface area covered by the erosion control mat.

671.06  Basis of Payment.  The Department will not pay for maintenance as detailed in 671.04 that is required due to the Contractor’s negligence, carelessness, or failure to install erosion controls.

If erosion control items in the Contract are properly placed according to the Contract Documents, the Department will pay for maintenance detailed in 671.04 or according to 109.05.

The Department will pay for liming and fertilizing of areas covered by the mats under Item 659.  The Department will not pay for the seeding and mulching performed under or over the mats.

The Department will pay for accepted quantities at the contract prices as follows:

Item           Unit                                Description

671             Square Yard                    Erosion Control Mat, Type ___
                       (Square Meter)               

671             Square Yard                    Erosion Control Mat
                       (Square Meter)

700 MATERIAL DETAILS

700 MINIMUM REQUIREMENTS FOR SAMPLING MATERIALS

Spec No.

Material

Material only Inspection or Sampling Requirements

Post Inspection Instructions

203

Embankment

Assure 203.02 Q and R materials conform to the individual material requirements.  Sample materials when requested by the Engineer.

Follow S 1015 for acceptance

Soil Embankment: 50 lb (23 kg)

Granular Embankment: 50 lb (23 kg)

 ™

258.02

Dowel Bar Retrofit

Silicone Sealant– Obtain letter of certification stating that the material meets the requirements of item 258.  Material to be shipped from manufacturer not more than 9 months prior to use.

Dowel Bar grout - Verify brand name of material is on QPL at the time of use.

Notify District Testing if rejecting material.

If material non-performs or looks defective during use submit a use a 1 quart sample to the Laboratory

301

302

Asphalt Concrete Base

Project: Visually inspect delivered loads and newly placed mat

Plant: Test 1 sample in 4 days for verification. Observe other contractor QC sample and QC test 1 in 4 days.

Plant: Conduct minimum monitoring requirements.

Project: Contact project Engineer/ DCA/DET immediately if problems are seen

Plant: Compare results per 403.  Report on monitoring.

304

Aggregate Base

Perform compaction conforming to supplement 1015 and 304.05

Products will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use submit a use a 1 quart sample to the Laboratory

305

PC Concrete Pavement

Make two 6"x6"x4' beams for every 7500 yd² (6500 m²) or fraction thereof daily.  Field test beams for required load for the specification.

Sample asphalt cement conforming to 702.01

Report results in CMS (Trns.port SiteManager ™ ).

Core samples taken every 2000 sq. yds by Contractor.  Conform to S 1064

307

Non Stabilized Drainage Base

Provide samples conforming to 703.12 for design verification.  Provide in process samples as directed by the Engineer.  Sample material conforming to 703.12

Determine locations for thickness tolerance checks according to S 1064. 

407

Tack Coat

If obtaining a sample  draw at least one gallon from the sampling valve or tap and discard prior to obtaining a one-quart sample.

Tag and ship to sample to the District lab for OMM Asphalt Materials testing.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use submit a use a 1 quart sample to the Laboratory.

409

Sawing and Sealing Asphalt Concrete pavement Joints

Assure backer rod is on QPL at the time of use.

Inspect material for condition.

Document in CMS (Trns.port SiteManager ™).

Follow joint seal material sections for sampling and acceptance requirements

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District testing and OMM

421

Micro Surfacing

Project: Conduct a test strip per 421.09, inspect per 421.10 and accept per 421.11.

422

Chip Seal with Polymer Binder

Project: Conduct a test strip per 422.05.  Clean the surface per 422.06.  Verify binder and aggregate application per 422.07 and 422.08.  Ensure contractor quality control per 422.10.  Verify all of 422.11 is met for acceptance.

423

Fibers for Asphalt Concrete:

Polyester

Propylene

Polypropylene

Verify type and  brand name of material is on QPL at the time of  use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use submit a use a 1 quart sample to the Laboratory.

424

Asphalt Concrete (Fine Graded Polymer)

For Type A see 301,302 procedures.  For Type B see 448 procedures.

442

 Asphalt Concrete

Project and Plant: See requirements for 446 or 448 as specified for the 442 item.

Sample asphalt cement conforming to 702.01

443

Asphalt Concrete (Stone Mastic)

See 446 requirements.

446

Asphalt Concrete 

Project: Visually inspect delivered loads and newly placed mat

Sample asphalt cement conforming to 702.01

Project: Obtain daily mix sample for District test unless otherwise directed by the DET.

Project: Obtain 10 cores for each lot (day) within 48 hours for District test. Locate cores for sampling.

Project: See 702.04 or 702.13  for tack sample.

Plant: Conduct minimum monitoring requirements.

Plant: See 702.01 for PG binder sample

Project: Contact project Engineer/ monitoring team immediately if problems seen.

Project: Observe proper handling and quick delivery of the mix  sample. Place cores in box  flat side down, do not stack boxes, do not leave in weather, deliver to lab promptly.

Plant: Report on monitoring.

448

Asphalt Concrete

Project: Visually inspect delivered loads and newly placed mat

Sample asphalt cement conforming to 702.01

Project: Give lot sample location to the District monitoring team unless otherwise directed by the DET.

Project: See 702.04 or 702.13  for tack sample.

Project: Conduct density gauge QA per S 1055

Plant: Conduct minimum monitoring requirements.

Plant: See 702.01 for PG binder sample

Project: Contact project Engineer/monitoring team immediately if problems seen.

Project: Re Core for S 1055 if gauge change or JMF change.

Plant: Report on monitoring.

451

PC Concrete Pavement

Make 6"x6"x4' beams for every 7500 yd² (6500 m²) or fraction thereof daily.  Make two beams if testing before 7 days.  Field test beams for required load for the specification.

Report results in CMS (Trns.port SiteManager ™).

Core samples taken every 2000 sq. yds by Contractor.  Conform to S 1064

451.09.B

Dowel Bond Breaking Material

Check new light form oil by labels on new cans.  No sampling required

Report material as not approved and follow policy for non specification materials

452

PC Concrete Pavement

Make 6"x6"x4' beams for every 7500 yd² (6500 m²) or fraction thereof daily. Make two beams if testing before 7 days.  Field test beams for required load for the specification.

Report results in CMS (Trns.port SiteManager ™).

Core samples taken every 2000 sq. yds by Contractor.  Conform to S 1064

499

Various Concrete Items

A sample for concrete strength testing consists of a set of three 4 × 8 inch cylinders when the maximum nominal aggregate is 1 inch or less. For concrete with maximum nominal aggregate sizes greater than 1 inch, a sample consists of a set of two 6 × 12 inch cylinders.

Within 24 to 48 hours after sampling, ship cylinders to Laboratory with required documentation.

499.02

Water                                                            

Potable water is satisfactory.

If question about water quality, obtain 1 gallon sample.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if water appears to contain sewage, oil, acid, or other matter.

503.09

Excavation for Structures

Backfill

Sampled only when requested by the Engineer per Section 203

Soil Embankment: 50 lb (23 kg)

Granular Embankment: 50 lb (23 kg)

504

Sheet Piling Left in Place

Use 711.03 materials

507.09

Bearing Piles 

Steel Pile Points                                        

Only use points from suppliers on the approved list on the Office of Materials Management website. .

Document in CMS (Trns.port SiteManager ™) as needed.

Notify District Testing if material non-performs or looks defective during use. Notify the contractor with non-compliance issues.

509.08

Reinforcing Steel - Plastic support chairs

Assure plastic supports conform to 709.15.

Maximum spacing of supports in slabs, beams and girders to be 4 feet; or less to prevent substantial deflection.

511

Concrete for Structures

NON QC/QA SPECIFICATIONS

Make one set of cylinders for spans over 20 ft each day, each 200 yd³.

For spans  20 ft span and under, make one set of cylinders each 50 yd³ or less.

Document in CMS (Trns.port SiteManager ™) as needed..

Field or Standard Cure according to ACI/ODOT specifications.

QC/QA SPECIFICATIONS

Follow requirements of 455 for quality assurance sampling and testing.

Document in CMS (Trns.port SiteManager ™) as needed..

Within 24 to 48 hours after sampling, ship cylinders to District Laboratory with required documentation.

Within 24 to 48 hours after sampling, ship quality assurance cylinders to District Laboratory with required documentation.

515

Prestressed Concrete Bridge Members

Assure products are supplied by a source on the Certified List for S-1079  maintained by OMM.

Received with TE-24.

Check dimension and condition

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM, Cement and Concrete section, 

515.15

Prestressed Concrete Bridge Members -Corrosion Inhibitors

Verify company and brand name of material is on QPL at the time of  use. Document in CMS (Trns.port SiteManager ™).

For Precast beams delivered on TE-24, verification performed by OMM.

526

Approach Slabs

 Make one set of cylinders for each day, each 200 yd³.

Document in CMS.

Field or Standard Cure according to ACI/ODOT specifications.

Within 24 to 48 hours after sampling, ship cylinders to Laboratory with required documentation.

609.02

Curbing, Concrete Medians, and Traffic Islands - Stone Curbs

Contact District Testing and OMM Aggregate Section to assure stone curb conforms to requirements of 609.02

610

Cellular Retaining Walls

610.04.A Cellular Products will be supplied by a source on the Certified Lists for S-1073 maintained by OMM.

Received with TE-24.

Check dimension, condition and compliance with approved drawings.

610.04.B Cellular Products accept by certified test data documentation at the Project .

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

613

Low Strength Mortar Backfill

Supplier to perform trial batches of 1 cy to ensure flowable consistency and yield.

Refer to Item 613.05 for alternate mix design.

Alternate mix designs will be submitted for approval 30 days prior to placement.. Submit written permission form to EPA 10 days prior to placement.

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

632.11

Traffic Signal Equipment 

Loop Detector Sealant

Verify manufacturer is on QPL.

Inspect for condition, appearance and package markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

633

Traffic Signal Controllers

Inspect material for condition and conformance to shop drawings.

Manufacturer’s certified test data required for acceptance.

Refer to Handbook of Procedures for Contractor Certification of Lighting, Signing & Traffic Signal Working Drawings on OMM Manual website.

Notify District Testing if rejecting material.

653.02

Topsoil

Obtain one (1) pint sample of material from each source and/or stockpile of visually different material from same source.

Use friction top, air tight metal container supplied by the Department.

Submit to Office of Geotechnical Engineering Operations.

Samples will include a TE-31 form or CMS (Trns.port SiteManager ™) print screen

657.02

RipRap for Tree Protection

Confirm with DET that the aggregate source has a acceptable performance history. For sources with poor performance require test data conforming to ASTM D5240

658.02

Tree Root Aeration - Aggregate

Assure source on the Certified List for S 1069 maintained by OMM

Assure aggregate meets soundness requirements.  Sample sources with no soundness history and obtain a 100 lb (45 kg) sample

659.03

Seeding and Mulching - Liming Materials

Only accept materials from suppliers licensed in Ohio.  See OMM website for list of Ohio Department of Agriculture list of licensed suppliers. 

Document in CMS (Trns.port SiteManager ™)

659.04

Seeding and Mulching - Commercial Fertilizer

Only accept materials from suppliers licensed in Ohio.  See OMM website for list of Ohio Department of Agriculture list of licensed suppliers. 

Inspect material for certified analysis and condition.

Non-standard application rate require approval prior to use

Document in CMS (Trns.port SiteManager ™).

Licensing is required. Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing & OMM.

659.07

659.08

659.09

S1022

Seeding and Mulching

Seeds

Legumes

Native Grasses and Wildflowers

Verify manufacturer is on certified supplier List maintained by OMM.

Received with TE-24 and description bill of lading.

Document in CMS (Trns.port SiteManager ™).

Verify District approval of seed mixture.

659.14

659.15

659.16

Seeding and Mulching - Mulch

Material should be reasonably free from foreign matter that would inhibit seed germination.

Notify District if rejecting material.

660.02

Sodding 

Verify company and brand name of material is on QPL at the time of  use.

Certification required for each shipment.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

661

Planting Trees Shrubs and Vines

[Trees]

[Shrubs]

[Vines]

Verify company and brand name of material is on QPL at the time of  use.

Inspect material for condition.

Plant material should be sealed until use.

Document in CMS (Trns.port SiteManager ™).

Final acceptance should take place after period of establishment.

Notify District Testing if rejecting material.

STANDARD MATERIALS SPECIFICATIONS

701.01

701.02

701.04

701.05

701.07

701.09

Cement, Hydraulic

ASTM Types I, IA, II, III

Masonry

Type IS(<25)

Verify manufacturer on Concrete Plant Batch Ticket is on Certified List for S 1028 maintained by OMM.

Verify material against bill of lading description.

Document in CMS (Trns.port SiteManager ™).

Obtain one  ½ gallon sample and original bill-of-lading  per concrete plant every 180 days  for QA. Ship sample to OMM laboratory.

Ensure that sample container is filled to capacity prior to transport.

701.10

Micro-Silica

Verify manufacturer on Concrete Plant Batch Ticket is on Certified List for S 1045 maintained by OMM.

Verify material against bill of lading description

Document in CMS (Trns.port SiteManager ™).

Obtain one  ½ gallon sample and original bill-of-lading  per concrete plant every 180 days  for QA.  Ship sample to OMM laboratory.

Ensure that sample container is filled to capacity prior to transport.

701.11

Ground Granulated Blast Furnace (GGBF) Slag

Verify manufacturer on Concrete Plant Batch Ticket is on Certified List for S 1034 maintained by OMM.

Verify material against bill of lading description

Document in CMS (Trns.port SiteManager ™).

Obtain one  ½ gallon sample and original bill-of-lading  per concrete plant every 180 days  for QA.  Ship sample to OMM laboratory.

Ensure that sample container is filled to capacity prior to transport.

701.13

Fly Ash

Verify manufacturer on Concrete Plant Batch Ticket is on Certified List for S 1026 maintained by OMM.

Verify material against bill of lading description

Document in CMS (Trns.port SiteManager ™).

If high LOI  fly ash verify manufacturer on Concrete Plant Batch Ticket is on List for S 1115.

Obtain one  ½ gallon sample and original bill-of-lading  per concrete plant every 180 days  for QA. Ship sample to OMM laboratory.

Ensure that sample container is filled to capacity prior to transport.

702.01

Asphalt Binder

Certified asphalt PG binder:   As directed by the Lab.

Plant: Minimum of one sample per project per season, except for inconsequential quantities.

Non-Certified PG binder: Will be sampled and approved by the Department before use.

Certified binder: Plant:  Submit sample to Lab.

Non-certified binder: Submit to Lab.  Do not allow asphalt production until material is approved.

702.02

702.03

702.04

702.07

702.13

Cut Back Asphalt

Cut Back Asphalt Emulsions

Emulsified Asphalts

Asphalt Emulsion MWS

SBR Asphalt Emulsion

Certified material:

At the refinery or source as directed by the Lab. Project and/ or Plant: One sample per each 25,000 gallons. None for less than 300 gallons.

Non-certified material: Will be sampled and approved by the Department before use.

702.13 – Provide Certified Test Data per specification requirements.

Certified material:  Submit to Lab.

Non-certified material: Submit to Lab. Do not use until approved by Lab.

702.05

702.06

Asphalt Primer Waterproofing

Asphalt Waterproofing

Verify type and brand name of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager™)

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM Asphalt Cement Section.

702.16

Polymer Emulsified Binder

Type A: Certified Material.  At the refinery or source as directed by the Lab. Project and/ or Plant Sample per 422.10.

Non-certified material: Will be sampled and approved by the Department before use.

Type B: Certified test data

Type A: Certified material:  Submit to Lab.  

Non-certified material: Submit to Lab. Do not use until approved by Lab.

702.17

Crack Sealant

Material is pre-tested and approved.

Will be shipped with TE-24.

Document in CMS (Trnsport SiteManager ™).

Notify District Testing if rejecting material.

 If material non-performs or looks defective during use Notify District Testing and OMM Asphalt Section.

Type 1

Type II

Provide fibers listed on the QPL.  Provide PG64-22 conforming to 702.01

Notify District Testing if rejecting material.

 If material non-performs or looks defective during use Notify District Testing and OMM Asphalt Section.

Type III

Provide fibers listed on the QPL.  Provide PG64-22 conforming to 702.01

Type IV

Provide fibers listed on the QPL

703.02

703.04

703.05

703.08

Coarse Aggregate from Certified Stock

Coarse Aggregate will be supplied by a Pre-Qualified producer/supplier (S1069).  Verify the producer/supplier is Pre-Qualified using the Pre-Qualified Producer/Supplier list maintained by OMM (website).

Document in CMS.

60 to 75 lb. QC sample taken by District lab at source a minimum four (4) times per year.

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.02

703.04

703.05

703.08

Coarse Aggregate from Non-Certified Stock

Coarse Aggregate will be supplied by a Pre-Qualified producer/supplier (S1069).  Verify the producer/supplier is Pre-Qualified using the Pre-Qualified Producer/Supplier list maintained by OMM (website).60 to 70 lb. QC sample taken from each 2600 ton (2360 metric ton) stockpile, submitted to OMM Aggregate Section. 100 lb QC sample for sizes 1,2, and 24.

Document in CMS.

Do not use until tested and approved.

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.02

703.03

703.04

703.05

703.06

703.10

Fine Aggregate from Certified Stock 

Fine Aggregate will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

30 to 40 lb. QC sample taken by District lab at source a minimum four (4) times per year.

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.02

703.03

703.04

703.05

703.06

703.10

Fine Aggregate from Non-Certified Stock

Fine Aggregate will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

30 to 40 lb. QC sample taken from each 1800 ton (1640 metric ton) stockpile, submitted to OMM Aggregate Section.

Document in CMS (Trns.port SiteManager ™).

Do not use until tested and approved.

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.02

703.04

703.05

Dense Graded Aggregate from Certified Stock

Dense Graded Aggregate will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

90 to 100 lb. QC sample taken by District lab at source a minimum four (4) times per year.

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.02

703.04

703.05

Dense Graded Aggregate from Non-Certified Stock

Dense Graded Aggregate will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

90 to 100 lb. QC sample taken from each 5200 ton (4720 metric ton) stockpile, submitted to OMM Aggregate Section.

Document in CMS (Trns.port SiteManager ™).

Do not use until tested and approved.

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.07

Materials Mineral filler

For limestone dust assure from a source on Certified List for S 1069.

For Portland cement assure source is on Certified list for S 1028

For inert mineral filler sample for gradation. Submit to District Lab.

703.11

  Type 1

Structural Backfill for 611 Bedding and Backfill from Certified Stock

Assure materials provided by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

90 to 100 lb. QC sample taken by District lab at source a minimum four (4) times per year.

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.11

  Type 1

Structural Backfill for 611 Bedding and Backfill from Non-Certified Stock

Assure materials provided by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

90 to 100 lb. QC sample taken from each 5200 ton (4720 metric ton) stockpile, submitted to OMM Aggregate Section.

Document in CMS (Trns.port SiteManager ™).

Do not use until tested and approved.

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.11

  Type 2

Structural Backfill for 611 Bedding and Backfill from Certified Stock

Assure materials provided by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

90 to 100 lb. QC sample taken by District lab at source a minimum four (4) times per year.

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.11 Type2

Structural Backfill for 611 Bedding and Backfill from Non-Certified Stock

Assure materials provided by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

90 to 100 lb. QC sample taken from 5200 ton (4720 metric ton) stockpile, submitted to OMM Aggregate Section.

Document in CMS (Trns.port SiteManager ™).

Do not use until tested and approved.

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.11 Type 3

Structural Backfill for 611 Bedding and Backfill from Certified Stock

Assure materials provided by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

60 to 70 lb. QC sample taken by District lab at source a minimum four (4) times per year.

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.11 Type 3

Structural Backfill for 611 Bedding and Backfill from Non-Certified Stock

Assure materials provided by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

60 to 70 lb. QC sample taken from each 5200 ton (4720 metric ton) stockpile, submitted to OMM Aggregate Section.

Document in CMS (Trns.port SiteManager ™).

Do not use until tested and approved.

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.13

Coarse Aggregate for Items 451 and 452

Assure materials provided by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Assure materials are on the OMM Freeze Thaw List

Follow requirements of coarse aggregate 703.02

Document in CMS (Trns.port SiteManager ™).

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.14

Steel Slag Aggregate for Non-Pavement Use

Assure materials from a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Stockpile and sample each 2500 tons (2300 metric tons).  Notify the District laboratory for inspection of sources and to obtain split samples.  Test for expansion

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.16

Suitable Materials for Embankment Construction

Multiple materials listed.  Follow the requirements of the individual material specification

Follow the requirements of the individual material specification

Modification required for 703.16

703.17

Dense Graded Aggregate for Item 304 from Certified Stock

Products will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

90 to 100 lb. QC sample taken by District lab at source a minimum four (2) times per year.

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.17

Dense Graded Aggregate for Item 304 from Non-Certified Stock

Products will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

90 to 100 lb. QC sample taken from each 5200 ton (4720 metric ton) stockpile, submitted to OMM Aggregate Section.

Document in CMS (Trns.port SiteManager ™).

Do not use until tested and approved.

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.18

Aggregate for Items 410, 411, and 617from Certified Stock

Products will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

90 to 100 lb. QC sample taken by District lab at source a minimum four (4) times per year.

No project sampling required except if project believes there is a problem with the material [either gradation or quality]

703.18

Aggregate for Items 410, 411, and 617from Non-Certified Stock

Products will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

90 to 100 lb. QC sample taken from each 5200 ton (4720 metric ton) stockpile, submitted to OMM Aggregate Section.

Document in CMS (Trns.port SiteManager ™)..

Do not use until tested and approved.

No additional project sampling required for approved, sampled tonnage  except if project believes there is a problem with the material [either gradation or quality]

703.19.A

Crushed Aggregate Slope Protection and Filter Aggregate for Dump Rock Fill

Products will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Document in CMS (Trns.port SiteManager ™).

No sampling required except if project believes there is a problem with the material [either gradation or quality]

703.19.B

Dumped Rock Fill and Rock Channel Protection

Products will be supplied by a supplier on the Pre-Qualified Supplier List for S 1069 maintained by OMM.

Confirm with OMM laboratory source has know durability history

Sample on direction of the OMM laboratory

Document in CMS (Trns.port SiteManager ™).

No sampling required except if project believes there is a problem with the material [either gradation or quality]

704.01

704.02

704.03

Block:

Brick

Concrete Masonry

Shale

Verify type of material is on QPL at the time of  use.

Inspect for condition and defects.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

When material non-performs or looks defective during use reject material and sample 12 brick representative of defect to OMM for QA follow-up.

705.01

Fiber Reinforced Polymer (FRP) Dowel Bars

Certified test data from an accredited testing facility will accompany each shipment.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing upon receipt of shipment.

705.03

Joint Filler

Preformed

Verify type and brand name of material is on QPL at the time of use.

Inspect for condition, appearance and dimension.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send one (1) 1.5'x2.5' sample representative of defect to OMM for QA follow-up.

705.04

Joint and Crack Sealer

Hot Applied

Material is pre-tested and approved.

Will be shipped with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

 If material non-performs or looks defective during use notify District Testing and OMM Asphalt Section for sampling requirements.

705.05

Burlap Cloth Materials

Inspect for condition, appearance and dimension.

Documenting in CMS (Trns.port SiteManager ™ ) .is not required

Only sample if there if questioning material meet specification

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

705.06

Sheet Curing Materials

Inspect for condition, appearance and dimension.

Documenting in CMS (Trns.port SiteManager ™ ) is not required.

Only sample if there if questioning material meet specification

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

705.07

Concrete Curing Compounds

Verify type and brand name of material is on QPL at the time of use.

Inspect for condition and appearance.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send one (1) quart sample representative of defect to OMM, Cement and Concrete section, for QA follow-up.

705.10

Air Entraining Admixtures

Verify type and brand name of material listed on Concrete Plant Batch Ticket is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Storage: Admixtures should be stored at concrete producer in such a manner to permit easy access for proper identification in weather resistant units.

Provide minimum QA sample of one (1) every 180 days per concrete plant, each material, each company. Minimum sample size one (1) quart

705.11

Joint Sealer

Preformed Elastomeric

Verify type and brand name  of material is on QPL at the time of use.

Inspect for condition, appearance, dimension and manufacturer trademark.

Document in CMS (Trns.port SiteManager ™). 

Notify District Testing if rejecting material because material non-performs or looks defective during use.

705.12

Chemical Admixtures for Concrete

Verify type and brand name  of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Storage: Admixtures should be stored at concrete producer in such a manner to permit easy access for proper identification in weather resistant units.

Provide minimum QA sample of one (1) every 180 days per concrete plant, each material, each company. Minimum sample size one (1) quart.

705.13

Neoprene Sheeting

Verify type and brand name of material is on approved list at time of use. Inspect for condition and appearance. Document in CMS (Trns.port Site Manager ™)

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

705.15

High Molecular Weight Methacrylate (HMWM)

Verify type and brand name  of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

705.20

Non Shrink, Non Metallic Grout

Verify type and brand name  of material is on QPL at the time of use. Ensure mixing is performed in accordance with manufacturer’s recommendations on the container. 

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM for sampling requirements.

705.21

Quick Setting Concrete Mortar

Verify type and brand name  of material is on QPL at the time of use. Ensure mixing is performed in accordance with manufacturer’s recommendations on the container. 

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM for sampling requirements.

705.22

Non-shrink Mortar

Verify manufacturer is on the Approved List maintained by OMM.  Ensure mixing is performed in accordance with manufacturer’s recommendations on the container.  Make three (3) or more 3"x6" cylinders from keyway mix.

Ship to OMM Concrete Section.

Document in CMS (Trns.port SiteManager ™).

Sample will be tested at 3, 7 and 28 days.

Do not open structure to traffic until a compressive strength of 5000 psi (34.5 MPa) is achieved.

705.23 A

Epoxy-urethane Sealers

Verify type and  brand name of material is on QPL at the time of  use.

Ensure mixing is performed in accordance with manufacturer’s recommendations on the container. 

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use obtain 1 qt (1 L) samples in a sealed container and send to OMM.

705.23 B

Non Epoxy Sealers

Verify type and  brand name of material is on QPL at the time of  use.

Ensure mixing is performed in accordance with manufacturer’s recommendations on the container. 

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use obtain 1 qt (1 L) samples in a sealed container and send to OMM.

705.24

Soluble Reactive Silicate

Verify type and  brand name of material is on QPL at the time of  use.

Ensure mixing is performed in accordance with manufacturer’s recommendations on the container. 

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

705.25

Gravity Fed Resin

Verify type and  brand name of material is on QPL at the time of  use.

Ensure mixing is performed in accordance with manufacturer’s recommendations on the container. 

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use obtain 1 qt (1 L) samples in a sealed container and send to OMM.

705.26

Epoxy injection Resin

Verify type and  brand name of material is on QPL at the time of  use.

Make sure that ports are properly installed and ensure mixing is performed in accordance with manufacturer’s recommendations

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

706.01

Non-Reinforced Concrete Pipe

Assure products are supplied by a source on the Certified List for S-1074  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.02

Reinforced Concrete Circular Pipe

Assure products are supplied by a source on the Certified List for S-1074  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.03

Reinforced Concrete Pipe, Epoxy Coated

Assure products are supplied by a source on the Certified List for S-1074  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.04

Reinforced Concrete Elliptical Culvert,

Storm Drain and Sewer Pipe

Assure products are supplied by a source on the Certified List for S-1074  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.05

Precast Reinforced

Concrete Box Sections

Assure products are supplied by a source on the Certified List for S-1073  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.051

Precast Reinforced Concrete 

Three-Sided Flat Topped Culverts

Assure products are supplied by a source on the Certified List for S-1073  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.052

Precast Reinforced Concrete Arch Sections

Assure products are supplied by a source on the Certified List for S-1073  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.053

Precast Reinforced Concrete Round Sections

Assure products are supplied by a source on the Certified List for S-1073  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.06

Perforated Concrete Pipe

Assure products are supplied by a source on the Certified List for S-1074  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.07

Concrete Drain Tile

Assure products are supplied by a source on the Certified List for S-1074  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.08

Vitrified Clay Pipe

Verify type and brand name  of material is on QPL at the time of use.

Inspect for condition, appearance and dimension.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.09

Clay Drain Tile

Verify type and brand name  of material is on QPL at the time of use.

Inspect for condition, appearance and dimension.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Cement and Concrete section, 

706.10

Bituminous pipe joint filler

Verify type and brand name  of material is on QPL at the time of use.

Inspect for condition, appearance and dimension.

Document in CMS (Trns.port SiteManager ™).

If rejecting material because material non-performs or looks defective during use, notify District Testing and OMM ,  Asphalt Concrete section, 

706.11

Resilient and Flexible Gasket Joints

Verify type and brand name of material is on QPL at the time of use.

Inspect for condition, appearance and dimension.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, Structural Metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

706.12

Resilient and Flexible Joints

Verify type and brand name of material is on QPL at the time of use.

Inspect for condition, appearance and dimension.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM Structural Metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

706.13

Precast Reinforced Concrete Manhole Riser Sections, Catch Basins and Inlet Tops, and Temporary Barriers

Assure products are supplied by a source on the Certified List for S-1073  maintained by OMM

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM ,  Cement and Concrete section,  if rejecting material because material non-performs or looks defective during use.

706.14

Flexible Plastic Gaskets

Verify type and brand name of material is on QPL at the time of use.

Inspect for condition, appearance and dimension.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, Structural Metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

706.15

Precast Reinforced Concrete Outlets

Assure products are supplied by a source on the Certified List for S-1073  maintained by OMM

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM ,  Cement and Concrete section,  if rejecting material because material non-performs or looks defective during use.

707.01

Metallic Coated Corrugated Steel Conduits and Underdrains

[½ inch and 1/4 depth corrugations]

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.02

Metallic Coated Corrugated Steel Conduits

[1 inch depth corrugation]

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.03

Structural Plate Corrugated Steel Structures

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.04

Precoated, Galvanized Steel Culverts

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and cracks.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use

707.05

705.07

Bituminous Coated Corrugated Steel Pipe and Arches with Paved Invert

[½ inch depth corrugations]

[1 inch depth corrugations]

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.10

Steel Tubing

Square and Rectangular

Generally a fabricated component received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.11

Mortar Lined Corrugated Steel Pipe

[any corrugation depth]

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.12

Corrugated Steel Spiral Rib Conduits

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use

707.13

707.14

Bituminous Lined Corrugated Steel Pipe 

[½ depth corrugations]

[1 depth corrugations]

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.15

Corrugated Steel Box Culverts

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.18

Polymer Precoated, Galvanized Steel Conduits with precoated galvanized smooth steel interior liner

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimension and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.19

Aluminum Coated Steel Conduits with precoated galvanized smooth steel interior liner

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimension and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.20

Galvanized Coated Steel Conduits with precoated galvanized smooth steel interior liner

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimension and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.21

Corrugated Aluminum Alloy Conduits and Underdrains

[1/4, 7/16 & ½ inch depth corrugations]

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimension and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.22

Corrugated Aluminum Alloy Conduits

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimension and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.23

Aluminum Alloy Structural Plate Conduits

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.24

Corrugated Aluminum Spiral Rib Conduits

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.25

Corrugated Aluminum Box Culverts

Products will be supplied by a source on the Certified List for S-1019  maintained by OMM.

Received with TE-24.

Check dimensions and markings.

Document in CMS (Trns.port SiteManager ™ ).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

707.31

707.32

707.33

Polyethylene  Corrugated Pipe

Products will be supplied by a source on the Certified List for S-1066  maintained by OMM.

Received with TE-24.

Check dimension and markings.

Document in CMS (Trns.port SiteManager ™ ).

Notify District Testing and OMM, asphalt section,  if rejecting material because material non-performs or looks defective during use.

707.41

Smooth-Wall Polyvinyl Chloride Underdrain Pipe

Verify type and brand name of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

707.42

Polyvinyl Chloride Corrugated Smooth Interior Pipe

Verify type and brand name of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

707.43

Polyvinyl Chloride Profile Wall Pipe

Verify type and brand name of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

707.45

Polyvinyl Chloride Solid Wall Pipe

Verify type and brand name of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

707.46

Polyvinyl Chloride Drain Waste and Vent Pipe

Verify type and brand name of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

707.47

ABS and Polyvinyl Chloride Composite Pipe

Furnish certified test data conforming to 101.03 to the Engineer.

Document in CMS (Trns.port SiteManager ™).

Accept based on inspection of material for type, condition, dimension, receipt and verification of manufacturer’s certified test data.

Notify District Testing if rejecting material.

707.48

Polyvinyl Chloride Large-Diameter Solid Wall Pipe

Verify type and brand name of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

707.51

ABS Drain Waste and Vent Pipe

Furnish certified test data conforming to 101.03 to the Engineer.

Document in CMS (Trns.port SiteManager ™).

Accept based on inspection of material for type, condition, dimension, receipt and verification of manufacturer’s certified test data.

Notify District Testing if rejecting material.

707.52

ABS Sewer Pipe

Furnish certified test data conforming to 101.03 to the Engineer.

Document in CMS (Trns.port SiteManager ™).

Accept based on inspection of material for type, condition, dimension, receipt and verification of manufacturer’s certified test data.

Notify District Testing if rejecting material.

707.62

Polypropylene Corrugated Single Wall Pipe

Furnish a letter of certification documenting the material meets specification requirements

Document in CMS (Trns.port SiteManager ™).

Accept based on inspection of material for type, condition, dimension, receipt and verification of manufacturer’s certified test data.

Notify District Testing if rejecting material.

707.65

Polypropylene Corrugated Double  Wall Pipe

Furnish a letter of certification documenting the material meets specification requirements

Document in CMS (Trns.port SiteManager ™).

Accept based on inspection of material for type, condition, dimension, receipt and verification of manufacturer’s certified test data.

Notify District Testing if rejecting material.

707.69

Polypropylene Corrugated Tripe Wall Pipe

Furnish a letter of certification documenting the material meets specification requirements

Document in CMS (Trns.port SiteManager ™).

Accept based on inspection of material for type, condition, dimension, receipt and verification of manufacturer’s certified test data.

Notify District Testing if rejecting material.

707.70

Welded and Seamless Steel Pipe

Verify type and brand name of material is on QPL at the time of use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural metals and Welding section,  if rejecting material because material non-performs or looks defective during use.

708.01

Inorganic Zinc Silicate Primer Paint

Products will be supplied by a source on the Certified List for S-1084  maintained by OMM.

Verify type and brand name of material is on QPL at the time of use.

Inspect material container for markings, expiration date and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, chemical section,  if rejecting material because material non-performs or looks defective during use.  Obtain a 1 qt (1 L) sample representative of the defects.

708.02

708.02B

708.02C

708.02D

OZEU Structural Steel Pant

Organic Zinc Prime Coat

Epoxy Intermediate Coat

Urethane Finish Coat

Products will be supplied by a source on the Certified List for S-1084  maintained by OMM.

Verify type and brand name of material is on QPL at the time of use.

Inspect material container for markings, expiration date and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, chemical section,  if rejecting material because material non-performs or looks defective during use.  Obtain a 1 qt (1 L) sample representative of the defects.

709.01

Deformed and Plain Billet Steel Bars for Concrete Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain three (3) 30" (.8 m) long samples of each rebar size, with markings, and submit for QA testing by the Laboratory.

709.03

Rail Steel Deformed and Plain Bars for Concrete Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain three (3) 30" (.8 m) long samples of each rebar size, with markings, and submit for QA testing by the Laboratory.

709.05

Axle Steel Deformed and Plain Bars for Concrete Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain three (3) 30" (.8 m) long samples of each rebar size, with markings, and submit for QA testing by the Laboratory.

709.08

Cold-Drawn Steel Wire for Concrete Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain three (3) 30" (.8 m) long samples of each diameter and submit for QA testing by the Laboratory.

709.09

Fabricated Steel Bar or Rod Mats for Concrete Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain 3 ft x 3 ft (1 m x 1 m) of the mat and submit for QA testing by the Laboratory.

709.10

Welded Steel Wire Fabric for Concrete Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain 3 ft x 3 ft (1 m x 1 m) of the mat and submit for QA testing by the Laboratory.

709.11

Deformed Steel Wire for Concrete Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain 3 ft x 3 ft (1 m x 1 m) of the mat and submit for QA testing by the Laboratory.

709.12

Welded Deformed Steel Wire Fabric for Concrete Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain 3 ft x 3 ft (1 m x 1 m) of the mat and submit for QA testing by the Laboratory.

709.13

Coated Dowel Bars

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain 3 dowel bars and submit for QA testing by the Laboratory.

709.14

Epoxy-Coated Steel Wire and Welded Wire Fabric for Reinforcement

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain 3 ft x 3 ft (1 m x 1 m) of the mat and submit for QA testing by the Laboratory.

709.15

Plastic Supports for Reinforcing Steel

Products will be supplied by a source on the Approved List maintained by OMM.

Inspect for dimension and condition.

Notify District Testing if rejecting material that non-performs or looks defective during use. 

709.16

Galvanizing Steel Option for Bridge Spirals

Products will be supplied by a source on the Certified List for S-1068  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain three (3) 30" (.8 m) long samples of each rebar size, with markings, and submit for QA testing by the Laboratory.

710.01.A

710.01 B

Barbed Wire

Products will be supplied by a source on the Certified List for S-1067  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain a 5 ft (1.5 m) length of barbed wire and submit for QA testing by the Laboratory.

710.02

Woven Steel Wire Fence, Type 47

Products will be supplied by a source on the Certified List for S-1067  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain 4 ft (1.2 m) width of fencing and submit for QA testing by the Laboratory.

710.03

Chain-Link Fence

[ including Fittings and Accessories]

Products will be supplied by a source on the Certified List for S-1067  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain samples as directed by the Laboratory.

710.06

Deep Beam Rail

Products will be supplied by a source on the Certified List for S-1042  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain three (3) 1 ft (0.3 m) lengths of guardrail from the same section and submit for QA testing by the Laboratory.

710.09

Wire Rope Rail

Inspect for dimension, condition, appearance and markings on tag or reel.

Submit one (1) six (6) ft. sample to OMM.

Document in CMS (Trns.port SiteManager ™).

Approval required prior to use. Notify District Testing and OMM.

710.11

Fence Posts and Braces

[Lumber]

[Steel]

Products will be supplied by a source on the Certified List for S-1067 and S-1072 maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

710.12

Square-Sawed and Round Guardrail Posts

Products will be supplied by a source on the Certified List for S-1042  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

710.14

Pressure Treated Guardrail and Fence Posts, Braces, and Blocks

Products will be supplied by a source on the Certified List for S-1042 and   S-1067  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

710.15

Steel Guardrail Posts

Products will be supplied by a source on the Certified List for S-1042  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

710.16

Guard Posts

Products will be supplied by a source on the Certified List for S-1042 and    S-1067  maintained by OMM.

Received with TE-24.

Check dimension, markings and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

711.01

711.04

711.07

Structural Steel

Cold Rolled Steel

Steel Castings

Material supplied by a Fabricator source on the Certified List for Items 513, 516, 517 & 518 maintained by OMM.

Structural Steel Members are received with TE-24.

If questions concerning structural steel materials, contact OMM Structural Steel Section and notify District Testing.

711.02

Galvanized Steel

Any material supplied with galvanizing will conform to this specification.  Randomly inspect galvanizing for appearance and thickness of coating.

Notify District Testing if rejecting material.

711.03

Steel for Sheet Piling

Certified Mill Test Data required for new material.

Verify tensile and chemical properties meet requirements.

Inspect all material for dimension and condition.

Used material is not acceptable for permanent installations.

Document field inspection.

711.04

Cold Rolled Steel 

Contact OMM structural steel section for acceptance process.

Document in CMS (Trnsport SiteManager ™).

Notify District Testing and OMM structural section section if rejecting material.

711.07

Steel Castings

Contact OMM structural steel section for acceptance process.

Document in CMS (Trnsport SiteManager ™).

Notify District Testing and OMM structural section section if rejecting material.

711.08

Arc-welding Electrode & Fluxes

Verify manufacturer is on Approved List maintained by OMM.

Inspect for dimension, condition and markings.

Document in CMS (Trnsport SiteManager ™).

If material is not on Approved List, certification and test data from supplier will be submitted to OMM. Do not use until approval has been received.

711.09

High Strength Bolts

Nuts and Washers

Received with TE-24.

Inspect material for dimension, condition and markings.

Reject defective material.

Perform field testing of assembly combination per S-1080.

Document field inspection & testing in CMS (Trns.port SiteManager ™ ).

If field test does not meet requirements of S 1080, retest bolt, nut and washer combination after application of a lubricant.

Notify District Testing if rejecting material.

711.10

Machine Bolts

General specification for many common bolts

Verify material is component of certified supplier shipment like S-1042 for Guardrail Suppliers or S-1067 for Fence Suppliers.

Inspect for condition and coating.

Reject defective material.

Notify District Testing if rejecting material.

711.12

711.13

711.14

Gray Iron Castings

Ductile Iron Castings

Gray Iron & Ductile Iron Castings

Verify manufacturer is on Approved List maintained by OMM.

Received with TE-24.

Inspect for condition and defect.

Document in CMS (Trnsport SiteManager ™ ).

Notify District Testing if rejecting material

711.15

711.16

711.17

711.18

711.19

Sheet Copper

Phosphor Bronze Plate

Cast Bronze

Leaded Bronze

Sheet Lead

Material supplied by a Fabricator source on the Certified List for Items 513, 516, 517 & 518 maintained by OMM.

Structural Steel Members are received with TE-24.

Document in CMS (Trnsport SiteManager ™).

If questions concerning structural steel materials, contact OMM Structural Steel Section and notify District Testing.

711.20

Aluminum for Railings

Material supplied by a Fabricator source on the Certified List for Items 513, 516, 517 & 518 maintained by OMM.

Structural Steel Members are received with TE-24.

Document in CMS (Trnsport SiteManager ™).

If questions concerning structural steel materials, contact OMM Structural Steel Section and notify District Testing.

711.21

Preformed Bearing Pads

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

If material non-performs or looks defective during use notify District Testing and OMM.

711.22

Buried Liner Waterproofing Membrane

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defects.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

If material non-performs or looks defective during use notify District Testing and OMM.

711.23

Elastomeric Bearings

Only accept elastomeric bearings shipped by TE-24.and provided by certified suppliers conforming to S1081.   Notify district testing. to Inspect material to check location and number of internal shims utilizing an ice pick or similar tool.

Five (5) Durometer Gage readings should be taken and averaged to determine compliance with design plans.

Document in CMS (Trns.port SiteManager ™).

Field acceptable for durometer. Reading average range: +/- 7 points of design plan number.

711.24

Waterproofing fabric

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

711.25

Type 2 Membrane Waterproofing

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send one (1) 4 ft² sample representative of defect to OMM for QA follow-up.

711.26

Structural Timber, Lumber and Piling

Products will be supplied by a source on the Certified List for S-1072 maintained by OMM.

Received with TE-24 and supplier bill of lading.

Check dimension, quantity and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

711.27

Prestressing Steel

Material supplied by a Fabricator source on the Certified List for Items 515 maintained by OMM.

Prestressed Concrete Members are received with TE-24.

If questions concerning prstressed concrete or prestressed

711.28

Cellular Polyvinyl Chloride Sponge

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send

one (1) 1.5'x2.5' sample representative of defect to OMM for QA follow-up.

711.29

Type 3 Membrane Waterproofing

Verify type and  brand name of material is on QPL at the time of  use.

Membrane primer is 705.04 material

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send

one (1) 4 square ft sample representative of defect to OMM for QA follow-up.

711.30

Aluminum for Steps

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

711.31

Reinforced Propylene Plastic Manhole Steps

Verify type and brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

712.01

Expansion Shield Anchors

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain three(3) samples representative of defect to OMM for QA follow-up.

712.02

Calcium Chloride

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use contact OMM.

712.03

Sodium Chloride

Inspect material for condition.

Submit one (1) pint sample per Each Purchase Order to OMM.

Document in CMS (Trns.port SiteManager ™).

If additional samples required for material quantities exceeding 3000 tons, Notify District Testing.

712.04 A

Lime [masonry]

Sample & Inspect material for condition with 24 hrs of receipt.

One (1) five (5) lb sample.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

712.04 B

Lime [Quick] for Stabilization

Assure provided material is from suppliers certified under Supplement 1087 and listed on the Departments QPL.

Inspection for condition and defects

Document in CMS (Trns.port SiteManager ™).

If questions on material quality sample.

One (1) ten (10) lb sample of Quicklime. Send to Geotechnical Engineering.

Notify District Testing if rejecting material.

Samples may be taken in triplicate, if required. Contact Geotechnical Engineering.

712.04 C

Lime Kiln Dust for Stabilization

Assure provided material is from suppliers certified under Supplement 1087 and documentation for m S1087 is complete.  Document in CMS (Trns.port SiteManager ™).

If questions on material quality sample.

One (1) ten (10) lb sample of Lime Kiln Dust. Send to Geotechnical Engineering

Notify District Testing if rejecting material.

Samples may be taken in triplicate, if required. Contact Geotechnical Engineering.

712.06

Preservative Treatment for Structural Timber

Component material of pressure treated lumber.  No approval required.  Approval is for the wood including the preservative treatment

If questions on pressure treated lumber check the specific material item and follow those instructions

712.09

Geotextile Fabrics

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimensions conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use submit one (1) 4' x 4' sample representative of defect to OMM.

712.10

Prefabricated Edge Underdrain

Inspect material for condition and dimension.

Manufacturer’s certified test data required for acceptance.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

712.11

Temporary Erosion Control Mats Material

[Types A through I]

Inspect material for condition and dimension.

Manufacturer’s certified test data required for acceptance.

Field Acceptance item

Refer to Temporary Materials Policy for documentation requirements.

Notify District Testing if rejecting material.

712.12

Tied Concrete Block Mat

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimensions conform to plan requirements.

Document in CMS (Trns.port SiteManager ™)

Notify District Testing and OMM Concrete section,  if rejecting material because material non-performs or looks defective during use.

712.13

Articulating Concrete Block Revetment System

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimensions conform to plan requirements.

Document in CMS (Trns.port SiteManager ™)

Notify District Testing and OMM Concrete section,  if rejecting material because material non-performs or looks defective during use.

720.01

Rectangular Reflectors

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, color requirements and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM Chemical section,  if rejecting material because material non-performs or looks defective during use.

720.03

Flexible Delineator Posts

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM Chemical section,  if rejecting material because material non-performs or looks defective during use.

721.01

Raised Pavement Marker Castings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify type conforms to pre-qualification requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.  Obtain one (1) 4x2x0.48 in. sample representative of defect to OMM for QA follow-up.

721.02

Prismatic Retroreflector and Adhesive

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify type conforms to pre-qualification requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use. Obtain one (1) sample representative of defective RPM casting to OMM for QA follow-up.

721.03

Casting Adhesive

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM Chemical section,  if rejecting material because material non-performs or looks defective during use.

725.02

Wire and Cables

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send a sample representative of non -compliance or defect to  OMM for QA follow-up.

725.03

Unit Type Duct-Cable Systems

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send a 10 ft. sample representative of non -compliance or defect to OMM for QA follow-up.

725.04

Rigid Ferrous Metal Electrical Conduit and Fittings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition of coating and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send a sample representative of non -compliance or defect to OMM for QA follow-up.

725.051

Polyvinyl Chloride Conduit and Fittings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send a sample representative of non -compliance or defect to OMM for QA follow-up.

725.052

Polyethylene Conduit and Fittings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send a sample representative of non -compliance or defect to OMM for QA follow-up.

725.06

Polymer Concrete Pull Boxes

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use send a sample representative of non -compliance or defect to OMM for QA follow-up.

725.07

Plastic Pull Box

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.08

Portland Concrete Pull Boxes

Products will be supplied by a source on the Certified List for S-1073  maintained by OMM.

Received with TE-24.

Check dimension, markings, roughness or excessive cracks.

Item 604 Installation documented on CA-P-3 Inspection Form.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.10

Junction Boxes

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.11 B

Lamps for Luminaires

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.11 E

Conventional Luminaires for High Intensity Discharge Lamps (including Optical system, lamp, ballast and housing)

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.11 F

Wall Mounted Underpass Luminaires (including Optical system, lamp, ballast and housing)

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.11 G

High Mast/Low Mast Luminaire (including Optical system, lamp, ballast and housing)

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.12

Polyethylene, Fiberglas reinforced, Pull Box with Polymer concrete cover and support ring

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.15B

Fused Pull-Apart Connection

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.15C

Unfused Pull-Apart Connection

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.15D

Fused Bolted Connection

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.15E

Unfused Permanent Connection

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.16

Ground Rods

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use contact  OMM.

725.19H

Power Service Components

Wood Pole

Products will be supplied by a source on the Certified List for S-1072 maintained by OMM.

Received with TE-24 and supplier bill of lading.

Check dimension, quantity and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM, structural welding and metals section,  if rejecting material because material non-performs or looks defective during use.

725.20

Multiple Cell Polyvinyl Chloride Conduit and Fittings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, markings and conformance to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.21A

Luminaire Supports

Light Poles

Verify pole provided by Certified Manufacturer under Supplement 1091.

Inspect material for condition and conformance to plan requirements.

Accept with TE-24

Document in CMS (Trns.port SiteManager ™)

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.21B

Luminaire Supports

Light Towers

Inspect material for condition and conformance to plan requirements.

Verify pole provided by Certified Manufacturer under Supplement 1091.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

725.21B9

Luminaire Support

Anchor Bolts

OPTION 1

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, and conformance to plan requirements.

OPTION 2

Verify pole provided by Certified Manufacturer under Supplement 1091.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

726.01

Barrier Reflectors

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition and defect.

Verify dimension conform to plan requirements.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing and OMM Chemical section,  if rejecting material because material non-performs or looks defective during use.

730.01

Steel Tube and Pipe

This item typically is a component of a sign support.  Inspect total component for condition and conformance to shop drawings.               

Document in CMS (Trns.port SiteManager ™)

Notify District Testing if rejecting material.

730.015

U-Channel Posts

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District testing and OMM.

730.016

Square Posts

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.017

Wooden Box Beams

Contact OMM structural steel section for acceptance process.

Document in CMS (Trnsport SiteManager ™).

Notify District Testing and OMM structural section section if rejecting material.

730.02

Steel Anchor Bolts and Nuts

OPTION 1

Verify type and brand name of material is on QPL at the time of  use.

Inspect for condition, and conformance to plan requirements.

OPTION 2

Verify pole provided by Certified Manufacturer under Supplement 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.03

Steel Poles and Arms

Component material provided by Certified Manufacturer under Supplement 1093. 

Verify manufacturer is on 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.04

Base and Arm Plates

Component material provided by Certified Manufacturer under Supplement 1093. 

Verify manufacturer is on 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.05

Handhole Covers

Component material provided by Certified Manufacturer under Supplement 1093. 

Verify manufacturer is on 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.06

Pole Caps

Component material provided by Certified Manufacturer under Supplement 1093. 

Verify manufacturer is on 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.07

Arm Caps

Component material provided by Certified Manufacturer under Supplement 1093. 

Verify manufacturer is on 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.08

Steel Hardware

Component material provided by Certified Manufacturer under Supplement 1092 or 1093. 

Verify manufacturer is on 1092 or 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.09

Stainless Steel

Component material provided by Certified Manufacturer under Supplement 1092 or 1093. 

Verify manufacturer is on 1092 or 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.10

Stainless Steel Hardware

Component material provided by Certified Manufacturer under Supplement 1092 or 1093. 

Verify manufacturer is on 1092 or 1093

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.11

Aluminum Sheet and Plate

Component material provided by Certified Manufacturer under Supplement 1092 or 1093. 

Verify manufacturer is on 1092 or 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.12

Aluminum Extrusions

Component material provided by Certified Manufacturer under Supplement 1092 or 1093. 

Verify manufacturer is on 1092 or 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.13

Aluminum Tube and Pipe

Component material provided by Certified Manufacturer under Supplement 1092 or 1093. 

Verify manufacturer is on 1092 or 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.14

Aluminum Castings

Component material provided by Certified Manufacturer under Supplement 1092 or 1093. 

Verify manufacturer is on 1092 or 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.15

Aluminum Forgings

Component material provided by Certified Manufacturer under Supplement 1092 or 1093. 

Verify manufacturer is on 1092 or 1093.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.16

Aluminum Welding Rods

Normally only applies to shop fabrication.  If performing field aluminum welding contact District Testing and OMM for recommendations.

Notify District Testing if rejecting material.

730.17

Aluminum Hardware

Component material provided by Certified Manufacturer under Supplement 1092.

Verify manufacturer is on 1092.

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.18

Reflective Sheeting Type F

Use if certification provided.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.19

Reflective Sheeting Type G

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.191

Reflective Sheeting Type G reboundable

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.192

Reflective Sheeting Type H

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.193

Reflective Sheeting Type J

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.20

Nonreflective Sheeting

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

730.22

Silk Screen Inks

No field acceptance requirements.- part of 730.19,191,192 or 193 items.

730.23

Transparent Electronic Cuttable Films

No field acceptance requirements.- part of 730.19,191,192 or 193 items No field requirements.

731.03C

Changeable Message Sign, Electrical Type

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

731.05

Internally Illuminated Fixed Message Sign

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

731.06

Sign Flasher Assembly

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

731.07

School Speed Limit Sign Assembly

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

731.08

Flexible Conduit

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

731.10

Timer with Enclosure

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.01

Vehicular Signal Heads, Conventional

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.02

Vehicular Signal Heads, Optically Programmed, 12-inch (300 mm) Lens

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.03

Vehicular Signal Heads, Optically Programmed, 8-inch (200 mm) Lens

Provide Manufacturer’s Certification verify material meets specification requirements

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.04 C

Vehicular and pedestrian light Emitting Diode Lamps (LED)

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.05

Pedestrian Signal Heads

[Type A1]

[Type A2]

[Type D2]

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.06

Pedestrian Pushbuttons

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.07 A

Loop Detector Units Nema TS 1

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.07 B

Loop Detector Units Nema TS 2

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.08

Loop Detector Units, Delay and Extension Type

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trnsport SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.11

Signal Supports

Check provided by Certified Manufacturer under Supplement 1094  

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.12

Strain Poles

Check provided by Certified Manufacturer under Supplement 1094  

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.13

Wood Poles

Check provided by Certified Manufacturer under Supplement 1072  

Accept with TE-24.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.14

Down Guy Assemblies

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.15

Pedestals and Bases

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.16

Conduit Risers

See 725.04 requirements.

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.17

Cable Support Assemblies

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.18

Messenger and Tether Wire

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.19

Cable and Wire

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.20

Power Service

See 725.04 requirements

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

732.21

Disconnect Switch with Enclosure

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.02 A

Controller Unit Type TS2/A1

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.02 B

Controller Unit Type TS2/A2

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.02 C

Controller Unit Type 170E

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.02 D

Controller Unit Type 2070L and LC

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.03 A

Cabinet Type TS 1

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.03 B

Cabinet Type TS 2

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.03 C

Cabinet Type 332

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.03 D

Cabinet Type 334

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.03 E

Cabinet Type 336

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.04 A

Cabinet Riser for TS 1 – TS 2 cabinet

Field inspect for 1/4 aluminum thickness and accept.

Notify District Testing if rejecting material.

733.04 B

Cabinet Riser for Types 332, 334 or 336

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.05

Flasher Controller

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.06

Controller, Master, Traffic Responsive

Assure the same manufacturer as the supplied controller unit 733.02.

Notify District Testing if rejecting material.

733.07

Remote Monitoring Station

Compatible with the supplied 733.02 and 733.06 unit.

Notify District Testing if rejecting material.

733.09

Uninterruptible Power Supply (UPS)

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

733.09.C

Battery System

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for conformance to dimension and condition.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

740.02

Traffic Paint

Verify material is on APPROVED LIST maintained by OMM.

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

If rejecting for performance provide 1 qt (1 L) sample and notify District.

740.03

Polyester Pavement Marking

Verify material is on APPROVED LIST maintained by OMM.

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

If rejecting for performance provide 1 qt (1 L) sample and notify District.

740.04

Thermoplastic Pavement Marking

Verify material is on APPROVED LIST maintained by OMM.

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

If rejecting for performance provide 1 qt (1 L) sample and notify District.

740.05

Preformed Pavement Marking

Verify material is on APPROVED LIST maintained by OMM.

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

If rejecting for performance provide 1 qt (1 L) sample and notify District.

740.06

Work Zone Pavement Marking

[Type 1 Removable]

[Type 2 Non-Removable]

Materials accepted by Engineer.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

If rejecting for performance provide 1 qt (1 L) sample and notify District.

740.07

Epoxy Pavement Marking Material

Verify material is on APPROVED LIST maintained by OMM.

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

If rejecting for performance provide 1 qt (1 L) sample and notify District

740.08

Heat-Fused Preformed Plastic Pavement Marking Material

Verify material is on APPROVED LIST maintained by OMM.

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

If rejecting for performance provide 1 qt (1 L) sample and notify District

740.09 A

Glass Beads – for 740.02

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

Accept if accompanied by a TE-24

740.09 B

Glass Beads – for 740.03                       

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

Accept if accompanied by a TE-24

740.09 C

Glass Beads – for 740.04                       

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

Accept if accompanied by a TE-24

740.09 D

Glass Beads – for 740.07                       

Verify material is on Approved List maintained by OMM.

Accepted with TE-24.

Inspect container for appropriate markings.

Inspect material for uniform consistency.

Document in CMS (Trns.port SiteManager ™).

Accept if accompanied by a TE-24

748.01

Ductile Iron Pipe, Joints, and Fittings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.02

Polyvinyl Chloride (PVC) Pipe, Joints, and Fittings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.03

Polyethylene (PE) Service Branches and Fittings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.05

Copper Service Branches and Fittings

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.06

Steel Pipe Encasement

Basis of acceptance is certified test data containing documentation of domestic origin from manufacturer.

Notify District Testing if rejecting material

748.07

Polyethylene Encasement

Verify manufacturer certification conforms to ANSI/AWWA C105/A21.5

Inspect condition, dimension, suitability for intended use.

Notify District Testing if rejecting material.

748.08

Gate Valve and Valve Box

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.09

Inserting Valve and Valve Box

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.10

Cutting-in Sleeve, Valve, and Valve Box

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.11

Tapping Sleeve, Valve, and Valve Box

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.12

Tapping Saddle and Corporation Stop

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.13

Service Stop and Service Box

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

748.14

Meter, Setting, Stop, and Chamber

Inspect for condition, dimension, suitability for intended use.

Acceptance based on manufacturer’s statement of conformity.

748.15

Fire Hydrant

Verify type and  brand name of material is on QPL at the time of  use.

Inspect for condition, dimension, suitability for intended use.

Document in CMS (Trns.port SiteManager ™).

Notify District Testing if rejecting material.

If material non-performs or looks defective during use notify District Testing and OMM.

701  CEMENTITIOUS MATERIALS

701.00  Acceptance.  Provide cements meeting 701.01, 701.02, 701.04, 701.05, 701.07 and 701.09 and certified according to Supplement 1028; fly ash meeting 701.13 and certified according to Supplement 1026; ground, granulated blast furnace slag meeting 701.11 and certified according to Supplement 1034; and micro silica meeting 701.10 and certified according to Supplement 1045 without prior sampling, testing and approval by the Department.  Lists for certified cement, fly ash, GGBF slag and micro silica sources are maintained by the Laboratory.

701.01  Air-Entraining Portland Cement.  Provide air-entraining portland cement according to ASTM C 150, Type IA.  The Gillmore time of set and the air permeability (fineness) tests will govern.

701.02  Portland Cement.  Provide portland cement according to ASTM C 150, Type II.  The Gillmore time of set and the air permeability (fineness) tests will govern.

701.04  Portland Cement.  Provide portland cement according to ASTM C 150, Type I.  The Gillmore time of set and the air permeability (fineness) tests will govern.

701.05  High Early Strength Portland Cement.  Provide high early strength portland cement according to ASTM C 150, Type III.  The Gillmore time of set test shall govern.

701.07  Masonry Cement.  Provide masonry cement according to ASTM C 91.

701.09  Slag Modified Portland Cement.  Provide slag modified portland cement according to ASTM C 595, Type IS (< 25).

701.10  Micro-Silica.  Provide micro-silica according to ASTM C 1240.  Do not use micro-silica admixtures in dissolvable bags.

701.11  Ground Granulated Blast Furnace (GGBF) Slag.  Provide ground granulated blast furnace (GGBF) according to ASTM C 989, Grade 100 minimum.

701.13  Fly Ash for Use in Portland Cement Concrete.  Provide fly ash according to ASTM C 618, Class C or F, except ensure a maximum loss on ignition (LOI) of 3 percent.

Fly ash from sources certified according to Supplement 1026 and with an LOI greater than 3 percent may be approved for use by the Department if the fly ash is treated with a chemical conforming to Supplement 1115.

702  ASPHALT MATERIAL

Acceptance.  Asphalt binders 702.01 and liquid asphalts 702.02, 702.03, and 702.04 may be acceptable for shipment to and immediate use in construction projects.  Acceptance is according to Supplement 1032.

702.00  Application Temperatures.  Apply asphalt materials, according to the temperature ranges specified in Table 702.00-1.

Table 702.00-1

Type and Grade

of Material

Application Temperature Range °F (°C)

Spray

Mix

MC-30

50 to 120 (10 to 49)

---

MC-70

75 to 150 (24 to 66)

---

MC-250

100 to 225 (38 to 107)

100 to 225 (38 to 107)

MC-800

150 to 250 (66 to 121)

150 to 225 (66 to 107)

MC-3000

225 to 275 (107 to 135)

200 to 250 (93 to 121)

All Emulsions

50 to 160 (10 to 71)

50 to 140 (10 to 60)

Asphalt Primer for Waterproofing

50 to 80 (10 to 27)

---

Asphalt for Waterproofing

300 to 350 (149 to 177)

---

CBAE 350, CBAE 350  SP

100 to 150 (38 to 66)

100 to 150 (38 to 66)

CBAE 800, CBAE 800  SP

125 to 175 (52 to 79)

125 to 175 (52 to 79)

Primer 20

60 to 120 (16 to 49)

---

Primer 100

75 to 125 (24 to 52)

---

Asphalt Binders

350 (177) Max.

325 (163) Max.

Asphalt Binders Polymer modified with SB, SBR,  SBS, or Elv aloy

375 (190) Max

350 (177) Max.

702.01 Asphalt Binders. 

General.  According to AASHTO M 320-10 Table 1 except as follows.

Ensure PG 70-22M, PG 76-22M, PG 88-22M and PG 64-28 meet the requirements of Table 702.01-1. 

An independent laboratory will not be owned or operated, in whole or part, by the binder supplier, Contractor, or affiliates of either.

Materials and Manufacture.  Replace the requirements of AASHTO M 320-10 Table 1 Section 5 “Materials and Manufacture” Section with the following:

5.1         Supply PG Binder from the refining of crude petroleum, or combination of asphalt binders from the refining of crude petroleum, or asphalt binders and suitable liquid from the refining of crude petroleum, and possible organic modifiers for performance enhancement.  Material from the crude refining stream is considered neat.  Liquid from crude refining may be used for adjustments, but do not used liquid from crude refining for the purpose of substitution of crude refined asphalt binder in a PG Binder.  In the event of a failure investigation where asphalt binders exhibit unusual properties a supplier may be requested by the Laboratory to supply information about the makeup of a PG Binder.  Failure to cooperate will mean removal from Supplement 1032 certification.

5.2         A modifier may be any approved material of suitable manufacture that is proven compatible with asphalt binder (does not separate appreciably in routine storage), and that is dissolved or reacted in asphalt binder to improve its performance.  Performance enhancement is defined as a decrease in the temperature susceptibility of the asphalt binder while maintaining or improving desirable properties in a neat asphalt binder such as coat ability, adhesiveness and cohesiveness.  Unless otherwise noted limit modifiers to no more than 6.0 percent by PG Binder weight.

5.3         The use of previously used materials in a PG Binder must be approved by the Department.  Since no standard test procedures exist for reprocessed materials (and original tests were not developed with the use of such materials in mind), appropriate test methods may be chosen by the Department for review.  Department approval does not relieve the binder supplier from full responsibility for content and use of any previously used material in a PG Binder nor guarantee suitable performance enhancement as defined above.  The detected presence in a PG Binder sample of any unapproved previously used material will mean immediate removal from Supplement 1032 certification.  Limit approved reprocessed materials to 6.0 percent by PG Binder weight.

5.4         Ensure the PG Binder is homogeneous, free from water and deleterious materials, and does not foam when heated to 350 ºF (175 ºC).  Prove the asphalt binder (before modification or after modification if liquid modifier used) is fully compatible with a negative result by means of the Spot Test per AASHTO T 102 using standard naphtha solvent.   If standard naphtha shows a positive result, a retest using reagent grade 35 percent Xylene/ 65 percent Heptane (volume) may be used. 

5.5         Ensure the PG Binder is at least 99.0 percent soluble as determined by AASHTO T44.  Ensure any insoluble component is free of fibers or discrete particles more than 75 µm.

5.6         Ensure flash point is 500 ºF (260 ºC) minimum.  Ensure mass loss on RTFO of the final PG Binder grade is 0.5 percent maximum.

5.7         Ensure that PG 64-22 has a Penetration (AASHTO T49) of no more than 75.

5.8         Direct Tension testing is not required, unless otherwise required in this specification.

Requirements for PG Modified Binder. Furnish PG Modified Binder according to the requirements of Table 702.01-1 by modifying a non-oxidized, non-air blown, neat asphalt binder by using a styrene butadiene latex rubber compound (SBR polymer), a styrene butadiene styrene polymer block copolymer (SB, SBS polymer),an ethylene/ nbutyl acrylate/ glycidyl methacrylate copolymer (Elvaloy) as specified or Ground Tire Rubber (GTR) according to Supplemental Specification 887.  For SB, SBS products the polymer supplier will certify to the refiner and Contractor that the polymer used meets a minimum 68 percent by weight butadiene content.  Perform SB, SBS, Elvaloy or GTR  modification prior to shipment to the asphalt concrete mixing plant (pre-blend).  Perform SBR modification at the asphalt concrete mixing plant (post-blend) or prior to shipment to the asphalt concrete mixing plant (pre-blend) where allowed by specification.

Polyphosphoric acid (PPA) is allowed in PG binders as follows. PPA is a polymer of orthophosphoric acid.  When using PPA ensure all the applicable requirements of the required PG binder in Table 702.01-1 are met. Ensure PPA does not contain water. To retain Supplement 1032 certification suppliers of PPA modified asphalt will provide a written certification to OMM that the amount of PPA used is less than 1.0% by weight of neat binder.  Suppliers of PPA can have their Supplement 1032 certification removed for not following the above PPA requirements. 

For each project, the PG Modified Binder supplier will give the Contractor a handling guide specifying temperature, circulation, shelf life, and other requirements for assuring the PG Modified Binder will perform as desired.  Give this handling guide to the Monitoring Team and place a copy in the plant control room and plant laboratory.

If PG Modified Binder is retained at the asphalt concrete mixing plant for more than two weeks before use or beyond the supplier recommended shelf life, whichever is less, a top and bottom sample test (material property difference between samples taken from the top and bottom of the storage tank) will be performed by the Laboratory on samples retrieved by the Contractor at the District’s direction.  Do not use material on hand until approved.

Table 702.01-1

Material Requirements for PG Modified Binder

Test / Requirement

SBR Polymer

Pre Blended Binder

Note

Final PG Binder Grade

70-22M

(a, b)

64-28

(b)

64-28

(a)

70-22M (a,k)

76-22M (a,k)

88-22M  (a,l)

c

Actual Pass Temperatures

Report

i

RTFO Mass Change, percent max

0.5

d

Phase Angle, max

78

80

76

d

Elastic Recovery, min

65

75

90

e, d

Toughness, in. lb

125

105

f, d

Tenacity, in lb.

70

80

f, d

Elongation, in. min

20

20

f, d

Ductility, in. min

28

28

j, d

Separation, F max

10

g, d

Homogeneity

None Visible

h, d

a.  Pre-blended Binder.  Use a base neat asphalt binder that is a -22 grade for 70-22M and 76-22M.  Use a base neat asphalt binder that is a -28 grade for 64-28.  64-28 can be neat, PPA modified or modified with SB, SBS or Elvaloy.  Ensure SB, SBS or Elvaloy modified 64-28 meets all requirements listed. Rotational viscosity for 88-22 not required.

b.  Post-blended Binder made from neat Supplement 1032 certified or preapproved standard PG Binder grade and SBR  solids amount equal to or above 3.5 percent by weight of total binder to achieve the PG Binder grade.  Ensure all listed properties are met.

c.  Without Direct Tension, graded with actual pass temperatures

d.  PG Modified Binder

e.  AASHTO T301, 10cm @ 77 ºF (25 ºC), hold 5 min. before cutting, on RTFO material for SB, SBS, Elvaloy

f.  ASTM D 5801, 50cm/min @ 77 ºF (25 ºC)

g.  Softening point difference of top and bottom of tube sample conditioned at 340 ºF (171 ºC) for 48 hours. Compatibility of polymer and neat binder is sole responsibility of supplier.  Formulate PG Modified Binder to retain dispersion for 3 days minimum.

h.  Heat a minimum 400 gram sample at 350 ºF (177 ºC) for 2.5-3 hours.  Pour entire sample over a hot No 50 (300 µm) sieve at 340ºF (171 ºC).  Look for retained polymer lumps.

i.   Actual high and low temperature achieved by PG Modified Binder beyond required grade, but will not grade out to the next standard PG Binder grade for low temperature.

j.   AASHTO T51, @ 39 ºF (4 ºC), 1 cm/min

k.  SB, SBS,Elvaloy or Supplemental Specification 887 GTR 

l.   SB, SBS, Elvaloy

702.02  Cut-Back Asphalt.  Provide medium curing cut-back asphalt according to AASHTO M 82.  Instead of viscosity on the residue, the penetration in note 2 (AASHTO M 82) will govern.

702.03  Cut-Back Asphalt Emulsions.  Prepare emulsions by compounding a suitable volatile solvent and water with 702.01 asphalt to produce emulsions according to Table 702.03-1.

Table 702.03-1

CBAE-

350

CBAE-

350

Special

CBAE-

800

CBAE-

800

Special

Primer

20

Primer

100

Kinematic Viscosity at 60 °C, Centistokes

350-700

350-700

800-1600

800-1600

20-40

100-200

Water Content[1], %

4-12

4-12

4-12

4-12

3-8

3-8

Volatile Solvent[1], %

12-25

12-25

10-20

10-20

Asphalt Content[1], %

67+

67+

72+

72-

45+

60-

Adhesion Test[1]

[2]

[2]

[2]

[2]

Wet Stone Coating Test[1]

[2]

[2]

[2]

[2]

Stripping Test[1]

[2]

[2]

Tests on Residue From Distillation

Penetration at 25 °C

80-150

80-150

80-150

80-150

100-200

100-200

Ductility at 25 °C, in. cm

100+

100+

100+

100+

100+

100+

Total Binder (Sol. in CSx), %

99+

99+

99+

99+

99+

99+

[1]   Perform tests according to Supplement 1014.

[2]   Meets

702.04  Emulsified Asphalts.  Provide emulsified asphalts according to AASHTO M 140 or AASHTO M 208 and specification limits will be producible for at least 30 days from project delivery.

702.05  Asphalt Primer for Waterproofing.  Provide asphalt primer for waterproofing according to ASTM D 41 Type 2.  

Furnish materials according to the Department’s Qualified Products List (QPL).

702.06  Asphalt for Waterproofing.  Provide asphalt for waterproofing according  to ASTM D 312, Type III.

Furnish materials according to the Department’s Qualified Products List (QPL).

702.07  Asphalt Emulsion MWS.  Prepare asphalt emulsion MWS from a base material according to 702.01, except vary the penetration to meet the float test and penetration specified below.  Ensure that the emulsion coats the aggregate readily, thoroughly, and uniformly.  Ensure that the specified characteristics do not change during transportation, normal storage and that the emulsion is according to the following when tested according to AASHTO T 59 for at least 30 days after application:

Saybolt furol viscosity at 77 °F (25 °C), seconds

50+ [1]

Asphalt residue, percent

68+

Settlement, 7 days, percent

5-

Sieve test

0.1-

Coating test

[2]

Oil distillate, percent

7-

Withstand freezing to

-10 ºF (-23 °C) [3]

Particle charge

Negative

Penetration, 77 °F (25 °C) [6]

[4]

Float test at 140 °F (60 °C), seconds [6]

1200+ [5]

Total bitumen soluble CS₂ [6]

97.5+

Ash content, percent [6]

2.0-

[1]  Pumpable.

[2]  Use aggregates to test the emulsion that are from sources standardized by the Laboratory.  Use aggregates consisting of 100 percent passing a 3/8 inch (9.5 mm) sieve and 0 percent passing a 1/4 inch (6.3 mm) sieve.  Wash the standard reference aggregates with distilled water until free of dust, and dry them.

          Weigh 3.280 ounces (93 grams) of the dry graded reference aggregate into a suitable container.  Weigh 0.247 ounces (7 grams) of the emulsion onto the aggregate in the container, and vigorously mix the contents for 5 minutes.  After mixing, thoroughly coat the stone.  Completely immerse the mixture in tap water, and immediately pour off the tap water.  Ensure that the aggregate surface area is at least 90 percent coated.

[3]  When shipped after October 1 and before April 15, except if the emulsion is stored and mixed at temperatures of emulsion, aggregate, and atmosphere above 40 °F (5 °C).

[4]  Select the penetration within the following ranges of the designation specified:

[5]  AASHTO T 50, except immediately pour residue from distillation into the float collar at 500 °F (260 °C); or if the residue has been allowed to cool, heat it again to 500 °F (260 °C) and pour it into the float collar.

[6]  Test on residue from distillation.

Designation

Penetration at 77 °F (25 °C)

MWS 300

300+

MWS 150

150 to 300

MWS 90

90 to 150

MWS 60

60 to 90

702.13  SBR Asphalt Emulsion.  Provide material consisting of asphalt emulsion SS-1, SS-1h, CSS-1 or CSS-1h per 702.04 and Supplement 1032, blended with SBR emulsion per 702.14, to produce a residual mixture of asphalt binder and SBR solids having a composition of 97.0 ± 0.3 percent asphalt binder and 3.0 ± 0.3 percent SBR solids by weight.

Furnish a certification to the Engineer and signed by the contractor containing the following:

A.      The weight of SBR emulsion blended with the asphalt emulsion.

B.      The weight of asphalt emulsion blended with the SBR emulsion.

C.      The SBR emulsion manufacturer certification per 702.14.

D.      The percent of asphalt binder in the asphalt emulsion (residue by distillation).

E.      The percent of SBR solids in the SBR emulsion.

F.      The percent of SBR solids in the mixture of asphalt binder residue and SBR solids.

G.      Name of Certified asphalt emulsion producer and asphalt emulsion.

Determine the weight of the SBR emulsion to be added to a designated weight of asphalt emulsion to provide the percent of SBR solids in the mixture of asphalt residue and SBR solids using the following formula:

where:

                          X =  pounds (kilograms) of SBR emulsion

                          A =  percent SBR solids in the SBR emulsion

                          B =  percent of asphalt residue of the asphalt emulsion

                         W =  pounds (kilograms) of the asphalt emulsion

For field blending, ensure the asphalt emulsion and SBR emulsion are thoroughly mixed as follows before application:  Add to the distributor the asphalt emulsion and the required amount of the SBR emulsion of the appropriate SBR emulsion type (i.e. cationic or anionic).  Heat and circulate the distributor contents for at least 30 minutes to ensure complete blending.  Re-circulate the distributor contents for 10 minutes just prior to application.  If the distributor has set for 12 hours without circulation, repeat the heating and circulating of the distributor contents for 30 minutes prior to application.

Draw samples of the mixed SBR and asphalt emulsion after mixing the materials as indicated above. Emulsion will comply with all specification requirements for at least 30 days after application.

702.14  SBR Emulsion.  Ensure the SBR emulsion is a cold polymerized Styrene Butadiene synthetic rubber (SBR) in latex form specifically compounded for use in asphalt binders and asphalt emulsions.  Ensure the manufacturer of the SBR emulsion furnishes a written certification of the total SBR solids content of the SBR emulsion and actual test results showing compliance with both of the following requirements:

A.      SBR emulsion:

Type of SBR Emulsion:

Anionic

Cationic

SBR solids Styrene Butadiene Ratio

27 ±5 : 73 ±5

27 ±5 : 73 ±5

Total SBR solids, % by weight

60-72

60-72

SBR solids Residual Styrene, % by weight

0.1 max

3.5 0.1 max

Ash, % of total SBR solids by weight

3.5 max

3.5 max

pH

9-11

4-6

Viscosity, Brookfield Units, Model RVF, spindle No 2 @20 RPM@ 77° F (25 ºC)

2000 max

2000 max

B.      Combination of 3.0 – 4.0 % SBR solids with 96.0 – 97.0 % PG 64-22 meeting 702.01 by weight:

Toughness inch-pounds (N×m),  Minimum 133 (15)

Tenacity, inch-pounds (N×m),  Minimum 80 (9)

702.16  Polymer Emulsified Binder.  Material will meet specification requirements of the table below for at least 30 days after application

Table 702.16 Polymer Emulsified Binder

Emulsion (AASHTO T 59)

Type A

(b)

Type B (b,c,g)

Saybolt Furol Viscosity

100-550 (50 ºC)

20-100

(25 ºC)

Storage stability, 24 hrs., % difference, max (a)

1

1

Demulsibility, 35 ml of 0.8% Dioctyl Sodium Sulf., min

50

60

Demulsibility, 35 ml of 0.02N, CaCl₂, %, min

60

Sieve test, (distilled water), %, max

0.1

0.05

Distillation to 190 ºC, residue % solids (d)

68

63

Oil distillate, %, max

2

2

Distillation Residue

Penetration, 100g, 5 sec @77 ºF( 25ºC) AASHTO T 49

70-100

90-150

Softening point, º C, min AASHTO T 53

60

Solubility in TCE, %, min ASTM D 2042 or D 5546

97.5

97.5

Elastic Recovery, 50 ºF (10º C),  %, min             AASHTO T 301, (e),(,g)

70

58

Toughness/Tenacity,

 77 ºF (25º C), 50 cm/min, Nm ASTM D 5801 (f)

report

 16.0/ 9.0

Ductility, 39 ºF (4º C),1cm/min, min                   AASHTO T 51, (f)

70

Notes:

      (a) After standing undisturbed for 24 hours, the surface will show no white, milky colored substance, but will be a smooth homogeneous color throughout.

(b)  CRS-2P, test within 20 days of project sampling. Limits for both certified source and project samples.

(c)  HFRS-2P, test within 20 days of project sampling.

(d)  See Supplement 1013. 

(e)  Straight molds.  Hold at test temperature for 90 minutes.  Place in ductilometer and elongate 10 cm at 5 cm/min.  Hold for 5 minutes and cut.  After 1 hour retract the broken ends to touch and note elongation in cm (X).  Percent Recovery = ((10-X)/10) x 100.

(f)  SBR

(g)  SBS, SB

702.17 Crack Sealant

A. Type I Crack Sealant.       Conform to 705.04

B. Type II Crack Sealant.     Provide a mixture of PG 64-22 certified binder (Supplement 1032) and polyester fibers (recycled fibers not permitted) according to the following requirements:

Denier; ASTM D 1577*...................................... 3.0 to 6.0

Length........................... 0.25 ± 0.02 inch (6.35 ± 0.51mm)

Crimps; ASTM D 3937............................................. None

Tensile str, min. ASTM D2256*..... 70,000 psi (483 Mpa)

Specific gravity................................................ 1.32 to 1.40

Minimum melting temperature................... 475 ºF (256 ºC)

Ignition temperature......................... 1000 ºF (538 ºC) min.

*This data must be obtained prior to cutting the fibers.

The fiber and fiber manufacturer must be on the Qualified Products List.

Combine materials so the fibers are a minimum of 5.0 percent by total weight of the asphalt binder.  Ensure combined materials are according to the following properties:

Strength (at break) at 72 ºF (22 ºC) 350 psi (2.4 MPa) min.

.... at 0 ºF (-18 ºC) ......................... 500 psi (3.5 MPa) min.

Elongation (at break)        at 72 ºF (22 ºC)    50 percent min.

.... at 0 ºF (-18 ºC) ..................................... 20 percent min.

The option for using premixed and prepackaged Type II crack sealant is permitted provided (1) the fibers and the fiber binder are according to the requirements as shown and, (2) the fiber binder is according to the manufacturer’s specifications.  Furnish certified test data from the fiber binder manufacturer annually to the Laboratory, and when requested by the Laboratory.  Furnish a letter of certification with each shipment stating that the material complies with specification requirements.

C. Type III Crack Sealant.      Provide a mixture of PG 64-22 certified binder (Supplement 1032) and polypropylene fibers (recycled fibers not permitted) according to the following requirements:

Denier; ASTM D 1577*........................................... 15 ±3

Length,........................... 0.39 ± 0.08 inch (9.91 ± 2.0 mm)

Crimps; ASTM D 3937............................................. None

Tensile strength, min, ASTM D 2256* 40,000 psi (276 MPa)

Specific gravity................................................. 0.91 ± 0.04

Minimum melting point............................. 320 ºF (160 ºC)

*   This data must be obtained prior to cutting the fibers.

The fiber and fiber manufacturer must be on the Qualified Products List.

Combine materials so the fibers are a minimum of 7.0 percent by total weight of the asphalt binder.  Ensure combined materials are according to the following properties:

Strength (at break) at 72 ºF (22 ºC) 350 psi (2.4 MPa) min.

.... at 0 ºF (-18 ºC).......................... 500 psi (3.5 MPa) min.

Elongation (at break).................................. at 72 ºF (22 ºC)          50 percent min.

.... at 0 ºF (-18 ºC) ..................................... 20 percent min.

D. Type IV Crack Sealant.    Provide a prepackaged, preapproved mixture of modified binder according to the following properties and minimum 2.0 percent polyester fibers (recycled fibers not permitted) according to the following properties.  Place sealant with a manufacturer’s representative for the fiber binder on site to ensure proper application and conditions.

Modified binder:

Cone penetration, 77 ºF (25 ºC)................................ 50-90

Flow, 140 ºF (60 ºC)........................................ 1.0 cm max

Resilience, 77 ºF (25 ºC)............................... 25-60 percent

Ductility, 77 ºF (25 ºC)...................................... 40 cm min

Bond, 0 ºF (-18 ºC), 100 percent ext. Pass ........... 5 cycles

Impact, 0 ºF (-18 ºC)................................................... Pass

Compression recovery.......................................... 0.40 min

Recommended pour temperature............... 380 ºF (193 ºC)

Safe heating temperature............................ 410 ºF (210 ºC)

Fiber must meet requirements for Type II polyester fiber.  Fiber and fiber manufacturer must be on the Qualified Products List.

Safe heating temperature............................ 400 ºF (204 ºC)

Softening point............................................ 190 ºF (88 ºC)

Viscosity, 400 ºF (225 ⁰C).............................. 3000 cp min

Cone penetration, 77 ºF (25 ºC)................................ 25-45

Workability - Capable of being melted and applied through a pressure feed, indirect heated and agitated melter

Flexibility*.................................................................. Pass

* 1 inch (25mm) sample at -20 ºF (-30 ºC), 90 degree bend, 10 sec

Crack sealant and crack sealant manufacturer must be on the Qualified Products List.

703  AGGREGATE

703.01  General.

The following abbreviations apply:

CCS                Crushed Carbonate Stone.

ACBFS          Air Cooled Blast Furnace Slag

GS                   Granulated Slag

RACP             Reclaimed Asphalt Concrete Pavement 

RPCC             Recycled Portland Cement Concrete

OH                  Open Hearth Slag

EAF                Electric Arc Furnace Slag

BOF                Basic Oxygen Furnace Slag

PCS                Petroleum Contaminated Soil

Pre-qualified Aggregate Supplier Program (Supplement 1069). Provide aggregate materials to the Ohio Department of Transportation from pre-qualified suppliers.

A.      Soundness.  When the major portion of the unsound material in a coarse aggregate acquires a mud-like condition when tested for soundness, ensure that the maximum loss for all uses is 5 percent.

B.      Stockpiles.  Use stockpiling and loading methods that permit ready identification of the aggregates and to minimize segregation.  Clean the sites for stockpiles before storing materials.  Do not remove aggregates from stockpiles within 1 foot (0.3 m) of the ground until final cleanup of the work.  Do not use material that has become mixed with foreign matter, wood or other size or grades of aggregates.

Handle aggregates in such a manner that the moisture content is reasonably uniform for each day’s run.

C.      Size.  Provide aggregate according to the size specified in the material specification, the construction item, or as shown in AASHTO M 43.

D.      Method of Test.  Provide aggregate tested by the following methods:

Amount finer than No. 200 (75 mm) sieve............... S1004

Clay lumps............................................................... S1017

Coal and lignite........................................ AASHTO T 113

Crushed pieces........................................... ASTM D 5821

Deleterious materials................................................ S1029

Effect of organic impurities on

strength of mortar...................................... AASHTO T 71

Liquid limit................................................ AASHTO T 89

Percent of wear, Los Angeles

.... abrasion test............... AASHTO T 96 or ASTM C 535

Plasticity index........................................... AASHTO T 90

Sieve analysis............................................... S1004, S1005

Sieve analysis of mineral filler................... AASHTO T 37

Sodium sulfate soundness test,

.... 5 cycle................................................. AASHTO T 104

Specific Gravity and percent absorption

.... for fine and coarse aggregate............................... S1031

Unit weight................................................ AASHTO T 19

Lightweight chert in aggregates............... AASHTO T 113

Sand equivalent........................................ AASHTO T 176

Uncompacted void content....................... AASHTO T 304

Flat and elongated....................................... ASTM D 4791

Rapid freezing and thawing..... ASTM C 666, Procedure B

Insoluble residue of carbonate

.... aggregates.............................................. ASTM D 3042

Compaction testing of Unbound Materials............... S1015

In place gradation sampling...................................... S1090

Sulfur leachate test.................................................... S1027

Soundness of aggregate by freezing

.... and thawing......................................... AASHTO T 103

Micro-Deval............................................ AASHTO T 327

Silicon Dioxide............................................. ASTM C 146

Sodium sulfate soundness test,

.... Rock slabs............................................. ASTM D 5240

E.      Steel Slag Aggregate.  Provide open-hearth (OH), basic oxygen furnace (BOF), and electric arc furnace (EAF) steel slag aggregate (known as steel slag) according to the following requirements when 703.04 aggregate for asphalt concrete base or 703.05 aggregate for asphalt intermediate course is specified.  Do not use OH, BOF, or EAF slag as the fine or coarse aggregate (virgin or recycled) for asphalt surface courses.

Supply all steel slag from sources according to Supplement 1071.  Furnish steel slag to a size meeting the specified grading requirements.  Provide steel slag aggregate meeting the specified coarse or fine aggregate quality requirements.  Ensure that measurements of soft pieces includes soft lime, lime oxide, or magnesia agglomerations or any foreign materials prone to rapid disintegration under construction processing and weathering conditions.  Ensure that additional testing beyond those listed are performed or required any time poor quality steel slag is suspected due to visual inspection, testing, or field performance problems.

Provide a letter of certification to the Engineer from the steel slag processor for every shipment of steel slag to the Contractor.  In addition the steel slag processor must provide the Engineer with the following:

Quality control records (created in accordance with Supplement 1071).

Documentation of the steel slag production, processing, and stockpile retrieval

Failure to follow the processor QC plan or continued problems with performance recognized by the Laboratory attributable to steel slag is cause for limiting steel slag use from that processor.

F.      Restrictions.  When an aggregate source is specially designated with a “SR or SRH” according to Guidelines for Maintaining Adequate Pavement Friction in Surface Pavements, the aggregate source will be restricted for use in surface pavement according to the methods in the guidelines.  The document, Guidelines for Maintaining Adequate Pavement Friction in Surface Pavements, is available on the OMM website under “Material Information by Category, Aggregate”, or the Office of Pavement Engineering’s website.

703.02   Aggregate for Portland Cement Concrete.

A.      Fine Aggregate.

1.      Provide fine aggregate consisting of natural sand or sand manufactured from stone.

2.      Sieve analysis.

Sieve Size

Total Percent Passing

3/8 inch   (9.5 mm)

100

No. 4       (4.75 mm)

95 to 100

No. 8       (2.36 mm)

70 to 100

No. 16     (1.18 mm)

38 to 80

No. 30     (600 mm)

18 to 60

No. 50     (300 mm)

5 to 30

No. 100   (150 mm)

0 to 10

No. 200   (75 mm)

0 to 5

Should the fineness modulus of a job control sample of sand from any source vary by more than 0.20 percent from that of the representative sample from that source, the sand may be rejected.

3.      Physical properties.

Maximum

Loss, sodium sulfate soundness test

   Item 305

12 %

   Items 255, 256, 451, 452, 511, 515, 519, 526, 602, 611, 604, 608, 609, 610, 622, and 625

10 %

Aggregations of soil, silt, etc. by weight

0.5 %

When tested for the effect of organic impurities on strength of mortar, ensure that the compressive strength at 3 and 7 days of mortar made with untreated sand is not less than 95 percent of the compressive strength of mortar made with treated sand.

Provide fine aggregate for Items 255, 256, 451, 452, 526, and 511 deck slabs with at least 25 percent siliceous particles as determined by the acid insoluble residue test [ASTM D3042].  Ensure material has been tested and results are on file at the Laboratory.  For sources not tested and on file at the laboratory, submit certified test data from an AMRL accredited independent laboratory verifying the minimum 25 percent.

B.      Coarse Aggregate.

1.      Provide coarse aggregate consisting of washed gravel, CCS, or crushed ACBFS.

2.      Physical properties.

Percent of wear, Los Angeles test, maximum
(CCS or washed gravel)

40 %

Unit weight, compacted, minimum (slag)

70 lb/ft³

(1120 kg/m³)

Loss, sodium sulfate soundness test, maximum:

   Item 305

15 %

   Items 255, 256, 451, 452, 511, 519, 526, 602, 611, 604, 609, 610, 622, and 625

12 %

   Item 515

10 %

Deleterious substances shall not exceed the following:

Percent by Weight

Material Type

Super-Structure

All Other

Concrete

Soft pieces

2.0

3.0

Coal and lignite

0.25

1.0

Clay lumps

0.25

0.25

Pieces having a length greater than 5 times the average thickness

15

15

Shale and shaly material

0.5

1.0

Limonitic concretions

0.5

1.0

Alkali

0.5

1.0

Metallic particles

0.5

1.0

Chert, that disintegrates in 5 cycles of the soundness test

0.5

1.0

Additional requirement for ACBFS aggregate:

Total Sulfur as S, maximum (ASTM C114)

2.0%

3.      Amount passing the No. 200 (75 mm) sieve.  Ensure that the percent by weight of material passing the No. 200 (75 mm) sieve in the aggregate portion of the concrete mix does not exceed the following:

Percent by Weight

Material Type

Super-Structure

All Other Concrete

CCS and crushed ACBFS

3.4

3.8

Washed gravel

2.0

2.2

703.03  Fine Aggregate for Mortar or Grout.

A.      Provide fine aggregate consisting of natural sand or sand manufactured from stone or ACBFS.

B.      Sieve Analysis.

Natural Sand

Manufactured Sand

Sieve Size

Total Percent Passing

No. 4       (4.75 mm)

100

100

No. 8       (2.36 mm)

95 to 100

95 to 100

No. 50     (300 mm)

10 to 40

20 to 40

No. 100   (150 mm)

0 to 15

10 to 25

No. 200   (75 mm)

0 to 5

0 to 10

C.      Physical properties.

Maximum

Loss, sodium sulfate soundness test

10 %

Aggregations of soil, silt, etc. by weight

0.5 %

When tested for the effect of organic impurities on strength of mortar, ensure that the compressive strength of mortar made with untreated sand is not less than 95 percent of the compressive strength of mortar made with treated sand.

703.04  Aggregate for Asphalt Concrete Base (301 and 302).

A.      Provide coarse aggregate for asphalt concrete base used in combination with rigid pavement consisting of CCS, gravel, or crushed ACBFS.

Provide coarse aggregate for asphalt concrete base used in flexible pavements consisting of CCS, gravel (see note [1] in table below), or crushed ACBFS.  Provide fine aggregate for asphalt concrete base consisting of natural sand or sand manufactured from stone, gravel, or ACBFS.  Crushed Steel Slag (OH, EAF or BOF) conforming to 703.01.E and 401.03 may be used for coarse and fine aggregate in asphalt concrete base used in flexible pavements.

B.      Physical properties.

Percent of wear, Los Angeles test, maximum
(CCS or washed gravel)

50 %

Unit weight, compacted, minimum (slag)

65 lb/ft³

(1040 kg/m³)

Loss, sodium sulfate soundness test, maximum

15 %

Percent by weight of fractured pieces
(one or more faces), minimum

40 %

Micro-Deval Abrasion Loss test, maximum
(for coarse aggregate gravel only)

22 % [1]

[1]  If the MD value is greater than the specification limit conform to Supplement 1010.

Deleterious substances shall not exceed the following:

Material Type

Percent by Weight

Soft pieces

3.0

Coal and lignite

1.0

Clay lumps

0.25

Pieces having a length greater than 5 times the average thickness

15

Shale and shaly material

2.5

Chert that disintegrates in 5 cycles of the soundness test

2.5

703.05  Aggregate for Asphalt Concrete (Intermediate and Surface Courses), Prime Coat (408), Chip Coat (422), and Microsurfacing (421).

A.      Fine Aggregate.

1.      Provide fine aggregate consisting of natural sand or sand manufactured from stone, gravel, ACBFS or, for intermediate courses only, steel slag (OH, EAF or BOF) conforming to 703.01.E and 401.03.

2.      Sieve analysis.

Sieve Size

Total Percent Passing

3/8 inch   (9.5 mm)

100

No. 4       (4.75 mm)

90 to 100

No. 8       (2.36 mm)

65 to 100

No. 16     (1.18 mm)

40 to 85

No. 30     (600 mm)

20 to 60

No. 50     (300 mm)

7 to 40

No. 100   (150 mm)

0 to 20

No. 200   (75 mm)

0 to 10

3.      Physical properties.

Maximum

Loss, sodium sulfate soundness test

15 %

Aggregations of soil, silt, etc., by weight

0.5 %

B.      Coarse Aggregate.

1.      Provide coarse aggregate consisting of CCS, crushed ACBFS, washed gravel, or for intermediate courses only, steel slag (OH, EAF or BOF) conforming to 703.01.E and 401.03.

2.      Physical properties.

Percent of wear, Los Angeles test, maximum
(CCS or washed gravel)

40 %

Unit weight, compacted, minimum (slag):

   Asphalt Concrete, 408 and 422

70 lb/ft³

(1120 kg/m³)

Loss, sodium sulfate soundness test, maximum:

   Asphalt Concrete and 422

12 %

   421

15 %

Percent by weight of fractured pieces
(one or more faces), minimum

40 %

Micro-Deval Abrasion Loss test, maximum
(for gravel only)

20 % [1]

[1]  If the MD value is greater than the specification limit conform to Supplement 1010.

Deleterious substances shall not exceed the following:

Material Type

Percent by Weight

Soft pieces

3.0

Coal and lignite

1.0

Clay lumps

0.25

Amount finer than No. 200 (75 mm) sieve

3.0

Pieces having a length greater than 5 times the average thickness

15

Shale and shaly material

2.5

Limonitic concretions

2.5

Alkali

2.5

Chert that disintegrates in 5 cycles of the soundness test

2.5

C.      General Requirements for Fine Aggregate.  For fine aggregate calculate each individual sieve fraction soundness loss and ensure that the fractional size does not exceed 13.0 percent for all surface courses, intermediate courses and any asphalt concrete course directly below an open graded friction course.

703.06  Sand Cover (407 and 408).

A.      Furnish sand cover consisting of natural sand or sand manufactured from stone or ACBFS.

B.      Sieve analysis.

Sieve Size

Total Percent Passing

No. 4       (4.75 mm)

90 to 100

No. 50     (300 mm)

7 to 40

No. 200   (75 mm)

0 to 10

703.07  Mineral Filler.

A.      Furnish mineral filler consisting of limestone dust, portland cement, or other inert mineral matter.  Ensure the mineral filler is thoroughly dry and free from lumps.

B.      Sieve analysis.

Sieve Size

Total Percent Passing

No. 30     (600 mm)

100

No. 50     (300 mm)

95 to 100

No. 200   (75 mm)

65 to 100

703.08  Granulated Slag.

A. Furnish Granulated Slag (GS) consisting of glassy, granular materials formed when molten blast furnace slag or electric-furnace slag is rapidly chilled, as by immersion in water.  The Department may reject material containing mill waste, cinders, large pieces of ungranulated slag, or other matter foreign to the production of slag in the normal operation of the blast furnace or electric furnace.

Furnish material of such nature that it will compact to the satisfaction of the Engineer.

B. Sieve analysis.

Sieve Size

Total Percent Passing

2 inch      (50 mm)

100

1 inch      (25 mm)

85 to 100

No. 100   (150 mm)

0 to 15

703.10  Screenings.

A. Furnish screenings for No. 10 size gravel, stone, or ACBFS.  Where crushed material is specified, ensure that it is crushed from material larger than the 1/2-inch (12.5 mm) sieve.

B. Physical properties.

Maximum

Loss, sodium sulfate soundness test

15 %

703.11  Structural Backfill for 611 Bedding and Backfill.  Furnish structural backfill for 611 bedding and backfill consisting of CCS, gravel, natural sand, sand manufactured from stone, foundry sand, ACBFS, GS, or RPCC.

Furnish ACBF Slag according to Supplement 1027.

Furnish granulated slag according to 703.08.

Do not use GS for Type 3 Structural Backfill.

The use of RPCC is permitted without wear testing or sodium soundness testing requirements if the Contractor provides information proving the material met this specification at the time of its original incorporation.  The use of RPCC is not permitted in conjunction with aluminum pipe or aluminum coated steel pipe.  Ensure that the RPCC use does not contain more than two percent steel.

Reclaimed asphalt concrete is not allowed for any bedding or backfill materials.

Use foundry sand if the material meets these requirements and meets the requirements of the Ohio EPA, Division of Surface Water, Policy 400.007 “Beneficial use of Non-Toxic Bottom Ash, Fly Ash and Spent Foundry Sand and Other Exempt Waste,” and all other regulations.  Ten days before using foundry sand on the project, submit written permission from the Ohio EPA to the Engineer.  Instead of written permission from the Ohio EPA, the Contractor may elect to have an independent consultant pre-qualified by ODOT in remedial design environmental site assessment review the proposed usage.  The consultant will provide all documentation utilized to ensure that the proposed usage is according to all Ohio EPA regulations.  Ensure that the consultant coordinates all EPA required meetings, documentation, and testing requirements.  Ensure that the consultant certifies this to the Department.

A. Structural Backfill Type 1 and 3.

1.  Furnish Type 1 structural backfill that meets the gradations of Items 304, 411, or 617, except 0 to 20 percent may pass the No. 200 sieve.  Furnish Type 3 structural backfill that meets the gradations of Size No. 57 or 67 from Table 703.01-1.

2.  Physical properties.

Percent of wear, Los Angeles test, maximum
(CCS or washed gravel)

50 %

Loss, sodium, sulfate soundness test, maximum

15 %

Percent by weight of fractured pieces
(one or more faces), minimum (Type 3 only)

90 %

Deleterious substances shall not exceed the following:

Material Type

Percent by weight

Shale and shaly material

5.0

Chert, that disintegrates in 5 cycles of the soundness test

5.0

Ensure that the portion of the material passing through the No. 40 (425 mm) sieve has a maximum liquid limit of 25 and a maximum plasticity index of 6.

Crush gravel for Type 3 from material retained on the 1/2 inch (12.5 mm) sieve.

B.      Structural Backfill Type 2.

1.      Furnish Type 2 structural backfill that meets the gradations of 703.05.A, 703.02.A, or one of the gradations below:

Sieve Size

Total Percent Passing

2 1/2 inch                (63 mm)

–

100

1 inch      (25.0 mm)

–

70 to 100

3/4 inch   (19.0 mm)

100

–

3/8 inch   (9.5 mm)

80 to 100

–

No. 4       (4.75 mm)

60 to 100

25 to 100

No. 8       (2.36 mm)

45 to 95

–

No. 40     (425 mm)

–

10 to 50

No. 50     (300 mm)

7 to 55

–

No. 200   (75 mm)

0 to 15

5 to 15

2.      Physical properties:

Percent of wear, Los Angeles test, maximum
(CCS or gravel)

50 %

Loss, sodium sulfate soundness test, maximum

15 %

Ensure that the portion of the material passing through the No. 40 (425 mm) sieve has a maximum liquid limit of 25 and a maximum plastic index of 6.

703.13  Coarse Aggregate for Items 305, 451 and 452.  In addition to the requirements of 703.02, the following aggregate requirements apply.

When the total combined quantity of the listed items is greater than 10,000 square yards (8000 m²), provide size No. 57 or 67 from Table 703.01-1.  If the total combined quantity of the listed items is less than 10,000 square yards (8000 m²), then provide one of the following sizes from Table 703.01-1:  No. 7, 78, 8, 57, or 67.

If gravel or limestone No. 57 or 67 size is selected in either of the above cases, then ensure that the coarse aggregate incorporated into the concrete is tested according to ASTM C 666, Procedure B.  Ensure that the area generated under the curve obtained by plotting the expansions of test specimens verses the number of test cycles does not exceed 2.05 at 350 or less cycles.

Ensure that the validity of results of freeze thaw-resistance testing is as outlined below:

Range of Area under Curve[1]

Status of Source Approval

0.00 to 1.00

Valid for two years from date approved[2]

1.01 to 2.05

Valid for one year from date approved[2]

2.06 to 4.00

Not Approved, one retest allowed[3]

> 4.00

Not Approved, no retesting allowed[3]

[1]  As measured at 350 cycles.

[2]  If a notable change in the properties of the aggregate originating from the affected source is determined from quality control testing, a retest of freeze-thaw resistance may be requested before the original expiration date.  The Laboratory will make the determination to retest.

[3]  Except as noted, the Department will not retest the material unless the producer of the material sends a written request to the Department with substantiation that significant changes in operation have been made (e.g., new processing equipment, material from a new ledge, etc.).

The Laboratory will maintain a list of approved sources.

703.14  Non Pavement Open-Hearth, Electric Arc Furnace, and Basic Oxygen Furnace Steel Slag Aggregate Use.  Provide steel slag according to the following requirements.

1.      Non-confined Applications. When using OH, EAF, and BOF slag in applications where the steel slag will not be confined, ensure that the slag meets the requirements in 703.14.A (deleterious substances and crushing), and in 703.14.B (aging and stockpiling requirements). Recycled steel slag from Department or non-Department projects may be used in applications where the recycled steel slag will not be confined.

2.      Confined Applications. When using OH, EAF, and BOF slag in applications where the steel slag will be confined, ensure the steel slag meets all requirements of 703.14. The use of recycled steel slag from Department or non-Department projects is not allowed in confined applications.

A.      Deleterious Substances (soft pieces). Deleterious substances include soft lime, lime oxide,or magnesia agglomerations or any foreign materials prone to rapid disintegration under construction processing and weathering conditions.

Furnish steel slag with less than 3 percent deleterious substances (soft pieces) by weight. The Department will use Supplement 1029 (hand crushing of soft pieces) to determine the soft pieces.

Crushing of steel slag is not allowed.

B.      Aging and Stockpiling Requirements. Stockpile and age all steel slag as follows:

1. Grade and stockpile the material into maximum size piles of 25,000 ton (23,000 metric tons). Before and during the stockpiling operation, add water to these materials to provide a uniform moisture content not less than their absorbed moisture. Ensure that the stockpile is maintained in a moist condition during the required stockpiling period.

2. Ensure that the producer mixes the stockpile when the outside surface of the pile has crusted over. The Department will inspect the stockpile every 2 months to ensure no crusting occurs. Do not mix frozen stockpile material. Suspend the aging period when the stockpile is frozen for more than one month.

3. Ensure that this aging period is at least 6 months in duration and starts over if any new material is added to the pile during the aging period.

C.      Identification of Steel Slag. Clear, definitive, and undisputable identification of the proposed material being steel slag is required.

The producer will show the Department evidence that the material supplied is steel slag. This information will consist of, but is not limited to, the following:

1.      Steel producer.

2.      Production dates.

3.      Production rates.

4.      Stockpiling dates.

5.      Type of steel furnace(s).

6.      All known Department and non-Department projects where the material was previously used.

This identification of steel slag and the source may be supplemented by other information approved by the Department or by using 10 years of good performance data. Ensure that the producer submits to the Department projects where the steel slag has been used without expansion or tufa problems. The Department will review the above projects as part of the identification approval process.

D.      Tufa Performance Verification of Steel Slag. Tufa is a precipitate form of calcium carbonate that can clog up the underdrain systems. Some steel slag sources clog up underdrain systems and some do not. Tufa performance verification is based on field performance and Department’s inspection of the underdrain systems.

Tufa performance verification is required.

Ensure that the producer submits past projects that are at least 10 years old that used the proposed steel slag source to the Department. The Department may consider projects that are less than 10 years old for tufa performance verification if it can be determined by the Department that the age of the steel slag incorporated in the project was 10 years old or greater. Ensure the producer supplies the Department with construction plans with the underdrains and underdrain outlets marked on the plans, or other suitable method, approved by the Department, showing the underdrain system. Ensure the producer marks the underdrain outlets in the field for inspection. The Department will inspect the underdrain systems for tufa deposits. If tufa deposits are found in the outlets or in the underdrain system, the Department will reject the steel slag source.

E.      Expansion Testing of Steel Slag. After the aging and stockpiling requirements are met, expansion testing is required for steel slag.

Perform expansion testing according to Pennsylvania Department of Transportation PTM No. 130, the ODOT equivalent to this test or expansion testing acceptable to the Department.

Ensure that the producer hires an independent AASHTO accredited and Department approved laboratory to perform at least half of the expansion testing. At the producer’s option, up to half of the required expansion testing may be performed by the producer’s laboratory. The Laboratory will observe the expansion testing and approve each independent and producer laboratory.

Perform expansion testing for every 2500 tons (2300 metric tons) or fraction thereof of the material stockpiled in accordance with 703.14.B. For steel slag less than 10 years old, retain a spilt portion of the expansion sample. Reduce the split sample to 5 lbs (2500 g) and test for   total percent MgO by X-Ray florescence and total percent periclase (hard burned MgO) by X-Ray diffraction.

The maximum allowable total expansion for each test is less than 0.50 percent. If any one test fails in the stockpile, the Department will reject the entire stockpile.

When sampling for expansion, ensure that the producer notifies the Department at least 48 hours before the sampling. The Department will verify that the sample came from the correct stockpile and take independent split samples, if required.

Submit the expansion test data and a suitably presented summary of the expansion test data to the Department for approval. Submit X-Ray florescence and X-Ray diffraction data to the Department. The Department reserves the right to perform independent testing to verify the laboratory results at any time.

The Department expansion test data takes precedence over the producer or independent laboratory expansion testing results in the event of a conflict. The Department will make the final determination on all conflicting data.

If the material fails the expansion testing, then stockpile the material for a minimum of two additional months from the date of last sampling and retest for expansion. Only materials that pass the expansion test are approved for use.

703.16  Suitable Materials for Embankment Construction.  Natural soil, natural granular material, granular material types, slag material, brick, shale, rock, random material, RACP, RPCC, or PCS as further defined below are suitable for use in embankment construction.  The Engineer will submit samples of soils not identified from the plan subsurface investigation, from borrow sources or materials appearing questionable in the field.

Furnish ACBFS according to Supplement 1027.

Furnish RPCC with the reinforcing steel cut to a maximum length of 1 inch (25 mm) outside the pieces.

Ensure that pieces of RACP do not exceed 4 inches (100 mm) in the largest dimension.

Furnish steel slag according to 703.14.

When using steel slag, RPCC, or RACP, completely blend it with at least 30 percent natural soil or natural granular material.

When using coal, completely blend it with natural soil or natural granular materials.  Make at least 90 percent of the blend natural soil or natural granular materials.

A.      Natural Soils.  Furnish natural soils as defined in 203.02.I and classified as Department Group Classifications A-4-a, A-4-b, A-6-a, A-6-b, and A-7-6 as further defined below:  Furnish soils with a maximum dry density of at least 90 pounds per cubic foot (1450 kg/m³).

Do not use soils having a liquid limit in excess of 65 or soils identified as Department Group Classifications A-5, or A-7-5 in the work.

B.      Granular Embankment Materials.  Furnish natural granular materials as defined in 203.02.H and classified as Department Group Classifications A-1-a, A-1-b, A-3, A-3-a, A-2-4, A-2-6, or A-2-7.

Do not use granular material classified as A-2-5.

C.      Granular Material Types.  Furnish CCS, gravel, ACBFS, durable sandstone, durable siltstone, GS, or blended natural soil or natural granular materials blended with OH, BOF, EAF, or RPCC as detailed above.  Furnish durable sandstone and siltstone with a slake durability index greater than 90 percent according to ASTM D 4644.

Except for GS, furnish the following gradations for the granular material types, by weight:

1.      Granular Material, Type A.  Furnish material having less than 25 percent by weight of the grains or particles passing the No. 200 (75 µm) sieve.

2.      Granular Material Type B.  For Item 204, furnish the gradation of Items 304, 411, or 617.  For Item 203, furnish the gradation of Items 304, 411, or 617 except 0 to 20 percent will be allowed to pass the No. 200 (75 μm) sieve.

3.      Granular Material Type C.  Furnish well graded material that meets the following gradation:

Sieve Size

Total Percent Passing

3 inch      (75 mm)

100

2 inch      (50 mm)

70 to 90

1/2 inch   (12.5 mm)

30 to 60

No. 200   (75 mm)

0 to 13

4.      Granular Material Type D.  Furnish the gradation of 100 percent passing the 8 inch (200 mm) sieve, less than 60 percent passing the 3 inch (76 mm) sieve, less than 40 percent passing the 3/4 inch (19 mm) sieve, and 0 to 20 percent passing the No. 200 (75 µm) sieve.

5.      Granular Material Type E.  Furnish any of the coarse aggregates from No. l through 67 inclusive on Table 703.01-1.

6.      Granular Material Type F.  Furnish material according to the following:

a.      Well graded material.

b.      A gradation with a top size from 8 inches (200 mm) to 3 inches (76 mm) and a bottom size of No. 200 (75 µm) sieve.

c.      An evenly graded material between the top and bottom size.

d.      Compactable, stable, and serves the intended use.

D.      Shale.  Furnish shale as defined in 203.02 and as further defined below.  Ensure that the shale is tested for durability to determine whether the shale is durable or nondurable shale.  Test the shale according to the following procedure:

1.      Obtain a piece of shale that is typical and representative of the rest of the shale.  The size of the piece should be about 6 inches (150 mm).  If a 6-inch (150 mm) sample is not available, then the shale is nondurable.

2.      Place the piece of shale in a bucket of water.  Examine the deterioration or slaking of the shale after 48 hours.  If the shale has deteriorated, then the shale is nondurable.

3.      If the shale has not deteriorated after being in water for 48 hours, then break down the shale over a 3/4 inch (19.0 mm) sieve by hand pressure.  If 75 percent or less of the shale is retained on the 3/4 inch (19.0 mm), then the shale is nondurable.

4.      If more than 75 percent of the shale is retained on the 3/4 inch (19.0 mm) sieve or, then perform a field test for durability.  The field test for durability consists of compacting the shale with six passes of a steel drum roller which has a minimum compaction force of 500 pounds per lineal inch (57 kN/mm) of roller drum width.  Provide documentation to the Engineer to verify the roller meets the compaction force requirement.

a.      If more than 40 percent of the shale breaks down, by visual inspection, then the shale is nondurable.

b.      If less than 40 percent of the shale breaks down, by visual inspection, then the shale is durable.

703.17  Aggregate Materials for 304.  Furnish aggregate that is CCS, crushed gravel, crushed ACBFS, GS, or steel slag.

Furnish GS according to the requirements of 703.08.

Furnish steel slag according to 703.14

Furnish ACBFS according to Supplement 1027.

Determine aggregate acceptance before incorporation into the work based on samples taken from stockpiles.

A.      Furnish CCS, crushed gravel, crushed ACBFS, and steel slag that meets the following gradation:

Sieve Size

Total Percent Passing

2 inch      (50 mm)

100

1 inch      (25.0 mm)

70 to 100

3/4 inch   (19.0 mm)

50 to 90

No. 4       (4.75 mm)

30 to 60

No. 30     (600 mm)

9 to 33

No. 200   (75 mm)

0 to 15 [1]

[1]  Furnish steel slag that has 0 to 10 percent passing through the No. 200 (75mm) sieve

Furnish gravel used under Item 304 that is crushed from material retained on the 1/2 inch (12.5 mm) sieve.

B.      Furnish CCS, crushed gravel, ACBFS, and steel slag that meets the physical property requirements:

Percent of wear, Los Angeles test, maximum
(CCS or crushed gravel)

50 %

Loss, sodium sulfate soundness test, maximum

15 %

Percent by weight of fractured pieces
(one or more faces), minimum

90 %

[1]

[1]  Does not apply to steel slag

Ensure deleterious substances in CCS, crushed gravel, and ACBFS do not exceed the following:

Material Type

Percent by weight

Shale and shaly material

5.0

Chert, that disintegrates in 5 cycles of the soundness test

5.0

Except for GS, ensure that the portion of the material passing through the No. 40 (425 mm) sieve has a maximum liquid limit of 25 and a maximum plasticity index of 6.

703.18  Materials for Items 410, 411, and 617.  Furnish CCS, gravel, ACBFS, GS, OH slag, BOF slag, EAF slag, RPCC, or RACP for materials.

If RPCC and RACP are used, provide the following information:

1.      Specification item that the material was originally constructed under.

2.      The applicable material requirements of the original construction item.

If the original construction requirements meet or exceed the requirements of this specification, then the shale, sodium soundness and Los Angeles abrasion test for RACP and RPCC may be waived.  The plastic index and clay requirements are not required for RACP.  Use RPCC that is free of steel.

Furnish OH, BOF, and EAF slag according to 703.14

Use ACBFS according to Supplement 1027.

Furnish GS according to 703.08.

A.      Gradations.  Furnish for Items 617, 410, and 411 RACP materials according to the following gradation:

Sieve Size

Total Percent Passing

1 1/2 inch                (37.5 mm)

100

3/4 inch   (19.0 mm)

80 to 100

3/8 inch   (9.5 mm)

60 to 90

No. 4       (4.75 mm)

30 to 90

No. 30     (600 mm)

3 to 20

Except for GS and RACP, use the following gradations for Items 410, 411, and 617.

Furnish materials for Item 410  according to one of the following gradations:

Sieve Size

Type A

Type B

Type C

Total Percent Passing

1 1/2 inch                (37.5 mm)

100

100

Size

No. 4 or 57

from

Table

703.01-1

1 inch      (25.0 mm)

90 to 100

75 to 100

3/4 inch   (19.0 mm)

60 to 100

60 to 100

3/8 inch   (9.5 mm)

40 to 60

35 to 75

No. 4       (4.75 mm)

15 to 30

30 to 60

          Do not use RACP for Type C material.

Furnish materials for Item 411 according to the following gradation:

Sieve Size

Total Percent Passing

1 1/2 inch                (37.5 mm)

100

1 inch      (25.0 mm)

75 to 100

3/4 inch   (19.0 mm)

60 to 100

3/8 inch   (9.5 mm)

35 to 75

No. 4       (4.75 mm)

30 to 60

No. 30     (600 mm)

7 to 30

No. 200   (75 mm)

3 to 15

Furnish materials for Item 617 according to the following gradation:

Sieve Size

Total Percent Passing

1 inch      (25.0 mm)

100

3/4 inch   (19.0 mm)

60 to 100

3/8 inch   (9.5 mm)

35 to 75

No. 4       (4.75 mm)

30 to 60

No. 30     (600 mm)

9 to 33

No. 200   (75 mm)

0 to 15

B.      Physical properties.

Item

410

Item

411

Item

617

Percent of wear, Los Angeles test, maximum

50 %

–

–

Loss, sodium sulfate soundness test, maximum

–

15 %

–

Percent by weight of fractured pieces
(one or more faces), minimum

–

–

90 %

Gravel used, portion retained on a No. 4 (4.75 mm) sieve (one or more faces) minimum crushed

–

40 %

–

Maximum plasticity index of material passing No. 40 (425 mm) sieve

–

6

–

Deleterious substances shall not exceed the following:

Material Type

Percent by weight

Item

410

Item

411

Item

617

Shale and shaly material

–

5 % [1]

12 %

Clay

10 %

–

–

[1]  Where the major portion of the material in a coarse aggregate, from a source on record at the Laboratory, has shown the characteristics of acquiring a mud-like condition when tested for soundness, test it for soundness and ensure that the maximum loss is 5 percent.

703.19   Rock and Aggregate Materials for Item 601.

A.      Crushed Aggregate Slope Protection and Filter Aggregate for Dump Rock Fill.  Furnish crushed gravel, limestone, sandstone, RPCC, ACBFS, OH slag, BOF slag, or EAF slag for crushed aggregate slope protection and filter aggregate for dump rock fill.

Use ACBFS slag according to Supplement 1027.

Use OH, BOF, and EAF slag according to 703.14

Furnish Size No. 1 or 2 from Table 703.01-1, or according to the following gradation for crushed aggregate slope protection:

Sieve Size

Total Percent Passing

4 inch      (100 mm)

100

3 1/2 inch                (90 mm)

90 to 100

2 1/2 inch                (63 mm)

25 to 90

1 1/2 inch                (37.5 mm)

0 to 25

3/4 inch   (19.0 mm)

0 to 10

For a filter for rock channel protection, use Size No. 3 or 4 from Table 703.01-1.

Physical properties.

Percent of wear, Los Angeles Test, maximum
(CCS or gravel)

50 %

Loss, sodium sulfate soundness test, maximum
(except for RPCC)

15 %

Percent by weight of fractured pieces
minimum (CCS or gravel)

90 %

Loss for RPCC, AASHTO T 103 Soundness of Aggregates by Freezing and Thawing

20 % [1]

[1]  Use Method C using 25 cycles.

B.      Dumped Rock Fill and Rock Channel Protection.  Furnish gravel, broken recycled portland cement concrete (RPCC), broken sandstone, broken siltstone, and broken limestone for dumped rock fill and rock channel protection.  Furnish sandstone, siltstone, and limestone that is free of laminations, seams, and fractures, or injury due to blasting.

Except for RPCC, test for soundness according to ASTM D 5240.  Use materials having a maximum 30 percent single slab loss and a maximum 20 percent cumulative loss.  Slab heights and lengths will be a minimum of 8 inches.  For RPCC, test for soundness according to AASHTO T 103 as stated in 703.18.A. 

The Department may waive testing when the stone source has a known durability history.

Do not use thin, slab-like pieces, or any pieces having a dimension larger than 36 inches (1 m).  Do not use RPCC with reinforcing steel protruding more than 1 inch (25 mm) beyond the outside surface of the concrete pieces.

Furnish dumped rock fill and rock channel protection materials consisting of the four material types defined below:

1.      Type A material has at least 85 percent of the total material by weight larger than an 18-inch (0.5 m) but less than a 30-inch (0.8 m) square opening and at least 50 percent of the total material by weight larger than a 24-inch (0.6 m) square opening.  Furnish material smaller than an 18-inch (0.5 m) square opening that consists predominantly of rock spalls and rock fines, and that is free of soil.

2.      Type B material has at least 85 percent of the total material by weight larger than a 12-inch (0.3 m) but less than a 24-inch (0.6 m) square opening and at least 50 percent of the total material by weight larger than an 18-inch (0.5 m) square opening.  Furnish material smaller than a 12-inch (0.3 m) square opening that consists predominantly of rock spalls and rock fines, and that is free of soil.

3.      Type C material has at least 85 percent of the total material by weight larger than a 6-inch (150 mm) but less than an 18-inch (0.5 m) square opening and at least 50 percent of the total material by weight larger than a 12-inch (0.3 m) square opening.  Furnish material smaller than a 6-inch (150 mm) square opening that consists predominantly of rock spalls and rock fines, and that is free of soil.

4.      Type D material has at least 85 percent of the total material by weight larger than a 3-inch (75 mm) but less than a 12-inch (0.3 m) square opening and at least 50 percent of the total material by weight larger than a 6-inch (150 mm) square opening.  Furnish material smaller than a 3-inch (75 mm) square opening that consists predominantly of rock spalls and rock fines, and that is free of soil.

704  MASONRY UNITS

704.01  Clay or Shale Brick.  Furnish clay or shale brick conforming to ASTM C 32, with the following modifications:

4.1  Furnish bricks of such size and shape as to allow their incorporation in the structure in conformance with the specified dimensions of the structure.

6.1 Furnish materials according to the Department’s Qualified Products List (QPL).

704.02  Concrete Brick.  Furnish concrete brick according  to ASTM C 55,  with the following modifications:

4.1.1 and 4.1.2  Use cement conforming to 701 Portland Cement.

4.2  Use aggregate that conforms to the quality requirements of 703.02.

8.1 Furnish materials according to the Department’s Qualified Products List (QPL).

8.2  Sample and test the brick according to ASTM C 140.  Furnish bricks of such size and shape as to allow their incorporation in the structure in conformance with the specified dimensions of the structure.  Furnish bricks that have a rectangular cross-section with square corners.  Ensure that the ends, edges, and one face are plain surfaces.

704.03  Concrete Masonry Blocks.  Furnish concrete masonry blocks conforming to ASTM C 139, with the following modification:

4.1.1 and 4.1.2  Use cement conforming to 701 Portland Cement.

7.1 Furnish materials according to the Department’s Qualified Products List (QPL).

7.2 Furnish blocks of such size and shape as to allow their incorporation in the structure in conformance with the specified dimensions of the structure.

705  CONCRETE INCIDENTALS

705.01  Fiber Reinforced Polymer (FRP) Dowel Bars.  Furnish round and straight fiber reinforced polymer (FRP) dowel bars.  Ensure that the resin used to manufacture the FRP bars consists of an acrylic modified epoxy resin with a minimum of 5 percent and a maximum of 7 percent tensile elongation at break.  Ensure that the minimum glass fiber content is 70 percent by weight.  Furnish dowels of a type meeting the dimensional requirements of the standard construction drawings Provide certified test data according to 101.03 with each shipment.

705.03  Preformed Fillers.  Furnish preformed fillers according to AASHTO M 153 or AASHTO M 213, with the following modification:

5.7    For materials manufactured as described in 4.1.1 and 4.1.2, ensure that the producer certifies to the Engineer that the asphalt content is at least 35 percent by weight of the filler.

Furnish materials according to the Department’s Qualified Products List (QPL).

705.04  Hot Applied Joint Sealer,   Furnish hot applied joint sealer conforming to ASTM D 6690, Type II   Use this material as the primer for Type 3 membrane.

705.05  Burlap Cloth.  Furnish burlap cloth according to AASHTO M 182, Class 2.  

705.06  Sheet Materials for Concrete Curing.  Furnish sheet materials conforming to AASHTO M 171 for moisture loss and reflectance only. 

705.07  Liquid Membrane-Forming Compounds for Curing Concrete.  Furnish liquid membrane-forming compounds conforming to ASTM C 309, with the following modification:

5.3    In addition - liquid membrane-forming compounds will have a minimum solids content of 25% . 

6.1    Water Retention -  Liquid membrane-forming compound, when tested in accordance with 10.1, shall have a water loss of  not more than: 0.15 kg/m² @ 24 hours and 0.40 kg/m² @ 72 hours.

7.1    Reflectance -  Type 2 curing compound  will  have a minimum daylight reflectance of 65%.

10.4  In addition - Mix Type 2 curing compound until uniform in color and consistency, and then pour into a glass graduated cylinder (Kimax 150 ml) to the 150 ml mark.  The Type 2 curing compound should have a rate of settling such that its uniformly white portion as visible to the eye is not less than 145 ml at 2 hours and not less than 125 ml at 24 hours after filling the Kimax cylinder .  The test should be performed at 73.0 ± 3.5 oF (23 ± 2 oC). During this test the glass cylinder should be stoppered and left undisturbed.        

11.1  In addition,  Equip the containers for Type 2 white pigmented liquid membrane forming compounds with mechanical agitators.  Assign each container in any batch or lot, a number as the container is being filled. 

Furnish materials according to the Department’s Qualified Products List (QPL)

705.10  Air-Entraining Admixtures.  Provide air-entraining admixtures conforming to AASHTO M 154.  Conform to Supplement 1001 for approval. 

Furnish materials according to the Department’s Qualified Products List (QPL)

705.11  Preformed Elastomeric Compression Joint Seal for Concrete.

A.      General.  Provide preformed elastomeric compression joint seal conforming to ASTM D 2628, with the following modifications:

5.1    Ensure that the size and design is as shown on the plans.

7.2    The Engineer will perform inspection at the project site. 

7.3    If sampled, provide a minimum of 3 feet (1.0 m), with all manufacturers’ markings,

12.1  In addition, ensure that markings are every 1 foot (305 mm).  Use lubricants recommended by the seal manufacturer to install preformed compression seals.

B.      Qualification.  Obtain Department approval of each design, shape, width, depth, web, and shell thickness before use.  Submit drawings of the seals showing all dimensions and dimension tolerances and weight per foot (meter) with the request for approval. 

Furnish materials according to the Department’s Qualified Products List (QPL)

705.12  Chemical Admixture for Concrete.  Provide chemical admixtures conforming to ASTM C 494.  Ensure that the minimum relative durability factor is 90. 

Furnish materials according to the Department’s Qualified Products List (QPL)

705.13  Neoprene Sheeting. Provide material conforming to the following:

Test Description

Specification

Requirement

Thickness (inch)

ASTM D751

0.094±0.01

Breaking Strength, Grab (lb)

ASTM D751

 700 × 700

(long. × trans.)

Adhesive Strip, 1” wide × 2” long (lb)

ASTM D751

9

Burst Strength (psi)

ASTM D751

1400

Heat Aging, 70 hr., 212 ºF, 180 º bend without cracking

ASTM D2136

No cracking of coating

Low temperature brittleness, 1 hr., -40 º F, bend around ¼” mandrel

ASTM D2136

No cracking of coating

Furnish material according to the Department’s Approved Products List.

705.15  High Molecular Weight Methacrylate (HMWM) Resin.  Provide low viscosity, non-fuming high molecular weight methacrylate (HMWM) resin conforming to the following:

Viscosity

Less than 25 cps (Brookfield viscometer, Model RVT with UL adaptor or Model LVF, # spindle and UL adaptor C @ 77 °F (25 °C) (ASTM D 2849)

Density

Greater than 8.4 lb/gal Ca 77 °F (25 °C) (ASTM D 2849)

Flash Point

Greater than 200 °F (93 ºC) (PenskyMartens CC)
(ASTM D 93)

Vapor Pressure

Less than 1.0 mm Hg C @ 77 °F (25 °C) (ASTM D 323)

TG (DSC)

Greater than 135 °F (58 °C) (ASTM D3418)

Shelf Life

Must be 1 year minimum at manufacturers recommended environmental considerations

Gel Time

Greater than 40 min, 100 g mass (ASTM D 2471)
(thin film)

Percent Solids

Greater than 90% by weight

Bond Strength

Greater than 1500 psi (10.5 MPa) (ASTM C 882)

Furnish materials according to the Department’s Qualified Products List (QPL)

705.20  Non Shrink, Non Metallic Materials.  Provide anchoring materials for installing anchor bolts, dowels and similar material in concrete which are non-shrink, 100% solids, two part (resin and hardener), fast setting, and moisture insensitive.

A.      Provide certified test data according to 101.03 showing compliance with the following requirements.  Include manufacturer’s installation and application requirements.

Test Description

Specification

Requirements

Notes

Bond Strength (dry)

ASTM C882

2 day, Min. 1800 psi

Average of three samples [1]

Bond Strength after subjected to 300 cycles freeze/thaw testing

ASTM C882 specimens subjected to ASTM C666 Method B testing and the tested conforming to C882

Min. 1600 psi

Average of three samples [1]

Heat Deflection

ASTM D648

7 day, Min. 130 ºF

Linear Coefficient of Shrinkage

ASTM C531

% Max. 0.005

Pullout Strength Test (dry )

See procedure below

24 hours, Min. Load 22,500 lbs

Average of three cylinders in dry condition

Pullout Strength Test (wet )

See procedure below

24 hours, Min. Load 22,500 lbs

Average of three cylinders in wet condition

[1]  A total of six samples will be made under C882.  Three of the C882 samples will be tested under C666 Method B and those samples tested. 

Pullout Strength Test Procedure.  Perform pullout strength tests under dry and wet conditions as follows:

1.      Dry Condition (epoxy steel) 

Cast three concrete test blocks or cylinders, a minimum of 6 inches (150 mm) in width or diameter by 12 inch (300 mm) in depth.  Use concrete with a compressive strength of 4000+/- 500 psi at 28-days   Center a 6 3/4 inch (170 mm) deep hole, drilled the diameter required by the manufacturer’s requirements for installing a No. 6 (20M) rebar, in the block or cylinder by drilling or forming.  Dry the hole surfaces and clean the holes following manufacturer instructions.  Fill the hole with adhesive materials according to manufacturer recommendations.  Insert a No. 6 (20M) deformed reinforcing bar 30 inches (760 mm) long, cleaned and degreased, into the hole.  Hold and center the bar perpendicular to the concrete surface in the grout-filled hole during the curing period. 

2.      Wet Condition (epoxy steel)

Cast three concrete test blocks or cylinders, a minimum of 6 inches (150 mm) in width or diameter by 12 inch (300 mm)  in depth.  Use concrete with a compressive strength of 4000+/- 500 psi at 28-days.  Center a 6-3/4 inch (170 mm) deep hole, drilled the diameter required by the manufacturer’s requirements for installing a No. 6 (20M) rebar, in the blocks or cylinders by drilling or forming.  Wet the hole’s surfaces prior to applying the anchoring material by filling the hole with water and letting stand for five minutes.  Turn the samples over for two minutes to allow the excess water to drain from the hole, Turn all samples over to the upright positions and immediately fill hole with adhesive materials according to manufacturer recommendations.  Insert a No. 6 (20M) deformed reinforcing bar 30 inches (760 mm) long, cleaned and degreased into the hole.  Hold and center the bar perpendicular to the concrete surface in the adhesive-filled hole during the curing period. 

Cure Period.   Cure the specimen at 77 ± 5 °F (25 ± 3 °C) for 24 hours. 

Pullout Strength Test  Apply an axial load to the bar at a rate of 1/2 inch (13 mm) per minute until the bar pulls out of the specimen, or the concrete block or cylinder cracks or spalls.  Record the failure mode and applied load.

B.      Epoxy materials will also conform to ASTM C881, Type IV, Grade 3, Class A, B or C.

Supply the anchoring material in non-reactive containers and with their MSDS.  Label containers with the name of the product, the manufacturer, the shelf life expiration date, the batch number, quantity, and provide application instructions.

Maintain storage areas between 40 and 100 °F (5 and 38 °C).

Only use materials on the Department’s Qualified Products List (QPL).

705.21  Quick Setting Concrete Mortar.  Provide prepackaged mortar material that requires the addition of water only.

Only use materials meeting the following criteria:

A.      Capable of being extended 50 percent by dry mortar weight with aggregate meeting the following requirements:

(a)     Gradation requirements of Table 703.01-1 for No. 8, 89, 9, or a combination thereof.

(b)     AASHTO M 43, Maximum Passing No. 200 (75 mm) sieve - Not to exceed 0.2 percent.

(c)     AASHTO T 84 and T 85, Absorption - Not more than 2 percent.

(d)     AASHTO T 104, Soundness Loss - Not more than 2 percent.

1.      Ensure that the material meets the following requirements:

Test

Type 1

Type 2

Compressive Strength ASTM C 109[2]

psi (MPa)

@ 1 Hour

100 (0.7)

2000 (14)

@ 3 Hour

250 (1.7)

---

@ 24 Hours

2000 (14)

5000 (34)

@ 7 Days

---

7000 (48)

Compressive Strength ASTM C 39[1],[2]

psi (MPa)

@ 1 Hour

100 (0.7)

(2000) (14)

@ 3 Hour

150 (1.0)

---

@ 24 Hours

1000 (10)

3500 (24)

@ 7 Days

---

6000 (41)

Initial Set Time (min) ASTM C 266[2]

5 Minutes

10 Minutes

Bond Strength, ASTM C 882[1]

psi (MPa)

@ 24 Hours

1000 (7)

1000 (7)

@ 7 Days

1500 (11)

1500 (11)

Flexural Strength ASTM C 78[1]

psi (MPa)

@ 4 Hour

---

200 (1.4)

@ 3 Day

650 (4.5)

500 (3.4)

Freeze and Thaw ASTM C 666 (use either Procedure B or A) [1]

Procedure B (350 Cycles)
Durability Factor

80%

80%

Procedure A (300 Cycles)
Durability Factor

79%

79%

[1]  Extend test specimens 50 percent by dry mortar weight with aggregate.

[2]  Test the mortar as received with the addition of water.  Ensure that the amount of water is designated on the packing container by the manufacturer.

B.      Prequalify the material by placing and having the material evaluated conforming to Supplement 1070 for 3 years.  At the end of the 3 year rating the material will meet the following criteria:

1.      Percentage debonding/delamination ≤ 5%

2.      Percentage spalling ≤ 5%

3.      Mid panel average crack width ≤ 1/16 inch (1.6 mm) and total length of mid panel cracks ≤ 20 feet (6.1 m) total length

4.      Edge Cracking/debonding average crack width  ≤ 1/16 inch (1.6 mm) and total length of cracks ≤ 12 feet (3.6 m)

Furnish the Laboratory with a certified copy of test results from a recognized laboratory showing compliance with the requirements of this specification for item A.  Furnish the laboratory written documentation of the method of surface preparation and any primers, adhesives, or activators used in the field test.  Those will become requirements of the material system for subsequent approval or use. A recognized laboratory is one that is regularly inspected by the Cement and Concrete Reference Laboratory of the National Institute of Standards and Technology.

Provide quick setting concrete mortar packaged in strong moisture resistant paper bags or other suitable containers capable of withstanding shipping, normal handling, and storage without breakage.  The package will protect the material from deterioration when stored in a dry condition for a period of 1 year.  Each package or container must display information regarding the minimum nominal yield and instructions for mixing.  Calculate volumetric yield determinations using the manufacturers’ recommended water content.

Furnish materials listed on the Department’s Qualified Products List (QPL).

705.22  Nonshrink Mortar.  Provide nonshrink mortar conforming to ASTM C 1107, with the following modification:

9.1    In addition, ensure that the fluidity of the grout at the maximum water content is at least equal to a flowable mixture as defined in ASTM C 827, Section 8.2.2 and that the minimum flow is 125 @ 5 drops of the flow table in 3 seconds.

Furnish materials according to the Department’s  Approved materials list.

705.23  Concrete Sealers

A.      Provide an Epoxy-Urethane sealer incorporating a two component cross linked urethane and conforming to the following requirements:

1.      Absorption - ASTM C642 (non-air entrained concrete). Proportion and mix concrete according to ASTM C672. Sealed concrete, under total immersion, will not exceed 1.0% after 48 hours or 2.0% after 50 days

2.      Scaling Resistance - ASTM C672 A rating of “No scaling” after 100 cycles on the sealed concrete (non-air entrained concrete) as compared to “Severe Scaling” on untreated concrete.

3.      NCHRP 244, Series 11 - Cube Test

3.1    Weight gain - not to exceed 25% of untreated cube

3.2    Absorbed chloride - not to exceed 25% of untreated cube

4.      NCHRP 244, Series IV - Southern Exposure

4.1    Absorbed chloride - not to exceed 10% of untreated concrete

5.      Volatile Organic Compounds (VOC) maximum, ASTM D 3960, 3.33 lbs./gal(0.399 g/ml), as applied

Record and report the application rate (square footage/gallon) of sealer during the tests.

Provide test data from an approved independent testing facility. The sealer manufacturer funds the testing costs.

Furnish the test data, a one quart (one liter) sample, and the MSDS to the Office of Materials Management (OMM).  OMM will determine material acceptance. 

Furnish materials according to the Department’s Qualified Products List (QPL)

B.      Provide an Non-Epoxy sealer conforming to the following requirements:

1.      Absorption - ASTM C642 (non-air entrained concrete). Proportion and mix concrete according  to ASTM C672. Sealed concrete, under total  immersion, will not exceed 1.0% after 48 hours or 2.0% after 50 days

2.      Scaling Resistance - ASTM C672 A rating of “No  scaling” after 100 cycles on the sealed concrete (non-air entrained concrete) as compared to “Severe Scaling” on untreated concrete.

3.      NCHRP 244, Series 11 - Cube Test

3.1    Weight gain - not to exceed 25% of untreated cube

3.2    Absorbed chloride - not to exceed 25% of untreated cube

4.      NCHRP 244, Series IV - Southern Exposure

4.1    Absorbed chloride - not to exceed 10% of untreated concrete

5.      Volatile Organic Compounds (VOC) maximum, ASTM D 3960, 3.33 lbs./gal(0.399 g/ml), as applied

Record and report the application rate (square footage/gallon) of sealer during the tests.

Provide test data from an approved independent testing facility. The sealer manufacturer funds the testing costs.

Furnish the test data, a one quart (one liter) sample, and the MSDS to the OMM.  OMM will determine material acceptance. 

Furnish materials according to the Department’s Qualified Products List (QPL).

705.24  Soluble Reactive Silicate Provide a soluble reactive silicate (SRS) that is a blend of Na/K/FlxSiOx (sodium, potassium, fluoro or other silicate), surfactants, polymers, and stabilizers capable of thoroughly saturating and sealing concrete. The treatment system will meet the following performance requirements:

A.      Scaling Resistance - Treated concrete will pass ASTM C 672, Scaling Resistance test with a rating of 'No Scaling' after 100 cycles (non-air entrained concrete) as compared to "Severe Scaling' on untreated concrete.

B.      Absorption - The absorption of treated concrete under total immersion will not exceed 1.0 percent after 48 hours or 2.0 percent after 50 days (ASTM C 642, non-air entrained concrete). Concrete should be proportioned and mixed in accordance with ASTM C 672.

C.      Skid resistance - The skid resistance of treated concrete pavement will not be reduced by more than 10 percent as compared to the same untreated pavement. ASTM E 274 using ASTM E 501 ribbed tire at 40 mph (64 kph), five test average.

D.      AASHTO T 259 as modified. The standard T 259 Resistance of Concrete to Chloride Ion Penetration will; be modified as follows:

In addition to section 3.1, intentionally break the specimens so they have a full depth crack through the middle of the slab.

Install section 3.2 dams around the perimeter of the re-assembled, cracked, concrete specimens.  Caulk around the perimeter of the dam to assure that only the crack and the concrete will allow water to pass through or be absorbed. After assembly, measure the crack width at three locations and report the crack width. 

Perform the ponding of 3.4 until the 3% solution comes through the specimen’s crack. Record and report the time required for the solution to appear through the specimen’s crack.  Remove the solution from the specimens and re-dry according to 3.3 (T 259).

After drying apply the SRS to the specimen’s top surface at the manufacturer’s recommended rate of application. Record and report the rate of application.  Air dry the SRS coated dammed sample specimens for 7 days. After 7 days, re perform the ponding with 3% chloride solution until solution comes through the specimen’s crack or 14 days. Record the time the till the ponded solution comes through the crack.

Acceptable SRS materials will have a value of 2 or more when the ponding time before SRS application is divided into the ponding time after SRS application. 

Sections 3.5, 3,6, 4.1,4.2 and 5.1 (of T 259) will not apply.

Have tests performed by an approved independent testing facility acceptable to the Department.

Submit test data and a one quart (one liter) a technical data sheet and the MSDS to the OMM  for approval

Furnish materials according to the Department’s Qualified Products List (QPL).

705.25  Gravity-Fed Resin  Provide non shrink, non metallic resin conforming to ASTM C 881, Type 1, Grade 1, Class B or C and the following:

The maximum viscosity at the lowest allowable temperature will be 250 cps.  The manufacturer will provide test data to verify the viscosity at the lowest temperature for the class for which it is to be approved. 

A minimum average sand retention of 95.0% for three samples tested according to the Sand Penetration Test Method described below.

Show no signs of cracking, debonding or insufficient curing during the sand penetration test

A.      Sand Penetration Test Method.  This test will be conducted with the following equipment and materials:

1.      4 oz (118 ml) wax coated paper cup.  Maximum top diameter 2 5/16" (59 mm); bottom diameter 1 11/16" (43 mm0; height 2 3/8" 960 mm).

2.      20 - 30 grade sand (ASTM C 778)

3.      1 Pint non-absorbent container

4.      8 oz (240 ml) plastic cup

5.      Stirring stick or spatula

6.      Scale accurate to 0.1 g

7.      Disposable gloves

8.      Stop watch

9.      Thermometer

10.    Paint brush

B.      Perform the test as follows

1.      Assure the material and the room is at 73 °F (23 °C)

2.      Determine and record the tare weight of the paper cup (1).

3.      Introduce 100.0 grams of 20 - 30 graded sand (2) into the paper cup.

4.      Record the weight of the cup and the sand.

5.      Consolidate the sand in the cup by lifting the cup approximately ½ “ (13 mm) and dropping 25 to 30 times. Then lightly tap the sides of the cup 25 to 30 times with the fingers.  The sample may also be placed on a vibrating table for 10 to 15 seconds.

6.      Measure enough material into the 8 oz plastic cups (4) to make at least a 200 g sample.

7.      Combine the components into the non-absorbent container (3) and mix according to the manufacturer’s recommendations using a spatula or stirring stick (5).

8.      Pour 40.0g of material over the sand and record the weight of the resin, cup and sand

9.      Allow the resin, sand and cup to set undisturbed for 24 hours at 73 °F (23 °C).  Re-weigh the resin, cup and sand

10.    Remove as much of the paper cup from around the hardened resin and sand matrix as possible.  Lightly brush any loose sand from the matrix.  Weigh the hardened matrix.

11.    Calculate the percent of sand retained, F, as follows:

F = [E / (D - A)] × 100

Where,

                          A =  Tare weight of paper cup (g)

                          B =  Weight of cup and sand (g)

                          C =  Weight of fresh mixture of resin, cup and sand (g)

                         D =  Weight of cured mixture of resin, cup and sand (g)

                          E =  Weight of resin sand matrix as measured in step 10 (g)

12.    Report the average of three specimens mixed separately

13.    Also calculate and report the percent loss due to curing G as follows:

G = [(D - C) / (C - B)] × 100

14.    Examine the sand / resin matrix for signs of insufficient curing and bond, or excessive shrinkage.

Material Approval.  The manufacturer will provide certified test data verifying compliance with the above requirements; technical data sheet; current MSDS for the material; 1 gallon sample; and a letter certifying that the product formulation will not be altered without notification to the Department and OMM. 

OMM will determine materials acceptance and include in the Department’s qualified Products list (QPL).

Furnish materials according to the Department’s Qualified Products List (QPL).

705.26  Epoxy injection Resin. Provide epoxy injection resin  capable of application, positive adherence and strength  development when applied to moist or wet surfaces at temperatures of 33 °F (1 °C) and above.

Use products that contain 100% solids material and no non-reactive diluents, solvents or other fillers.  Provide materials that meet the following requirements:

A.      The injection material will meet the requirements of ASTM C 881 Type IV, Grade 1 and Class B or C and have a maximum viscosity of 600 cps at the lowest ambient material and substrate temperature to be used.

B.      The paste materials will meet the requirements of ASTM C 881 Type I, Grade 3 and Class B or C.

Material Approval.  The manufacturer of the materials is responsible for prequalifying the material and submitting the following to the OMM:

A.      An Independent certified test data indicating that the materials, when mixed according to the  manufacturer’s recommendations, meet the requirements listed above.

B.      Manufacturer’s technical data sheet for the paste and injection materials.

C.      MSDS for paste and injection materials.

D.      1 Gallon Sample or 2 kits of the injection materials

Furnish materials according to the Department’s Qualified Products List (QPL).

706  CONCRETE AND CLAY PIPE

706.01  Non-Reinforced Concrete Pipe.  Provide non-reinforced concrete pipe conforming to ASTM C 14 (ASTM C 14M), with the following modifications:

5.3    Does not apply.

6.2    Provide cementitious materials conforming to 701, except 701.07.

6.3    Provide aggregate conforming to the quality requirements of 703.02.

10.2  Ensure that the manufacture furnishes the number of pipe shown in the “Minimum Requirements for Sampling Materials” table, section 700.

10.3  In addition, perform external load crushing strength tests with hard rubber blocks on wood strips with plaster of paris bedding fillets.

13     Perform inspection at the project site.  Obtain random samples from materials delivered to the project site or at other locations designated by the Laboratory.  Ensure that the manufacturers of these materials are certified by the Office of Materials Management according to Supplement 1074.

15     Ensure that the markings also include “P” to denote non-reinforced pipe.

Testing Equipment.  Ensure that every manufacturer furnishing concrete pipe under these Specifications furnishes all facilities and personnel needed to perform the tests.

706.02  Reinforced Concrete Circular Pipe.  Provide reinforced concrete circular pipe conforming to ASTM C 655 (ASTM C 655M), with the following modifications:

Ensure that the minimum D-Load of the reinforced concrete pipe is as follows:

Size

Minimum

D-Load

12 in

(300 mm)

2000 lb

(100 kg)

15 in

(375 mm)

2000 lb

(100 kg)

18 in

(450 mm)

1250 lb

(62.5 kg)

21 in

(525 mm)

1250 lb

(62.5 kg)

24 in

(600 mm)

1250 lb

(62.5 kg)

27 in or larger

(675 mm or larger)

1000 lb

(50 kg)

1       In addition, ensure that this pipe is circular reinforced concrete pipe with circular or elliptical reinforcement, with and without quadrant and “S” strip reinforcement.

4.1    The acceptability of the pipe design is determined according to Section 10.  All designs in ASTM C 76 (ASTM C 76M), Tables 2 through 5, inclusive, are accepted designs with the 0.01-inch (0.3 mm) crack D-loads as follows:

ASTM C 76 (ASTM C 76M) Table No.

D-Load

0.01-inch

Crack

(0.3 mm)

Crack

2 (Class II)

1000 lb

(50 kg)

3 (Class III)

1350 lb

(65 kg)

4 (Class IV)

2000 lb

(100 kg)

5 (Class V)

3000 lb

(140 kg)

          All designs in Tables 706.02-1 through 706.02-4 are accepted designs with noted 0.01-inch (0.3 mm) crack and ultimate D-loads.  For intermediate D-loads, in Tables 2 through 5 of ASTM C 76 (ASTM C 76M), steel areas for a given wall thickness may be interpolated between Tables 2 and 3, 3 and 4, and 4 and 5 for a size and D-load as accepted designs.  Where different concrete strengths are listed in the tables, use the higher concrete.  In addition, steel areas, interpolated as above between Table 706.02-1 and Table 706.02-2, 36-inch (900 mm) through 108-inch (2700 mm) using the higher concrete strength, and interpolation of the circumferential steel between Table 706.02-3 and Table 706.02-4 using the wall thickness and stirrup designs in Table 706.02-4, are accepted designs.  Pipe manufactured according to an accepted pipe design will be accepted, at the option of the Laboratory, according to the basis of acceptance described in Section 4.1.1 or 4.1.2.

          Provide reinforced concrete pipe with S-stirrups according to Figure 706.02-1 (Figure 706.02-1M) and the following requirements:

1.      Provide steel conforming to 709.08, 709.10, 709.11, or 709.12.  Ensure that the wall thickness, amount of circular reinforcement, S-stirrup system, and concrete strength comply with Tables 706.02-2, 706.02-3, and 706.02-4.  Ensure that the spacing center-to-center of adjacent inner rings of circumferential reinforcement in a cage does not exceed 4 inches (102 mm) for pipe up to and including pipe having a 4 inches (102 mm) wall thickness or exceed wall thicknesses for larger pipe and in no case exceed 6 inches (152 mm).

2.      Ensure that each line of S-stirrups have a continuous “S” shape extending longitudinally from end to end of the pipe.  Ensure that they extend from the inner cage toward the outer surface of the pipe for a distance not less than the minimum amplitude.  Ensure that S-stirrups pass around and are in contact with each inside circumferential member of the inner cage.  Ensure that each line of S-stirrups lie essentially in a plane passing through the longitudinal axis of the pipe.

3.      Where more than one length of stirrup material is used per line, make a lap round one circumferential member of the inner cage.  Ensure that the ends of “S” shaped stirrups at splices include an outer bend.  Do not use more than three lengths of “S” material in a line and ensure that the minimum length of a section of S-stirrups is 30 inches (0.76 m).

Figure 706.02-1  Illustrative Example of S-Stirrup Support System for 0.01-inch Crack D-load 3000, 102-inch diameter Pipe Minimum Area Per Support 0.053 square inch, 11 Lines Spaced @ 5 1/8 inches.  For other classes and sizes, see Tables 706.02-2, 3, and 4.

Figure 706.02-1M  Illustrative Example of S-Stirrup Support System for 0.3 mm Crack D-Load 140.0, 2550 mm diameter Pipe Minimum Area per Support 34 mm², 11 Lines Spaced @ 128 mm.  For other classes and sizes, see Tables 706.02-2M, 3M, and 4M.

                   TABLE 706.02-1                                   Table 706.02-1M

            0.01-inch Crack D-Load 1000                      0.3 mm Crack D-Load 50.0

           Ultimate Strength D-Load 1500                   Ultimate Strength D-Load 75.0

Internal

Dia. of

Pipe

(inch)

Wall

Thick-

ness

(inch)

Circular Reinforcement

in Circular Pipe

Internal

Dia. of

Pipe

(mm)

Wall

Thick-

ness

(mm)

Circular Reinforcement

in Circular Pipe

(in²/ft of pipe)

(cm²/m of pipe)

Inner

Cage

Outer

Cage

Inner

Cage

Outer

Cage

Reinforcing Steel

709.11 or 709.12 Only

Concrete Strength, 4000 psi

Reinforcing Steel

709.11 or 709.12 Only

Concrete Strength, 27.6 MPa

36

  4

0.09

0.07

900

100

1.9

1.5

42

  4 1/2

0.11

0.08

1050

113

2.3

1.7

48

  5

0.13

0.09

1200

125

2.8

1.9

54

  5 1/2

0.16

0.12

1350

138

3.4

2.5

60

  6

0.19

0.14

1500

150

4.0

3.0

66

  6 1/2

0.21

0.16

1650

163

4.4

3.4

72

  7

0.23

0.17

1800

175

4.9

3.6

78

  7 1/2

0.25

0.19

1950

188

5.3

4.0

84

  8

0.29

0.21

2100

200

6.1

4.4

90

  8

0.33

0.24

2250

200

7.0

5.1

96

  8 1/2

0.37

0.26

2400

213

7.8

5.5

Reinforcing Steel

709.11 or 709.12 Only

Concrete Strength, 5000 psi

Reinforcing Steel

709.11 or 709.12 Only

Concrete Strength, 34.5 MPa

102

  8 1/2

0.41

0.28

2550

213

8.7

5.9

108

  9

0.47

0.30

2700

225

9.9

6.4

All Permitted Reinforcing Steel, Concrete Strength, 5000 psi

All Permitted Reinforcing Steel, Concrete Strength, 34.5 MPa

114

  9 1/2

0.56

0.42

2850

238

11.9

8.9

120

10

0.61

0.46

3000

250

12.9

9.7

126

10 1/2

0.65

0.49

3150

263

13.8

10.4

132

11

0.70

0.52

3300

275

14.8

11.0

144

12

0.80

0.60

3600

300

16.9

12.7

4.1.1 In addition, test the pipe designs covered by Tables 706.02-1, 706.02-2, 706.02-3, and 706.02-4 and ASTM C 76 (ASTM C 76M), Tables 2 through 5, and interpolated designs by the three-edge bearing method.  When the test load on the pipe reaches 115 percent of the required 0.01-inch (0.3 mm) crack D-load without developing a 0.01-inch (0.3 mm) or larger crack, accept the test specimen for strength.  If any test specimen fails to pass this test, but attained the 0.01-inch (0.3 mm) crack, continue the test until the ultimate D-load is reached.

4.1.2 In addition, accept pipe 54 inches (1350 mm) and larger in diameter covered by Tables 706.02-1, 706.02-2, 706.02-3, and 706.02-4, and ASTM C 76 (ASTM C 76M), Tables 2 through 5, and interpolated designs according to Section 12 and the following requirements:

1.      When pipe from a plant has been approved by the Laboratory for a specified design and pipe from the same plant has wall and steel area not less than the approved pipe.

2.      When it has been established that two or more plants have complied with the above requirements for the class and size under consideration, and the plant under consideration has established compliance with the above requirements for an adjacent size, and the wall and steel area are not less than the pipe tested at the two plants.

6.1.2.1  Provide cement according to 701.

6.1.2.2  Provide fly ash according to 701.13

6.1.3 Provide aggregates conforming to the quality requirements of 703.02.

6.1.5 Provide steel according to 709.08, 709.10, 709.11, or 709.12.

6.2.4 Ensure that no more than two holes are cast, drilled, or otherwise neatly made in the shell of each piece of pipe for the purpose of handling or laying.  Taper the holes unless drilled, and before backfilling, fill the tapered holes with portland cement mortar, precast concrete plugs secured with portland cement mortar, or a device on the Department’s approved list specifically designed for filling the hole.  Fill drilled holes with portland cement mortar.

7.1 and 7.3  In addition, perform strength tests using methods described in ASTM C 497 (ASTM C 497M).

10.1  In addition, ensure that pipe designs covered by Tables 706.02-1, 706.02-2, 706.02-3, and 706.02-4 and ASTM C 76 (ASTM C 76M) Tables 2 through 5 have the number of samples selected as shown in the “Minimum Requirements for Sampling Materials” table for each size, class, and production lot (pipe of the same size and class made from the same materials and by the same process and approximately the same production date) for test.

TABLE 706.02-2

0.01-inch Crack D-Load 1350                Ultimate Strength D-Load 2000

Internal

Dia. of

Pipe

(inch)

Wall

Thick-

ness

(inch)

Circular Reinforcement

in Circular Pipe

S-Stirrups

(in²/ft of pipe)

Minimum Area per Support Element

Number of Lines [1]

Longitudinal Spacing

Circumferential Spacing on Inner Cage

Minimum Amplitude of Stirrups [2]

Inner Cage

Outer Cage

Reinforcing Steel 709.11 or 709.12 Only

Concrete Strength, 4000 psi

36

  4

0.12

0.09

42

  4 1/2

0.15

0.11

48

  5

0.17

0.12

54

  5 1/2

0.21

0.16

60

  6

0.26

0.20

66

  6 1/2

0.30

0.21

72

  7

0.35

0.24

78

  7 1/2

0.40

0.27

84

  8

0.47

0.30

Reinforcing Steel 709.11 or 709.12 Only

Concrete Strength, 5000 psi

90

  8

0.64

0.35

96

  8 1/2

0.80

0.40

102

  8 1/2

0.96

0.44

108

  9

1.07

0.47

(in²)

(inch)

(inch)

(inch)

All Permitted Reinforcing Steel, Concrete Strength, 5000 psi

114

  9 1/2

0.69

0.52

0.041

5

2

6 1/8

6 5/8

120

10

0.74

0.55

0.041

5

2

6 1/2

7 1/8

126

10 1/2

0.79

0.60

0.041

5

2

6 7/8

7 5/8

132

11

0.85

0.64

0.041

5

2

7 1/4

8 1/8

144

12

0.97

0.73

0.041

5

2

8

9 1/8

[1]  Number of lines in the table indicates the number of longitudinal lines required in each top and bottom portion of the pipe.  The area of each support element in a pipe is two times the cross-sectional area of the S-stirrups wire used.  There shall be an equal number of these lines of S-stirrups on either side of the mid-point of both the top and bottom of the pipe.  See Figure 706.02-1.

[2]  The amplitude is the overall width of the line of stirrups.

TABLE 706.02-2M

0.3 mm Crack D-Load 65.0                    Ultimate Strength D-Load 100.0

Internal

Dia. of

Pipe

(mm)

Wall

Thick-

ness

(mm)

Circular Reinforcement

in Circular Pipe

S-Stirrups

(cm²/m of pipe)

Minimum Area per Support Element

Number of Lines [1]

Longitudinal Spacing

Circumferential Spacing on Inner Cage

Minimum Amplitude of Stirrups [2]

Inner Cage

Outer Cage

Reinforcing Steel 709.11 or 709.12 Only

Concrete Strength, 27.6 MPa

900

100

2.5

1.9

1050

113

3.2

2.3

1200

125

3.6

2.5

1350

138

4.4

3.4

1500

150

5.5

4.2

1650

163

6.4

4.4

1800

175

7.4

5.1

1950

188

8.5

5.7

2100

200

9.9

6.4

Reinforcing Steel 709.11 or 709.12 Only

Concrete Strength, 34.5 MPa

2250

200

13.5

7.4

2400

213

16.9

8.5

2550

213

20.3

9.3

2700

225

22.6

9.9

(mm²)

(mm)

(mm)

(mm)

All Permitted Reinforcing Steel, Concrete Strength, 34.5 MPa

2850

238

14.6

11.0

26

5

50

156

168

3000

250

15.7

11.6

26

5

50

165

181

3150

263

16.7

12.7

26

5

50

175

194

3300

275

18.0

13.5

26

5

50

184

206

3600

300

20.5

15.5

26

5

50

203

232

[1]  Number of lines in the table indicates the number of longitudinal lines required in each top and bottom portion of the pipe.  The area of each support element in a pipe is two times the cross-sectional area of the S-stirrups wire used.  There shall be an equal number of these lines of S-stirrups on either side of the mid-point of both the top and bottom of the pipe.  See Figure 706.02-1M.

[2]  The amplitude is the overall width of the line of stirrups.

TABLE 706.02-3

0.01-inch Crack D-Load 2000                Ultimate Strength D-Load 3000

Internal

Dia. of

Pipe

Wall

Thick-

ness

Circular Reinforcement

in Circular Pipe 

(in²/ft of pipe)

S-Stirrups

Minimum Area per Support Element

Number of Lines [1]

Longitudinal Spacing

Circum. Spacing

on Inner Cage

Min. Amplitude of Stirrups [2]

(inch)

(inch)

Inner Cage

Outer Cage

(in²)

(inch)

(inch)

(inch)

Concrete Strength, 5000 psi

78

  7 1/2

0.69

0.52

0.029

11

2

4 1/8

4 5/8

84

  8

0.74

0.56

0.029

11

2

4 5/8

5 1/8

90

  8

0.85

0.63

0.031

11

2

4 5/8

5 1/8

96

  8 1/2

0.91

0.69

0.034

11

2

5 1/8

5 5/8

102

  8 1/2

1.02

0.77

0.041

12

2

5 1/8

5 5/8

108

  9

1.07

0.80

0.045

11

2

5 5/8

6 1/8

114

  9 1/2

1.02

0.77

0.048

11

2

6 1/8

6 5/8

120

10

1.10

0.82

0.051

11

2

6 1/2

7 1/8

126

10 1/2

1.17

0.88

0.055

11

2

6 7/8

7 5/8

132

11

1.25

0.94

0.058

11

2

7 1/4

8 1/8

144

12

1.42

1.07

0.065

11

2

8

9 1/8

[1] and [2] Refer to footnotes in Table 706.02-2

TABLE 706.02-3M

0.3 mm Crack D-Load 100     Ultimate Strength D-Load 150

Internal

Dia. of

Pipe

Wall

Thick-

ness

Circular Reinforcement

in Circular Pipe 

(cm²/m of pipe)

S-Stirrups

Minimum Area per Support Element

Number of Lines [1]

Longitudinal Spacing

Circum. Spacing

on Inner Cage

Min. Amplitude of Stirrups [2]

(mm)

(mm)

Inner Cage

Outer Cage

(mm²)

(mm)

(mm)

(mm)

Concrete Strength, 34.5 MPa

1950

188

14.6

11.0

19

11

50

105

117

2100

200

15.7

11.9

19

11

50

117

130

2250

200

18.0

13.3

20

11

50

117

130

2400

213

19.3

14.6

22

11

50

130

143

2550

213

21.6

16.3

26

12

50

130

143

2700

225

22.6

16.9

29

11

50

143

156

2850

238

21.6

16.3

31

11

50

156

168

3000

250

22.3

17.4

33

11

50

165

181

3150

263

24.8

18.6

35

11

50

175

194

3300

275

26.5

19.9

37

11

50

184

206

3600

300

30.1

22.6

42

11

50

203

232

[1] and [2] Refer to footnotes in Table 706.02-2M

TABLE 706.02-4

0.01-inch Crack D-Load 3000                Ultimate Strength D-Load 3750

Internal

Dia. of

Pipe

(inch)

Wall

Thick-

ness

(inch)

Circular Reinforcement

in Circular Pipe

S-Stirrups

Minimum Area per Support Element

Number of Lines [1]

Longitudinal Spacing

Circum. Spacing

on Inner Cage

Minimum Amplitude

of Stirrups [2]

(in²/ft of pipe)

Inner Cage

Outer Cage

Concrete Strength, 6000 psi

6

  1 3/4

0.07

--

8

  1 3/4

0.07

--

10

  1 3/4

0.07

--

54

  5 1/2

0.86

0.62

60

  6

0.95

0.68

(in²)

(inch)

(inch)

(inch)

Concrete Strength, 5000 psi

54

  5 1/2

0.64

0.48

0.029

15

2

2 1/8

2 5/8

60

  6

0.70

0.53

0.029

14

2

2 5/8

3 1/8

66

  6 1/2

0.79

0.59

0.029

13

2

3 1/8

3 5/8

72

  7

0.87

0.66

0.029

12

2

3 5/8

4 1/8

78

  7 1/2

0.92

0.69

0.031

11

2

4 1/8

4 5/8

84

  8

0.99

0.74

0.034

11

2

4 5/8

5 1/8

90

  8

1.13

0.85

0.041

11

2

4 5/8

5 1/8

96

  8 1/2

1.20

0.90

0.045

11

2

5 1/8

5 5/8

102

  8 1/2

1.34

1.00

0.053

11

2

5 1/8

5 5/8

108

  9

1.51

1.13

0.063

11

2

5 5/8

6 1/8

114

  9 1/2

1.51

1.13

0.064

11

2

6 1/8

6 5/8

120

10

1.62

1.21

0.068

11

2

6 1/2

7 1/8

126

10 1/2

1.73

1.30

0.072

11

2

6 7/8

7 5/8

132

11

1.84

1.38

0.076

11

2

7 1/4

8 1/8

144

12

2.09

1.57

0.085

11

2

8

9 1/8

[1] and [2] Refer to footnotes in Table 706.02-2

TABLE 706.02-4M

0.3 mm Crack D-Load 140.0                  Ultimate Strength D-Load 175.0

Internal

Dia. of

Pipe

(mm)

Wall

Thick-

ness

(mm)

Circular Reinforcement

in Circular Pipe

S-Stirrups

Minimum Area per Support Element

Number of Lines [1]

Longitudinal Spacing

Circum. Spacing

on Inner Cage

Minimum Amplitude

of Stirrups [2]

(cm²/m of pipe)

Inner Cage

Outer Cage

Concrete Strength, 41.4 MPa

150

44

1.5

--

200

44

1.5

--

250

44

1.5

--

1350

138

18.2

13.1

1500

150

20.1

14.4

(mm²)

(mm)

(mm)

(mm)

Concrete Strength, 34.5 MPa

1350

138

13.5

10.2

19

15

50

54

67

1500

150

14.8

11.2

19

14

50

37

79

1650

163

16.7

12.5

19

13

50

79

92

1800

175

18.4

14.0

19

12

50

92

105

1950

188

19.5

14.6

20

11

50

105

117

2100

200

21.0

15.7

22

11

50

117

130

2250

200

23.9

18.0

26

11

50

117

130

2400

213

25.4

19.1

29

11

50

130

143

2550

213

28.4

21.2

34

11

50

130

143

2700

225

32.0

23.9

41

11

50

143

156

2850

238

32.0

23.9

41

11

50

156

168

3000

250

34.3

25.6

44

11

50

165

181

3150

263

36.6

27.5

46

11

50

175

194

3200

275

38.9

29.2

49

11

50

184

206

3600

300

44.2

33.2

55

11

50

203

232

[1] and [2] Refer to footnotes in Table 706.02-2M

11.1  Perform compression tests on cores according to ASTM C 497 (ASTM C 497M).

11.3  Does not apply.

12     Perform inspection at the project site.  Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory.

16     Furnish materials from suppliers certified according to Supplement 1074.

17     In addition, after the capital letter “D,” designate the D-load, the design wall thickness in millimeters (inches expressed as a decimal).  Ensure that pipe with S-stirrups have the symbol “S”.  Ensure that pipe requiring axis orientation without lift holes (i.e., stirrup pipe, quadrant reinforced pipe, elliptically reinforced pipe) has the centerline of the crown of the pipe marked inside and outside with the symbol “TB”.  Mark pipe with quadrant steel with the symbol “Q”.  Mark pipe with elliptical reinforcement with the symbol “E”.  Mark pipe with deformed wire reinforcement required in the design with the symbol “DF”.

706.03  Reinforced Concrete Pipe, Epoxy Coated.  Provide Type A reinforced concrete epoxy coated pipe conforming to 706.02 and Type B conforming to 706.04, with the following modification:

In the plant, prepare the interior barrel and joint surface areas of the concrete pipe to remove all forms of oil, laitance, and other deleterious materials and then line them with a high-build, polyamide-cured, two-component coal tar epoxy coating, Military Specification DOD-P-23236A (SH).  Spray the lining compound to obtain a continuous and relatively uniform and smooth lining with a minimum dry film thickness of 0.03 inch (760 mm).  Ensure that all coated pipe are free of surface irregularities such as air bubbles, delamination, lumping, sagging, blistering, pinholing, or porosity, in the coating film.

706.04  Reinforced Concrete Elliptical Culvert, Storm Drain, and Sewer Pipe.  Provide reinforced concrete elliptical culvert, storm drain, and sewer pipe conforming to ASTM C 507 (ASTM C 507M), with the following modifications:

4.1    Delete Class HE-A.  Table 706.04-1 includes additional design requirements.

5.1    All materials, processes of manufacture, and finished pipe are subject to inspection and approval by the Department.  When directed by the Laboratory, the manufacturer will cut holes in sections of the finished pipe for inspection.

6.2.1 Provide cement according to 701, except 701.07.

6.2.2 Provide fly ash according to 701.

6.3    Provide aggregates conforming to the quality requirements of 703.02.

6.5    Provide steel according 709.08, 709.10, 709.11, or 709.12.

7.2    In addition, manufacture horizontal elliptical pipe HE-II and HE-III using the design requirements of Table 706.04-1.

8.1    In addition, ensure that pipe made in accordance with 706.04-1 has three lines of reinforcement of elliptical shape.  Place the outer and inner lines of reinforcement so that the nominal protective covering of the concrete over the reinforcement in the barrel of the pipe is 1 inch (25 mm) subject to the variations permitted in Section 12.5.  Ensure that the third or middle line is in contact with and fastened securely to the inner line at the vertical axis of the pipe both top and bottom and to the outer line at the horizontal axis on both sides.  Ensure that the length of the middle line is the average of the length of the inner and outer line.  Ensure that the middle line is of an elliptical shape and runs smoothly between the specified points of contact with the inner and outer lines.

10     Ensure that no more than two holes are cast, drilled, or otherwise neatly made in the shell of each piece of pipe for the purpose of handling or laying.  Taper the holes unless drilled, and before backfilling, fill the tapered holes with portland cement mortar, precast concrete plugs secured with portland cement mortar, or a device on the Department’s approved list specifically designed for filling the hole.  Fill  drilled holes with portland cement mortar.

11.2  Select the specified number of pipe, as noted in the “Minimum Requirements for Sampling Materials” table, for the purpose of test at the plant and at random from the lot to be shipped or at the project site from the pipe delivered and that are pipe that would not otherwise be rejected under these Specifications.  Test pipe according to Section 5.1.1 except the Laboratory may accept pipe 54 inches (1350 mm) and larger in diameter according to Section 5.1.2 and the following requirements:

1.      When pipe from a plant has been approved by the Laboratory for a specified design, pipe from the same plant with wall and steel area not less than the approved pipe may be approved by means of tests on cores verifying absorption, strength, wall, and steel area.

2.      When it has been established that two or more plants have complied with the above requirements for the class and size under consideration and the plant under consideration has established compliance with the above requirements for an adjacent size, and the wall and steel area are not less than the pipe tested at the two plants.

11.3.1  Ensure that the load to produce a 0.01-inch (0.3 mm) crack and the ultimate load as determined by ASTM C 497 (ASTM C 497M) three-edge bearing method, is not less than shown in Tables 1, 2, and 706.04-1.  The ultimate strength test may be waived when the test load on the pipe reaches 115 percent of the required 0.01-inch (0.3 mm) crack D-load without developing a 0.01-inch (0.3 mm) or larger crack.

11.4  Perform compression tests for satisfying the minimum specified concrete strength requirement from cores drilled from the wall of the pipe.  Ensure that the diameter of the core is such that the capped height to diameter or L/D ratio lies between one and two.  Ensure that the cores are secured, prepared for testing, and tested by methods prescribed in the appropriate sections of ASTM C 497 (ASTM C 497M).  Ensure that the compressive strength of each core tested is equal to or greater than the design strength of the concrete.  If a core does not meet the required strength, test another core from the same pipe.  If this core does not meet the required strength, the Department may reject the pipe.  Make additional tests on other pipe to determine the acceptability of the lot.  When the cores cut from a section of pipe successfully meet the strength test requirement, ensure that the core holes are plugged and sealed by the manufacturer in a manner such that the pipe section will meet all of the test requirements of these Specifications.

11.9  Does not apply.

11.10  Does not apply.

14     Perform inspection at the project site.  Obtain random samples from material delivered to the project site or at other locations designated by the laboratory. 

Ensure manufacturers of these materials are certified according to Supplement 1074.

16     In addition, place the plant location on each pipe, and for pipe manufactured to design requirements of 706.04-1 place the letter “A” after the pipe class.  Ensure that the markings are legible and indented in the pipe section or painted on with waterproof paint.

Table 706.04-1  Design Requirements for
Horizontal Elliptical Pipe

Equiv.

Round

Size
(inch)

Rise (inch)

´

Span (inch)

Minimum Wall Thickness
(inch)

Minimum Reinforcement

(in²/ft)

HE-II

HE-III

D-Loads

0.01 = 1000

0.01 = 1350

Utl. = 1500

Utl. = 2000

78

63 × 98

8

3 lines totaling 0.87

3 lines totaling 1.23

84

68 × 106

8 1/2

3 lines totaling 0.97

3 lines totaling 1.33

90

72 × 113

9

3 lines totaling 1.03

3 lines totaling 1.43

96

77 × 121

9 1/2

3 lines totaling 1.13

3 lines totaling 1.54

102

82 × 128

9 3/4

3 lines totaling 1.23

3 lines totaling 1.70

108

87 × 136

10

3 lines totaling 1.43

3 lines totaling 1.85

The test load in lb/ft equals D-load × nominal inside span in feet. Concrete strength=5000 psi.

Table 706.04-1M  Design Requirements for
Horizontal Elliptical Pipe

Equiv.

Round

Size
(mm)

Rise (mm)

´

Span (mm)

Minimum Wall Thickness
(mm)

Minimum Reinforcement

(cm²/m)

HE-II

HE-III

D-Loads

0.03 = 50.0

0.03 = 65.0

Utl. = 75.0

Utl. = 100.0

1950

1585 ´ 2495

200

3 lines totaling 18.4

3 lines totaling 26.0

2100

1705 ´ 2690

213

3 lines totaling 20.5

3 lines totaling 28.2

2250

1830 ´ 2880

225

3 lines totaling 21.8

3 lines totaling 30.3

2400

1950 ´ 3070

238

3 lines totaling 23.9

3 lines totaling 32.6

2550

2075 ´ 3265

244

3 lines totaling 26.0

3 lines totaling 36.0

2700

2195 ´ 3455

250

3 lines totaling 30.3

3 lines totaling 39.2

The test load in kN/m equals D-load × nominal inside span in mm. Concrete strength=34.5 MPa.

706.05  Precast Reinforced Concrete Box Sections.  Provide precast reinforced concrete box section conforming to ASTM C 1577, with the following modifications:

Ensure that manufacturers of precast concrete members are certified by the Laboratory according to Supplement 1073.

6.2.1 Provide cement according to 701, except 701.07.

6.2.2 Provide fly ash according to 701.

6.3    Provide aggregates conforming to the quality requirements of 703.02.

6.5    Provide reinforcement according to 709.10 or 709.12.  Provide longitudinal distribution reinforcement according to 709.01, 709.10 or 709.12.

7.1    For the following box sizes, span by rise, refer to ASTM C1577: 8x4, 5, 6, 7; 10x5, 6, 7, 8, 9; and 12x4, 6, 8, 10 feet.  For the following box sizes, span by rise, refer to SS940: 14x4, 5, 6, 7, 8, 9, 10; 16x4, 5, 6, 7, 8, 9, 10; 18x4, 5, 6, 7, 8, 9, 10; and 20x4, 5, 6, 7, 8, 9, 10 feet.

9.1    Provide hardened concrete that contains a minimum of 4 percent entrained air for wet-cast sections with spans less than 14 feet (4200 mm) and for all sections with spans 14 feet (4200 mm) and greater.

9.4    Lift holes are not permitted.  Use handling devices that do not require a hole through the box.

10.1  Verify concrete strength using cylinders.  Do not ship items before the design strength of the concrete is reached.

11.5  A minimum cover of 1/2 inch (13 mm) over both circumferential and longitudinal reinforcement is required at the mating surfaces of joints.

15     In addition, mark the identification of the plant on each box section.  For box sections 14 feet (4200 mm) or greater, mark the reinforcing steel areas for the section on each box section.  Place the manufacturers’ name and required product information on the inside of the box section within the top one-half of the culvert.

706.051         Precast Reinforced Concrete Three-Sided Flat Topped Culverts.  Provide precast concrete three-sided flat topped culverts according to ASTM C 1504, with the following modifications:

Provide flat deck culvert structures with a minimum clear span (measured normal to the structure at the bottom of the haunch) of 14 feet (4200 mm) and a minimum opening rise (measured from bottom of leg to bottom of deck at the centerline of the structure) of 4 feet (1200 mm); and a maximum clear span of 34 feet (10,200 mm) and maximum opening rising of 10 feet (3000 mm).  Ensure that the minimum wall and deck thicknesses is 10 inches (250 mm) and 12 inches (300 mm) respectively, measured under the haunch normal to the structure and at the centerline of the span measured perpendicular to the structure.

Ensure manufacturers of precast concrete members are certified according to Supplement 1073.

5. Ensure the manufacturer submits design calculations, a structural load rating and shop drawings according to 611.04. Ensure the shop drawings include the following:

1.      Load rate the structure according to the requirements of section 900 of the Department’s Bridge Design Manual.

2.      All material specifications.

3.      All plan view.

4.      All elevation view.

5.      All headwall and wingwall attachment requirements.

6.      All dimensions.

7.      All maintenance of traffic phases.

8.      All section sizes.

9.      All design handling strength.

          The manufacturer may modify an approved shop drawing and resubmit for approval to the Department.

          Ensure that the shop drawings also include the following special information as required:

1.      For top mounted guardrail, show the guardrail plate and bolt locations in the plan view.  Ensure that holes are a minimum of 6 inches (150 mm) from a joint.

2.      For side mounted guardrail, show additional reinforcing details according to the plan details.

6.2.1 Provide cement according to 701, except 701.07.

6.2.2 Provide fly ash according to 70113.

6.3    Provide aggregates conforming to the quality requirements of 703.02.

6.4    Use chemical admixtures according to 705.12.  Use a corrosion inhibitor unless epoxy coated reinforcing steel is used.  An approved list of corrosion inhibiting admixtures is on file at the Laboratory.  Manufacturers should recognize that the corrosion inhibitors and admixtures may have an effect on strength, entrained air content, workability, etc. of their concrete mixes.  The manufacturers choice of one of these corrosion inhibitors does not alleviate meeting all design requirements of this structure.

6.4.1 Provide air-entraining admixture according to 705.10.

6.5    Provide epoxy coated reinforcement according to 709.00, Grade 60 (Grade 420), or 709.14.  In lieu of epoxy coated reinforcement, an approved corrosion inhibiting admixture may be added to the concrete at the approved dosage; and provide reinforcement according to 709.01, 709.03 or 709.05; Grade 60 (Grade 420) or 709.08, 709.10, 709.11 or 709.12. Provide epoxy or galvanized coated connections when connecting a precast structural unit into a cast-in-place structural component or between segments of adjacent precast structural units either manufactured as separate units or across construction joints when manufactured as one unit. Provide epoxy coated reinforcement according to 709.00 or 709.14, when these connections are designed using reinforcing steel. Provide galvanized coatings according to 711.02, when these connections are designed using connection plates, hardware or concrete inserts.

7.1    Design according to AASHTO LRFD Bridge Design Specifications, Section 12.14. Include a future wearing surface loading of 60 psf.

7.2    Ensure that the concrete cover dimension over reinforcement is a minimum of 2 inches (50 mm) in the slab and in the exterior of the leg.  Ensure that the interior of the leg reinforcement cover tapers from 1 inch (25 mm) at the bottom of the leg to 2 inches (50 mm) at the bottom of the haunch.

          Ensure that the ends of longitudinal reinforcement have a minimum cover of 1/2 inch (13 mm), and spacers used to position the reinforcement are plastic or epoxy coated steel regardless of whether a corrosion inhibiting admixture is used.

8       Ensure that the top slab is produced with a keyway joint.  The keyway provides a void volume equivalent to that of 12 inches (300 mm) prestressed beam as per Standard Construction Drawing PSBD-2-07.  Ensure that the joint in the leg sections is designed to produce a shear key or inter-locking joint.  Ensure that non-adjoining outside legs are flat.  Sandblast the joint surfaces to the satisfaction of the Department, or a 2000 pounds per square inch (14 MPa) water blast no more than 14 days prior to shipping.  Ensure that the culvert is designed such that the sections when laid together will make a continuous line with a smooth interior free of appreciable irregularities, all compatible with the permissible variations of Section 11.

9       Application of membrane waterproofing at any location other than the final location shown on the plans is prohibited.

9.1    Ensure that the aggregate, cement, and water are manufactured in conformance with 499.06, 499.07, and 499.09.

          Ensure that the temperature requirements of 511.08 and 511.15 are met.

          Ensure that the proportion of portland cement is not less than 564 pounds per cubic yard (335 kg/m³) of concrete.

          If used, add the corrosion inhibitor as an aqueous solution.  Consider the water in the solution as mixing water for the purpose of determining the w/c ratio of concrete.

9.2    Cure the three-sided sections in the forms for the length of time required to obtain the specified minimum design handling strength as defined in the shop drawings.  Test a cylinder to check each section’s design handling strength.  Repeat this test as often as needed.  Only one cylinder passing will ensure that the design handling strength has been met.  If the shop drawing shows no design handling strengths, then the minimum handling strength is assumed to be 100 percent of the design strength.  Ensure that the curing then continues either in or out of the forms until the specified minimum design strength is met.

9.2.1 Steam curing is an accelerated cure by low pressure steam or radiant heat within a suitable insulated enclosure to contain the live steam or heat.  The initial application of the steam or heat is from two to four hours after the final placement of concrete to allow the initial set to take place.  If retarders are used, increase the waiting period to 4 to 6 hours.  As an alternative, determine the actual time of initial set according to ASTM C 403.  Do not start curing until the actual time to initial set has elapsed.

          During the waiting period, ensure that the temperature within the curing enclosure is not less than 50 °F (10 °C).

          During the initial application of live steam or radiant heat, ensure that the ambient temperature within the curing enclosure increases at an average rate not exceeding 40 °F (22 °C) per hour until the curing temperature is reached.

          Ensure that the maximum curing temperature does not exceed 150 °F (65 °C).  Hold the design temperature until the concrete has reached the desired design strength.  Do not direct the application of live steam on the concrete forms so as to cause localized high temperatures.

9.2.2 Provide water curing according to 511.15 and 511.17, Method A.

9.2.3 Provide membrane curing according to 511.16, Method B.

9.3    Ensure that all forms are in place until the design handling strength is met.

9.4    Holes for handling or setting are not permitted.  Do not move members before the design handling strength of the concrete is reached, or shipped before the design strength of the concrete is reached.  Ensure that the manufacturers have equipment necessary to handle and transport the pieces without damaging them.

10     Ensure that the hardened concrete contains a minimum of 4 percent entrained air.

10.2.1 Keep the cylinders and matching culvert section together to guarantee the cylinders are matched with the corresponding culvert section; or, upon agreement by the Department, keep the cylinders at a location that will provide the same environment as the culvert sections.

10.2.2  For each section of the culvert, produce and mark at least four cylinders so that they are identifiable with the matching culvert section.

10.2.3  Conform to Supplement 1073 for acceptance.

10.2.3.1  Ensure that cylinder strengths conform to Supplement 1073.

10.3.3.2  Deleted.

10.4  Plug the core holes by using a concrete that is the same as that used in the section and cured in according to Section 9.2, or by a non-shrink grout that exceeds the concrete design strength.

11     The design in the plan reflects the external top slab elevation of the structure.  If the structure supplied has a deck thicker than the plan design, eliminate the difference between the design top slab elevation and the supplied top slab elevation by a reducing the leg length.  The Department may approve alternate methods to eliminate the difference between the design top slab elevation and the supplied top slab elevation.  The Department will not approve a change in the top slab elevation from that shown on the plans.

          The clear span shown is the minimum for the structure.  The manufacturer may provide a clear span greater than that shown.  Base the exact footer locations for both the elevation and offset on the manufacturer’s shop drawings.  Ensure that these footer locations are such that the centerline of the leg at the bottom of the haunch matches the centerline of the footer.

          All changes to the project resulting from the manufacturer’s dimensional changes in the structure are at no charge to the Department.

          Ensure that the sections are free of fractures spalls and chips.  Ensure that all surfaces have a smooth and regular finish being defined as a 1/4-inch variation within 4 feet (6 mm variation within 1.2 m).

11.1  Ensure that the slab and walls are perpendicular with a diagonal difference of not more than 0.5 percent.

          Ensure that the length of each section is within 1/2 inch (13 mm) of the design length.  Consider the length is the average of the length measured at each side and at the middle of the three-sided section.

11.4  Ensure that the maximum variation in the position of the reinforcement is 3/8 inch (9 mm), except that the cover over the reinforcement for the external surface of the top slab is not less than 2 inches (50 mm).  The above tolerances or cover requirements do not apply to mating surfaces at the joint.

11.5  Resubmit any change in reinforcement from the shop drawings for approval.

12     Make repairs according to the Department’s requirements.  The Department will not make additional payments for culvert repairs.  Repairs are acceptable if, in the opinion of the Department, the repairs are sound, properly finished, and cured.

13     Perform inspection at the project site. 

Furnish precast concrete components from suppliers certified according to Supplement 1073.

14     Form seams and slight surface irregularities that are expected from a wood panel forming system will not be cause for rejection.  In addition, hairline cracks less than 0.01 inch (0.25 mm) are not cause for rejection.

15.1  Ensure that the location of the product marking is on the interior of the three-sided section 1 foot (300 mm) below the leg haunch.

          Add the product marking upon removal of the forms.

          The manufacturer may be required to repeat the product markings before the project is final.

706.052         Precast Reinforced Concrete Arch Sections.  Provide precast reinforced concrete arch sections according to ASTM C 1504, with the following modifications:

This item shall consist of manufacturing precast reinforced concrete arch sections for culverts.

Ensure that manufacturers of precast concrete members are certified according to Supplement 1073.

5       Ensure the manufacturer submits design calculations, a structural load rating and shop drawings according to 611.04. Ensure the shop drawings include the following:

1.      Load rate the structure according to the requirements of section 900 of the Department’s Bridge Design Manual.

2.      All material specifications.

3.      All plan view.

4.      All elevation view.

5.      All headwall and wingwall attachment requirements.

6.      All dimensions.

7.      All maintenance of traffic phases.

8.      All section sizes.

9.      All design handling strength.

          The manufacturer may modify an approved shop drawing and resubmit for approval to the Department.

          Ensure that the shop drawings also include the following special information as required:

1.      For top mounted guardrail, the guardrail plate and bolt locations are shown in the plan view.  Holes shall be a minimum of 6 inches (150 mm) from a joint.

2.      The corrosion inhibitor being used, if any, and dosage rate.  Dosage rate will be approved by the Laboratory.

6.2.1 Provide cement according to 701, except 701.07.

6.2.2 Provide fly ash according to 701.13.

6.3    Provide aggregates conforming to the quality requirements of 703.02.

6.4    Use chemical admixtures according to 705.12.  Use a corrosion inhibitor unless epoxy coated reinforcing steel is used.  An approved list of corrosion inhibiting admixtures is on file at the Laboratory.  Manufacturers should recognize that the corrosion inhibitors and admixtures may have an effect on strength, entrained air content, workability, etc. of their concrete mixes.  The manufacturers choice of one of these corrosion inhibitors does not alleviate meeting all design requirements of this structure.

6.4.1 Provide air-entraining admixture according to 705.10.

6.5    Provide epoxy coated reinforcement according to 709.00, Grade 60 (Grade 420), or 709.14.  In lieu of epoxy coated reinforcement, an approved corrosion inhibiting admixture may be added to the concrete at the approved dosage; and provide reinforcement according to 709.01, 709.03 or 709.05; Grade 60 (Grade 420) or 709.08, 709.10, 709.11 or 709.12. Provide epoxy or galvanized coated connections when connecting a precast structural unit into a cast-in-place structural component or between segments of adjacent precast structural units either manufactured as separate units or across construction joints when manufactured as one unit. Provide epoxy coated reinforcement according to 709.00 or 709.14, when these connections are designed using reinforcing steel. Provide galvanized coatings according to 711.02, when these connections are designed using connection plates, hardware or concrete inserts.

7.1    Design according to AASHTO LRFD Bridge Design Specifications, Section 12.14. Include a future wearing surface loading of 60 psf.

7.2    Ensure that the concrete cover dimension over the outside circumferential reinforcement is a minimum of 2 inches (50 mm).  Ensure that the concrete cover dimension over the inside circumferential reinforcement is a minimum of 1 1/2 inches (38 mm).  The clear distance of the end circumferential wires shall not be less than 1 inch (25 mm) nor more than 2 inches (50 mm) from the ends of the sections.  Reinforcement shall be assembled utilizing single or multiple layers of welded wire fabric (three-layer maximum), or utilizing a single layer of deformed billet-steel bars.  The welded wire fabric shall be composed of circumferential and longitudinal wires and shall contain sufficient longitudinal wires extending through the section to maintain the shape and position of reinforcement.  Longitudinal distribution reinforcement may be welded wire fabric or deformed billet-steel bars.  The ends of the longitudinal distribution reinforcement shall be not more than 3 inches (75 mm) from the ends of the sections.

          The outside and inside circumferential reinforcing steel for the corners of the culvert shall be bent to such an angle that it is approximately equal to the configuration of the culverts outside corner.

7.3    Tension splices in the circumferential reinforcement shall not be made.  For splices other than tension splices, the overlap shall be a minimum of 12 inches (300 mm) for welded wire fabric or deformed billet steel bars.  The spacing center-to-center of the circumferential wires in a wire fabric sheet shall be not less than 2 inches (50 mm) or more than 4 inches (100 mm).  For the wire fabric, the spacing center-to-center of the longitudinal wire shall not be more than 8 inches (200 mm).  The spacing center-to-center of the longitudinal distribution steel for either line of reinforcing in the top slab shall be not more than 16 inches (410 mm).

8.1    Ensure the sections are produced with butt ends.  The ends of the sections shall be such that when the sections are laid together they will make a continuous line of sections with a smooth interior free of appreciable irregularities, all compatible with the permissible variations in these Specifications.  Provide a chamfer on the outside surface at the sections joint to form a void for a 7/8 ´ 1 3/8-inch (24 ´ 34 mm) flexible plastic gasket 706.14.

9       Application of membrane waterproofing on the arch section at any location other than the final location shown on the plans is prohibited.

9.1 Ensure that the aggregate, cement, and water are manufactured according to 499.06, 499.07, and 499.09.

          Ensure that the temperature requirements of 511.08 and 511.15 are met.

          Ensure that the proportion of portland cement is not less than 564 pounds per cubic yard (335 kg/m³) of concrete.

          If used, add the corrosion inhibitor as an aqueous solution.  Consider the water in the solution as mixing water for the purpose of determining the water-cement ratio of concrete.

9.2    Cure the arch sections in the forms for the length of time required to obtain the specified minimum design handling strength as defined in the shop drawings.  Test a cylinder to check each section’s design handling strength.  Repeat this test as often as needed.  Only one cylinder passing will ensure that the design handling strength has been met.  If the shop drawing shows no design handling strengths, then the minimum handling strength is assumed to be 100 percent of the design strength.  Ensure that the curing then continues either in or out of the forms until the specified minimum design strength is met.

9.2.1 Steam curing is an accelerated cure by low pressure steam or radiant heat within a suitable insulated enclosure to contain the live steam or heat.  The initial application of the steam or heat is from 2 to 4 hours after the final placement of concrete to allow the initial set to take place.  If retarders are used, increase the waiting period to 4 to 6 hours.  As an alternative, determine the actual time of initial set according to ASTM C 403.  Do not start curing until the actual time to initial set has elapsed.

          During the waiting period, ensure that the temperature within the curing enclosure is not less than 50 °F (10 °C).

          During the initial application of live steam or radiant heat, ensure that the ambient temperature within the curing enclosure increases at an average rate not exceeding 40 °F (22 °C) per hour until the curing temperature is reached.

          Ensure that the maximum curing temperature does not exceed 150 °F (65 °C).  Hold the design temperature until the concrete has reached the desired design strength.  Do not direct the application of live steam on the concrete forms so as to cause localized high temperatures.

9.2.2 Provide water curing according to 511.15 and 511.17, Method A.

9.2.3 Deleted.

9.3    Ensure that all forms are in place until the design handling strength is met.

          Holes for handling or setting are not permitted.  Do not move members before the design handling strength of the concrete is reached, or shipped before the design strength of the concrete is reached.  Ensure that the manufacturers have equipment necessary to handle and transport the pieces without damaging them.

10     Ensure that the hardened concrete contains a minimum of 4 percent entrained air.

10.2.1  Keep the cylinders and matching culvert section together to guarantee the cylinders are matched with the corresponding culvert section; or, upon agreement by the Department, keep the cylinders at a location that will provide the same environment as the culvert sections.

10.2.2  For each section of the culvert, produce and mark at least four cylinders so that they are identifiable with the matching culvert section.

10.2.3  Conform to Supplement 1073 for acceptance.

10.2.3.1  Ensure that cylinder strengths conform to Supplement 1073.

10.3.3.2  Deleted

10.4  Plug the core holes by using a concrete that is the same as that used in the section and cured according to Section 9.2, or by a non-shrink grout that exceeds the concrete design strength.

11.0  The under-run in length of a section shall not be more than 1/2 inch (13 mm).

          All changes to the project resulting from the manufacturer’s dimensional changes in the structure are at no charge to the Department.

          Ensure that the sections are free of fractures spalls and chips.  Ensure that all surfaces have a smooth and regular finish being defined as a 1/4 inch variation within 4 feet (6 mm variation within 1.2 m).

11.1  The internal dimensions shall vary not more than 1 percent from the design dimensions or more than 38 mm (1 1/2 inches), whichever is less.  The haunch dimensions shall vary not more than 19 mm (3/4 inch) from the design dimension.

11.4  Ensure that the maximum variation in the position of the reinforcement is 3/8 inch (9 mm), except that the cover over the reinforcement for the external surface of the top slab is not less than 2 inches (50 mm).  The above tolerances or cover requirements do not apply to mating surfaces at the joint.

11.5  Resubmit any change in reinforcement from the shop drawings for approval.

12.0  Make repairs according to the Department’s requirements.  The Department will not make additional payments for culvert repairs.  Repairs are acceptable if, in the opinion of the Department, the repairs are sound, properly finished, and cured.

13.0  Perform inspection at the project site. 

Furnish precast concrete components from suppliers certified according  to Supplement 1073.

14.0  Form seams and slight surface irregularities that are expected from a wood panel forming system will not be cause for rejection.  In addition, hairline cracks less than 0.01 inch (0.25 mm) will not be cause for rejection.

15.1  Ensure that the location of the product marking is on the interior of the arch section 1 foot (300 mm) below the leg haunch.

          Add the product marking upon removal of the forms.

          The manufacturer may be required to repeat the product markings before the project is final.

706.053         Precast Reinforced Concrete Round Sections. Provide precast reinforced concrete elliptical and circular arch sections according to ASTM C 1504, with the following modifications:

This item shall consist of manufacturing precast reinforced concrete elliptical and circular arch sections for culverts.

Ensure that manufacturers of precast concrete members are certified according to Supplement 1073.

5. Ensure the manufacturer submits design calculations, a structural load rating and shop drawings according to 611.04. Ensure the shop drawings include the following:

1.      Load rate the structure according to the requirements of section 900 of the Department’s Bridge Design Manual.

2.      All material specifications.

3.      Plan view.

4.      Elevation views.

5.      Headwall and wingwall attachment requirements.

6.      Dimensions.

7.      All maintenance of traffic phases.

8.      Section sizes.

9.      Design handling strength.

          The manufacturer may modify an approved shop drawing and resubmit for approval to the Department.

          Ensure that the shop drawings also include the following special information as required:

1.      For top mounted guardrail, the guardrail plate and bolt locations are shown in the plan view. Holes shall be a minimum of 6 inches (150 mm) from a joint.

2.      The corrosion inhibitor being used, if any, and dosage rate. Dosage rate will be approved by the Laboratory.

6.2.1 In addition, provide cement according to 701, except 701.07.

6.2.2 Only use fly ash conforming to 701.13.

6.3    Provide aggregates conforming to the quality requirements of 703.02.

6.4    Use chemical admixtures conforming to 705.12. Use a corrosion inhibitor unless epoxy coated reinforcing steel is used. An approved list of corrosion inhibiting admixtures is on file at the Laboratory. Manufacturers should recognize that the corrosion inhibitors and admixtures may have an effect on strength, entrained air content, workability, etc. of their concrete mixes. The manufacturer’s choice of one of these corrosion inhibitors does not alleviate meeting all design requirements of this structure.

6.4.1 Provide air-entraining admixture conforming to 705.10.

6.5    Provide epoxy coated reinforcement according to 709.00, Grade 60 (Grade 420), or 709.14. In lieu of epoxy coated reinforcement, an approved corrosion inhibiting admixture may be added to the concrete at the approved dosage; and provide reinforcement according to 709.01, 709.03 or 709.05; Grade 60 (Grade 420) or 709.08, 709.10, 709.11 or 709.12. Provide epoxy or galvanized coated connections when connecting a precast structural unit into a cast-in-place structural component or between segments of adjacent precast structural units either manufactured as separate units or across construction joints when manufactured as one unit. Provide epoxy coated reinforcement according to 709.00 or 709.14, when these connections are designed using reinforcing steel. Provide galvanized coatings according to 711.02, when these connections are designed using connection plates, hardware or concrete inserts.

7.1    Modify the first sentence as follows: Design according to AASHTO LRFD Bridge Design Specifications, Section 12.14. Include a future wearing surface loading of 60 psf.

7.2    Ensure that the concrete cover dimension over the outside circumferential reinforcement is a minimum of 2 inches (50 mm). Ensure that the concrete cover dimension over the inside circumferential reinforcement is a minimum of 1 1/2 inches (38 mm). The clear distance of the end circumferential wires shall not be less than 1 inch (25 mm) nor more than 2 inches (50 mm) from the ends of the sections. Reinforcement shall be assembled utilizing single or multiple layers of welded wire fabric (three-layer maximum), or utilizing a single layer of deformed billet-steel bars. The welded wire fabric shall be composed of circumferential and longitudinal wires and shall contain sufficient longitudinal wires extending through the section to maintain the shape and position of reinforcement. Longitudinal distribution reinforcement may be welded wire fabric or deformed billet-steel bars. The ends of the longitudinal distribution reinforcement shall be not more than 3 inches (75 mm) from the ends of the sections.

          Form the outside and inside circumferential reinforcing steel for the arch such that it is approximately equal to the configuration of the arch shape.

7.3    In addition, tension splices in the circumferential reinforcement shall not be made. For splices other than tension splices, the overlap shall be a minimum of 12 inches (300 mm) for welded wire fabric or deformed billet steel bars. The spacing center-to-center of the circumferential wires in a wire fabric sheet shall be not less than 2 inches (50 mm) or more than 4 inches (100 mm). For the wire fabric, the spacing center-to-center of the longitudinal wire shall not be more than 8 inches (200 mm). The spacing center-to-center of the longitudinal distribution steel for either line of reinforcing in the top slab shall be not more than 16 inches (410 mm).

8.1    Ensure the sections are produced with butt ends. The ends of the sections shall be such that when the sections are laid together they will make a continuous line of sections with a smooth interior free of appreciable irregularities, all compatible with the permissible variations in these Specifications and section 11 of ASTM C 1504. Provide a 3/4 × 3/4 inch (19 × 19 mm) minimum chamfer on the inside and outside surface at the sections joint.

Ensure that the design of the arch in its final constructed location is structurally continuous throughout the arch unit providing for flexural, compressive and shear force transfers. For arches that gain structural continuity by a cast in place closure at the project site, provide concrete with the same compressive strength as the precast arch. In addition, the cast in place closure shall provide continuity in the transverse direction (90 degrees to the span) along the lay length of the arches.

9.1    Ensure that the aggregate, cement, and water are manufactured according to 499.06, 499.07, and 499.09.

          Ensure that the temperature requirements of 511.08 and 511.15 are met.

          Ensure that the proportion of Portland cement is not less than 564 pounds per cubic yard (335 kg/m³) of concrete.

          If used, add the corrosion inhibitor as an aqueous solution. Consider the water in the solution as mixing water for the purpose of determining the water-cement ratio of concrete.

9.2    Cure the arch sections in the forms for the length of time required to obtain the specified minimum design handling strength as defined in the shop drawings. Test a cylinder to check each section’s design handling strength. Repeat this test as often as needed. Only one cylinder passing will ensure that the design handling strength has been met. If the shop drawing shows no design handling strengths, then the minimum handling strength is assumed to be 100 percent of the design strength. Ensure that the curing then continues either in or out of the forms until the specified minimum design strength is met.

9.2.1 Steam curing is an accelerated cure by low pressure steam or radiant heat within a suitable insulated enclosure to contain the live steam or heat. The initial application of the steam or heat is from 2 to 4 hours after the final placement of concrete to allow the initial set to take place. If retarders are used, increase the waiting period to 4 to 6 hours. As an alternative, determine the actual time of initial set according to ASTM C 403. Do not start curing until the actual time to initial set has elapsed.

          During the waiting period, ensure that the temperature within the curing enclosure is not less than 50 °F (10 °C).

          During the initial application of live steam or radiant heat, ensure that the ambient temperature within the curing enclosure increases at an average rate not exceeding 40 °F (22 °C) per hour until the curing temperature is reached.

          Ensure that the maximum curing temperature does not exceed 150 °F (65 °C). Hold the design temperature until the concrete has reached the desired design strength. Do not direct the application of live steam on the concrete forms so as to cause localized high temperatures.

9.2.2 Provide water curing according to 511.15 and 511.17, Method A.

9.2.3 Delete.

9.3    Ensure that all forms are in place until the design handling strength is met.

          Holes for handling or setting are not permitted. Do not move members before the design handling strength of the concrete is reached, or shipped before the design strength of the concrete is reached. Ensure that the manufacturers have equipment necessary to handle and transport the pieces without damaging them.

10     Ensure that the hardened concrete contains a minimum of 4 percent entrained air.

10.1  Cores drilled from the section are not permitted.

10.2.1        Keep the cylinders and matching arch section together to guarantee the cylinders are matched with the corresponding culvert section; or, upon agreement by the Department, keep the cylinders at a location that will provide the same environment as the arch sections.

10.2.2        For each section of the arch structure, produce and mark at least four cylinders so that they are identifiable with the matching arch section.

10.2.3        Conform to Supplement 1073 for acceptance.

10.2.3.1    Ensure that cylinder strengths conform to Supplement 1073.

11.0  The under-run in length of a section shall not be more than 1/2 inch (13 mm).

          All changes to the project resulting from the manufacturer’s dimensional changes in the structure are at no charge to the Department.

          Ensure that the sections are free of fractures spalls and chips. Ensure that all surfaces have a smooth and regular finish being defined as a 1/4 inch variation within 4 feet (6 mm variation within 1.2 m).

11.1  The internal dimensions shall vary not more than 1 percent from the design dimensions or more than 1 1/2 inches (38 mm), whichever is less. The haunch dimensions shall vary not more than 3/4 inch (19 mm) from the design dimension.

11.4  Ensure that the maximum variation in the position of the reinforcement is 3/8 inch (9 mm), except that the cover over the reinforcement for the external surface of the top is not less than 2 inches (50 mm). The above tolerances or cover requirements do not apply to mating surfaces at the joint.

11.5  Resubmit any change in reinforcement from the shop drawings for approval.

11.6  All interior and exterior arch surfaces shall have a smooth steel form finish.

12.0  Make repairs according to the Department’s requirements. The Department will not make additional payments for arch repairs. Repairs are acceptable if, in the opinion of the Department, the repairs are sound, properly finished, and cured.

13.0  The Department may perform inspection at the plant conforming to Supplement 1073 but final inspection and acceptance will be at the project site.

          Furnish precast concrete components from suppliers certified according to Supplement 1073.

14.0  Form seams and slight surface irregularities that are expected from a steel panel forming system will not be cause for rejection. In addition, hairline cracks less than 0.01 inch (0.25 mm) will not be cause for rejection.

15.1  Ensure that the location of the product marking is on the interior of the arch section 4 feet (1.2 m) above the base of the arch. Measure the 4 feet (1.2 m) from the base of the arch along the circumference of the interior surface.

          Add the product marking upon removal of the forms.

          The manufacturer may be required to repeat the product markings before the project is final.

706.06  Perforated Concrete Pipe.  Provide perforated concrete pipe according to ASTM C 444 (ASTM C 444M), and 706.01 or 706.02.

Ensure manufacturers providing materials are certified according to Supplement 1074.

706.07  Concrete Drain Tile.  Provide extra-quality concrete drain tile according to ASTM C 412 (ASTM C 412M), with the following modifications:

Ensure manufacturers providing materials are certified according to Supplement 1074.

4.0    This specification covers extra-quality concrete drain tile only.

5.1(3)  Does not apply.

6.2.1 Provide cement according to 701, except 701.07.

6.2.2 Provide fly ash according to 701.13

6.3    Provide aggregate conforming to the quality requirements of 703.02.

8.1    Perform inspection at the project site.  Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory.  Ensure manufacturers providing materials are certified according to Supplement 1074.

Testing.  Ensure that the manufacturer furnishes all facilities and personnel to carry out the tests.

706.08  Vitrified Clay Pipe.  Provide vitrified clay pipe according to ASTM C 700, with the following modifications:

Furnish materials according to the Department’s Qualified Products List (QPL).

14.0  Perform all tests except hydrostatic according to ASTM C 301.

15.0  Perform inspection at the project site.  Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory.

706.09  Clay Drain Tile.  Provide extra-quality clay drain tile according to ASTM C 4, with the following modifications:

6.1    Perform inspection at the project site.  Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory.

11, 12, and 13  Ensure that the manufacturer furnishes all facilities and personnel to carry out the tests.

Furnish materials according to the Department’s Qualified Products List (QPL).

706.10  Bituminous Pipe Joint Filler.  Provide cold applied, mineral filled, joint sealing compound for joints of bell and spigot, or tongue and groove sewer; or drain pipe conforming to the following:

A.      Composition.  Provide a steam-refined petroleum asphalt or a refined coal tar, dissolved in a suitable solvent, and containing an appropriate stiffener.

B.      General Requirement.  Provide a bituminous plastic cement that has a smooth, uniform mixture, not thickened or livered, and that shows a separation easily overcome by stirring.  Ensure that the material is of such consistency and properties that it is readily applied with a trowel, a putty knife, or with a caulking gun without pulling or drawing.  Provide a material that when applied to metal, concrete, or vitrified clay surfaces, exhibits good adhesive and cohesive properties and has only slight shrinkage after curing.  Provide a material that is not damaged by exposure to below freezing temperatures.

C.      Detail Requirements.  Provide materials conforming to the following requirements:

1.

When applied in a layer 1/16 to 1/8-inch (1.6 to 3.2 mm) thick on a tinned metal panel and cured at room temperature for 24 hours, the bituminous plastic cement shall set to a tough, plastic coating, free from blisters.

Minimum

Maximum

2.

Grease Cone Penetration (unworked, 150 grams, 25 °C, 5 sec, ASTM D 217, mm/10

175

250

3.

Weight, kg/L

1.17

--

4.

Non-volatile, 10 g, 105 to 110 °C,
24 hrs, %

75

--

5.

Ash, by ignition, %

25

45

Furnish materials according to the Department’s Qualified Products List (QPL).

706.11  Resilient and Flexible Gasket Joints.  Provide resilient and flexible gasket joints for concrete pipe according to ASTM C 443 (ASTM C 443M). 

Furnish materials according to the Department’s Qualified Products List (QPL).

706.12  Resilient and Flexible Joints.  Provide resilient and flexible joints for vitrified clay pipe according to ASTM C 425.

Furnish materials according to the Department’s Qualified Products List (QPL).

706.13  Precast Reinforced Concrete Manhole Riser Sections, Flat Slab Tops, Catch Basins and Inlet Tops, and Portable Barriers.  Provide precast reinforced concrete manhole riser sections, flat slab tops, catch basins and inlet tops, and portable barriers according to ASTM C 478 (ASTM C 478M), with the following modifications:

1.1    Provide precast catch basin tops where permitted by the plans.

4.1.2.1  Provide cement according to 701, except 701.07.

4.1.2.2  Provide fly ash according to 701.13.

4.1.4  Provide aggregate conforming to the quality requirements of 703.02.

4.1.6  Provide steel according to 709.01, 709.08, 709.10, or 709.12.  Provide epoxy coated steel according to 709.00 for the manhole flat slab tops, catch basin tops and inlet tops only.

7.0    Ensure that no more than two holes are cast, drilled, or otherwise neatly made in the shell of each piece of each riser section for the purpose of handling or laying.  Taper the holes unless drilled, and before backfilling fill the tapered holes with portland cement mortar, precast concrete plugs secured with portland cement mortar, or a device on the Department’s approved list specifically designed for filling the hole.  Fill drilled holes with portland cement mortar.

8.2.2 Absorption test does not apply

10.0  Perform inspection at the project site. 

11.0  In addition, mark the plant location on each manhole top or barrier section.

Ensure manufacturers providing materials are certified according to Supplement 1073

Ensure that the manufacturer submits design calculations to the Office of Hydraulic Engineering for structures that have a span of 10 feet or greater and are located in the pavement.  Ensure the design is based upon section 1000 of the Location and Design Manual, Volume 2.  Calculations must contain signatures from two (2) Professional Engineers qualified in structural design

706.14  Preformed Flexible Joint Sealant. Provide preformed flexible joint sealant for concrete conduit according to ASTM C 990. 

Furnish materials according to the Department's Qualified Product List (QPL).

706.15  Precast Reinforced Concrete Outlets.  Provide precast reinforced concrete outlets composed of cement conforming to 701, except 701.07.  Provide aggregate conforming to the quality requirements of 703.02.  Provide epoxy coated steel reinforcement conforming to 709.00.  Do not provide holes for handling or laying.  Ensure that the outlet hole are the same size as the outlet pipe.  Perform inspection at the project site. 

Ensure manufacturers providing materials are certified according to Supplement 1073

707  STEEL, ALUMINUM, AND PLASTIC PIPE

707.00  Acceptance.  Corrugated metal pipe conforming to 707.01, 707.02, 707.03, 707.04, 707.05, 707.07, 707.11, 707.12, 707.13, 707.14, 707.15, 707.21, 707.22, 707.23, 707.24, and 707.25 may be accepted for shipment to and immediate use in construction projects when provided from suppliers certified according to Supplement 1019.

707.01  Metallic Coated Corrugated Steel Conduits and Underdrains.  Provide conduits and underdrains having a corrugation depth of 1/2 or 1/4 inch (13 or 6.5 mm) and according to AASHTO M 36/M 36M, with the following modifications:

7.7.1 Helical corrugated pipe, 12-inch (300 mm) diameter and larger, shall have at least two annular corrugations at each end of each pipe length.

8.1.2 Ensure that the minimum wall thickness (coated) of steel pipe and pipe-arches is as follows:

Pipe

Pipe-Arch

Diameter

Wall Thickness

Size

Wall Thickness

(inch)

(inch)

(inch)

(inch)

6

0.052

8

0.064

10

0.064

12

0.064

15

0.064

17 ´ 13

0.064

18

0.064

21 ´ 15

0.064

21

0.064

24 ´ 18

0.064

24

0.064

28 ´ 20

0.064

27

0.064

30

0.064

35 ´ 24

0.064

33

0.064

36

0.064

42 ´ 29

0.064

42

0.064

49 ´ 33

0.079

48

0.064

57 ´ 38

0.109

54

0.109

64 ´ 43

0.109

60

0.109

71 ´ 47

0.138

66

0.138

77 ´ 52

0.168

72

0.138

83 ´ 57

0.168

78

0.168

84

0.168

Pipe

Pipe-Arch

Diameter

Wall Thickness

Size

Wall Thickness

(mm)

(mm)

(mm)

(mm)

150

1.32

200

1.63

250

1.63

300

1.63

375

1.63

430 ´ 340

1.63

450

1.63

530 ´ 380

1.63

525

1.63

610 ´ 460

1.63

600

1.63

710 ´ 510

1.63

675

1.63

750

1.63

885 ´ 610

1.63

825

1.63

900

1.63

1060 ´ 740

1.63

1050

1.63

1240 ´ 840

2.01

1200

1.63

1440 ´ 970

2.77

1350

2.77

1620 ´ 1100

2.77

1500

2.77

1800 ´ 1200

3.51

1650

3.51

1950 ´ 1320

3.51

1800

3.51

2100 ´ 1450

4.27

1950

4.27

2100

4.27

Ensure that the minus tolerance conforms to AASHTO M 218, M 274, or M 289.

TABLE 707.01-1  PIPE REQUIREMENTS

Nominal Inside

Corrugation Depth

Minimum

Diameter

Nominal

Width of Lap

(inch)

(mm)

(inch)

(mm)

(inch)

(mm)

27

675

1/2

13

2

50

33

825

1/2

13

2

50

8.3.2.1  Ensure that the minimum number of longitudinal rows of perforations is four.

9.1    Coupling bands shall have annular corrugations.

9.2    Ensure that coupling bands are not more than two nominal sheet thicknesses thinner than the thickness of the pipe to be connected.  For pipes 48-inch (1200 mm) diameter and smaller, ensure that the coupling band is not thinner than the 0.052-inch (1.32 mm) nominal sheet thickness.  For pipes 54-inch (1350 mm) diameter through 84-inch (2100 mm) diameter, ensure that the coupling band is not thinner than the 0.064-inch (1.63 mm) nominal sheet thickness.  For pipe diameters over 36 inches (900 mm), provide coupling bands that have at least one annular corrugation that indexes into the inboard corrugation of each pipe section joined.

707.02  Metallic Coated Corrugated Steel Conduits [1-inch (25 mm) Corrugations].  Provide conduits according to AASHTO M 36/M 36M, with the following modifications:

7.7.1 Helical corrugated pipe shall have at least two annual corrugations at each end of each pipe length.

8.1.2 Ensure that the minimum wall thickness (coated) of steel pipe and pipe-arches is as follows:

Pipe

Pipe-Arch

Diameter

Wall Thickness

Size

Wall Thickness

(inch)

(inch)

(inch)

(inch)

36

0.064

40 ´ 31

0.109

42

0.064

46 ´ 36

0.109

48

0.064

53 ´ 41

0.109

54

0.079

60 ´ 46

0.109

60

0.079

66 ´ 51

0.109

66

0.109

73 ´ 55

0.109

72

0.109

81 ´ 59

0.109

78

0.109

87 ´ 63

0.109

84

0.109

95 ´ 67

0.109

90

0.109

103 ´ 71

0.109

96

0.109

112 ´ 75

0.109

102

0.109

117 ´ 79

0.109

108

0.109

128 ´ 83

0.138

114

0.109

137 ´ 87

0.138

120

0.109

142 ´ 91

0.168

Pipe

Pipe-Arch

Diameter

Wall Thickness

Size

Wall Thickness

(mm)

(mm)

(mm)

(mm)

900

1.63

1010 ´ 790

2.77

1050

1.63

1160 ´ 920

2.77

1200

1.63

1340 ´ 1050

2.77

1350

2.01

1520 ´ 1170

2.77

1500

2.01

1670 ´ 1300

2.77

1650

2.01

1850 ´ 1400

2.77

1800

2.77

2050 ´ 1500

2.77

1950

2.77

2200 ´ 1620

2.77

2100

2.77

2400 ´ 1720

2.77

2250

2.77

2600 ´ 1820

2.77

2400

2.77

2840 ´ 1920

2.77

2550

2.77

2970 ´ 2020

2.77

2700

2.77

3240 ´ 2120

3.51

2850

2.77

3470 ´ 2220

3.51

3000

2.77

3600 ´ 2320

4.27

Ensure that the minus tolerance conforms to AASHTO M 218, M 274, or M 289.

9.1    Provide coupling bands with a minimum wall thickness (coated) of  0.064 inch (1.63 mm) and that have at least one annular corrugation that indexes into the inboard corrugations of each pipe section joined.

707.03  Structural Plate Corrugated Steel Structures.  Provide structural plate pipe, pipe arch, and arch structures according to AASHTO M 167 (AASHTO M 167M), with the following modification:

5.4    Assembly bolts may be galvanized by an electrolytic process.

707.04  Precoated, Galvanized Steel Culverts.  Provide conduits and coupling bands according to AASHTO M 245/M 245M, as modified by 707.01 and 707.02.  Ensure that the precoated, galvanized steel sheets conform to AASHTO M 246/M 246M, Type B.  Ensure that the polymeric coating is 10 mils (250 mm) on the interior and 10 mils (250 mm) on the exterior.

707.05  Bituminous Coated Corrugated Steel Pipe and Pipe Arches with Paved Invert [1/2-inch (13 mm) Corrugations].  Provide conduits and coupling bands according to 707.01 and to AASHTO M 190.  Provide either Type B half bituminous coated pipe, or pipe arches with paved invert or Type C fully coated pipe, or pipe arches with paved invert.

707.07  Bituminous Coated Corrugated Steel Pipe and Pipe Arches with Paved Invert [1-inch (25 mm) Corrugations].  Provide conduits and coupling bands according to 707.02 and to AASHTO M 190.  Provide either Type B half bituminous coated pipe, or pipe arches with paved invert or Type C fully coated pipe, or pipe arches with paved invert.

707.10  Square and Rectangular Steel Tubing.  Provide square and rectangular steel tubing according to ASTM A 501 or ASTM A 500, Grade B, with the following modifications:

Galvanize the tubing according to 711.02.

Test the tubular steel from all heat numbers supplied for toughness according to ASTM E 436, except as modified herein.  Take and test tubing test samples before delivery of the railing.  Ensure that the taking of the test samples is witnessed and the testing is performed by an independent test laboratory.  Submit certified test data for review and approval as specified in 501.06.

Perform testing on test specimens obtained from galvanized tubing with the same heat number as that being used.  Conduct the testing at a temperature of 0 °F (-18 °C) on 2 ´ 9-inch (50 ´ 225 mm) specimens supported to provide a 7-inch (180 mm) clear span.  Do not remove the galvanizing from the specimens.  Cut three 2 ´ 9-inch (50 ´ 225 mm) test specimens from each of the unwelded sides for a total of nine specimens.  If all three unwelded sides are not large enough to remove 2 ´ 9-inch (50 ´ 225 mm) specimens, then remove nine specimens from any unwelded side.

Disregard the three specimens from the side with the lowest average shear area when calculating the final average shear area.  If specimens were not removed from three unwelded sides, then disregard the three specimens with the lowest average shear area.  Calculate the final average shear area using the six remaining specimens.  If the average shear area falls below 50 percent, reject material from the heat represented by these tests.  However, if the average shear area is 30 percent or greater, the Department will allow one retest at a sampling frequently three times that of the first test, and with no samples excluded in calculating the average.  Reject materials not having a 50 percent average shear area upon retest.

Before galvanizing, the manufacturer of the tubing shall identify the product with the steel heat number (or with some number that is traceable to the heat number) and with the manufacturer’s unique identification code to facilitate acceptance or rejection of the material.  Ensure that the identification method is such that identification is on only one face of the section, and is repeated at intervals no greater than 4 feet (1.2 m), and does not extend into the curved surface of the tubing at the corners.

707.11  Mortar Lined Corrugated Steel Pipe.  Provide pipe according to 707.01 and 707.02 and having the interior coated with mortar according to ASTM A 849, Class C, with the following modifications:

These requirements apply to 24-inch to 120-inch (600 to 3000 mm) diameter conduit.  Conduits 24 to 60 inches (600 to 1500 mm) in diameter shall conform to 707.01.  Conduits 66 inches (1650 mm) and above in diameter shall conform to 707.01 or 707.02.  Ensure that the minimum wall thickness of the 707.02 steel pipe is 0.109 inch (2.77 mm).

7.7    Before the mortar lining is applied, apply a bituminous coating according to AASHTO M 190, Type A, or an approved barrier coating, to the inside surface of the conduits if they are fabricated from steel sheet according to AASHTO M 274 or M 289.

7.7    The mortar lining shall have a minimum thickness of 1/4 inch (6 mm) above the crests of the corrugations.  Ensure that the mortar lining is prequalified by the manufacturer by submitting to the Laboratory certified test data according to 101.03.  This data will include test data for all components of the mixture, and the 7 and 28-day compressive strengths of the mixture.

14     These conduits may be accepted for shipment to and immediate use in construction projects by using the manufacturer’s certification for the steel pipe and mortar.  Ensure that the certification states that the mortar is of the same design as that prequalified with the Laboratory.

707.12  Corrugated Steel Spiral Rib Conduits.  Provide conduits that have a center-to-center rib spacing of 7 1/2 inches (190 mm).  Provide conduits and fittings according to AASHTO M 36, Type IR, with the following modifications:

6.1    Fabricate pipe from aluminum coated sheet according to AASHTO M 274.

7.2.2 The ribs shall conform to AASHTO M 196, Section 7.2.2.

7.7.1 Reroll the ends of the individual pipe sections to form at least two annular corrugations on each end.  Paint the rerolled end with zinc rich paint.

8.1.2 Ensure that the minimum wall thickness (coated) of steel pipe is as follows:

Pipe

Diameter

Wall Thickness

Diameter

Wall Thickness

(inch)

(inch)

(mm)

(mm)

18

0.064

450

1.63

21

0.064

525

1.63

24

0.064

600

1.63

30

0.064

750

1.63

36

0.064

900

1.63

42

0.064

1050

1.63

48

0.064

1200

1.63

54

0.109

1350

2.77

60

0.109

1500

2.77

66

0.109

1650

2.77

72

0.109

1800

2.77

78

0.109

1950

2.77

84

0.138

2100

3.51

90

0.138

2250

3.51

9.1    Coupling bands shall have annular corrugations.

9.2    Coupling bands shall conform to 707.01.

9.3    A bell and spigot joint according to ASTM A760 (A760M) may be used with the following modifications:

          9.3.1          These joints may be used for conduits ranging in size from 18 (450mm) to 48 (1200mm) inches in diameter.

          9.3.2          Ensure the bell and spigot has a soil tight joint by use of a shop applied gasket on the bell end and a field applied gasket on the spigot end.

          9.3.3          Provide a minimum of 0.064 (1.63mm) inch nominal sheet thickness or not more than two (2) nominal sheet thickness thinner than the thickness of the pipe to be joined.

14.1  Ensure that the certification and sampling conforms to 707.01.

707.13  Bituminous Lined Corrugated Steel Pipe [1/2-inch (13 mm) Corrugations].  Provide pipe according to 707.01 and AASHTO M 190, Type D.

707.14  Bituminous Lined Corrugated Steel Pipe [1-inch (25 mm) Corrugations].  Provide pipe according to 707.02 and AASHTO M 190, Type D.

707.15  Corrugated Steel Box Culverts.  Provide corrugated steel box culverts according to ASTM A 964.

Ensure that all manufacturers are pre-approved.  Ensure that manufacturers not pre-approved submit a structural design criteria and analysis method to the Department before the project letting for approval.  The Department maintains a list of all pre-approved manufacturers.

Ensure that the manufacturer submits shop drawings and design calculations for review and written approval before manufacture.  Submit a minimum of seven copies of the drawings.  Allow a minimum of four weeks for approval.  Ensure that the shop drawings include the following:

A.     All structural design and loading information.

B.     All material specifications.

C.     All plan view.

D.     All elevation view.

E.      All headwall and wingwall attachment requirements.

F.      All dimensions.

G.     All maintenance of traffic phases.

H.     All plate size and dimensions.

The manufacturer may modify an approved shop drawing and resubmit for approval to the Department.

707.17  Spiral Rib Steel Pipe Arch.  Provide conduits according to AASHTO M36, Type IIA, with the following modifications:

6.1    Fabricate pipe from aluminum coated sheet according to AASHTO M 274.

7.2.2 The ribs shall conform to AASHTO M 196, Section 7.2.2.

9.1    Coupling bands shall have annular corrugations.

9.2    Coupling bands shall conform to 707.01.

14.1  Ensure that the certification and sampling conforms to 707.01.

Ensure that the minimum wall thickness of Spiral Rib steel pipe arches is as follows:

Pipe-Arch

Size

Wall Thickness

Size

Wall Thickness

(inch)

(inch)

(mm)

(mm)

20 × 16

0.079

500 × 410

2.01

23 × 19

0.079

580 × 490

2.01

27 × 21

0.079

680 × 540

2.01

33 × 26

0.079

830 × 670

2.01

40 × 31

0.079

1010 × 790

2.01

46 × 36

0.079

1160 × 920

2.01

53 × 41

0.109

1340 × 1050

2.77

60 × 46

0.109

1520 × 1170

2.77

66 × 51

0.109

1670 × 1300

2.77

73 × 55

0.109

1850 × 1400

2.77

81 × 59

0.138

2050 × 1500

3.51

707.18 Polymer Precoated, Galvanized Steel Conduits with precoated galvanized smooth steel interior liner.  Provide Type IA pipe which has a corrugated exterior with a smooth interior liner.  Provide corrugated exterior conduits and smooth liners according to 707.04 with the following modifications to AASHTO M 245:

7.5.1 Provide Polymer Precoated, Galvanized Steel Conduits with precoated galvanized smooth steel interior liner pipe with plain cut helical ends.  Match mark ends.  Install conduit so that match marks align and are in accordance with the layout drawings supplied by the manufacturer.

Provide external flat sheet coupling bands with a minimum wall thickness (coated) of .064 inch and that are a minimum of 12” wide.  Ensure coupling bands are polymer precoated, galvanized steel.

                9.3 Ensure a soil tight joint by the use of a flat gasket conforming to ASTM D1056 2B1 that is a minimum of 12” wide and centered over the joint.

707.19 Aluminum Coated Steel Conduits with precoated galvanized smooth steel interior liner.  Provide Type IA pipe which has a corrugated exterior with a smooth interior liner.  Ensure that the interior liner conforms to 707.04.  Ensure that the corrugated exterior conduit material conforms to AASHTO M274.  Provide corrugated exterior conduits per 707.01 or 707.02 with the following modifications to AASHTO M36:

                7.7.1 Provide Aluminum Coated Steel Conduits with precoated galvanized smooth steel interior liner pipe with plain cut helical ends.  Match mark ends.  Install conduit so that match marks align and are in accordance with the layout drawings supplied by the manufacturer.

9.2 Provide external flat sheet coupling bands with a minimum wall thickness (coated) of .064 inch and that are a minimum of 12” wide.  Ensure coupling bands are aluminum coated steel.

9.5 Ensure a soil tight joint by the use of a flat gasket conforming to ASTM D1056 2B1 that is a minimum of 12” wide and centered over the joint.

707.20 Galvanized Coated Steel Conduits with precoated galvanized smooth steel interior liner.  Provide Type IA pipe which has a corrugated exterior with a smooth interior liner.  Ensure that the interior liner conforms to 707.04.  Ensure that the corrugated exterior conduit material conforms to AASHTO M 218.  Provide corrugated exterior conduits per 707.01 and 707.02 with the following modifications to AASHTO M36:

7.7.1 Provide Galvanized Coated Steel Conduits with precoated galvanized smooth steel interior liner pipe with plain cut helical ends.  Match mark ends.  Install conduit so that match marks align and are in accordance with the layout drawings supplied by the manufacturer.

9.2 Provide external flat sheet coupling bands with a minimum wall thickness (coated) of .064 inch and that are a minimum of 12” wide.  Ensure coupling bands are galvanized coated steel.

                9.5 Ensure a soil tight joint by the use of a flat gasket conforming to ASTM D1056 2B1  that is a minimum of 12” wide and centered over the joint.

707.21  Corrugated Aluminum Alloy Conduits and Underdrains.  Provide conduits and underdrains having a 1/4, 7/16, or 1/2-inch (6.5, 11, or 13 mm) corrugation depth and according to AASHTO M 196/M 196M, with the following modifications:

8.1 and 8.2  Provide helically corrugated pipe 12 inches (300 mm) in diameter and larger that have at least two circumferential corrugations at each end of each pipe length.

8.1.2 Ensure that the minimum wall thickness of aluminum pipe and pipe arches is as follows:

Pipe

Pipe-Arch

Diameter

Wall Thickness

Size

Wall Thickness

(inch)

(inch)

(inch)

(inch)

6

0.048

8

0.060

10

0.060

12

0.060

15

0.060

17 ´ 13

0.060

18

0.060

21 ´ 15

0.060

21

0.060

24 ´ 18

0.060

24

0.060

28 ´ 20

0.075

27

0.075

30

0.075

35 ´ 24

0.075

36

0.075

42 ´ 29

0.105

42

0.105

49 ´ 33

0.105

48

0.105

57 ´ 38

0.135

54

0.105

64 ´ 43

0.135

60

0.135

71 ´ 47

0.164

66

0.164

72

0.164

Pipe

Pipe-Arch

Diameter

Wall Thickness

Size

Wall Thickness

(mm)

(mm)

(mm)

(mm)

150

1.22

200

1.52

250

1.52

300

1.52

375

1.52

430 ´ 330

1.52

450

1.52

530 ´ 380

1.52

525

1.52

610 ´ 460

1.52

600

1.52

710 ´ 510

1.91

675

1.91

750

1.91

885 ´ 610

1.91

900

1.91

1060 ´ 740

2.67

1050

2.67

1240 ´ 840

2.67

1200

2.67

1440 ´ 970

3.43

1350

2.67

1620 ´ 1100

3.43

1500

3.43

1800 ´ 1200

4.17

1650

4.17

1800

4.17

Ensure that the minus tolerance conforms to AASHTO M 197/M 197M.

9.2    Provide coupling bands with a minimum wall thickness (coated) of 0.060 inch (1.52 mm).  For pipe diameters 12 inches (300 mm) and larger, provide coupling bands that have at least one circumferential corrugation that indexes into the inboard corrugations of each pipe section joined.

707.22  Corrugated Aluminum Alloy Conduits.  Provide conduits having a 1-inch (25 mm) corrugation depth and according to AASHTO M 196/M 196M, with the following modifications:

8.1 and 8.2  Provide helically corrugated pipe that have at least two circumferential corrugations at each end of each pipe length.

8.1.2 Ensure that the minimum wall thickness of aluminum pipe is as follows:

Pipe

Diameter

Wall Thickness

Diameter

Wall Thickness

(inch)

(inch)

(mm)

(mm)

36

0.060

900

1.63

42

0.060

1050

1.63

48

0.060

1200

1.63

54

0.075

1350

1.91

60

0.105

1500

2.67

66

0.105

1650

2.67

72

0.105

1800

2.67

78

0.105

1950

2.67

84

0.105

2100

2.67

90

0.105

2250

2.67

96

0.105

2400

2.67

102

0.135

2550

3.43

108

0.135

2700

3.43

114

0.164

2850

4.17

120

0.164

3000

4.17

Ensure that the minus tolerance conforms to AASHTO M 197/M 197M.

9.2    Provide coupling bands that are not lighter than 0.060-inch (1.52 mm) nominal sheet thickness and that have at least one circumferential corrugation that indexes into the inboard corrugations of each pipe section joined.

707.23  Aluminum Alloy Structural Plate Conduits.  Provide aluminum alloy plates and fasteners for structural plate conduits according to AASHTO M 219/M 219M.

707.24  Corrugated Aluminum Spiral Rib Conduits.  Provide conduits that have a center-to-center rib spacing of 7 1/2 inches (190 mm).  Provide conduits and fittings according to AASHTO M 196, Type IR, with the following modifications:

7.5.1 Reroll the ends of the individual pipe sections to form at least two annular corrugations on each end.

8.1.2 Ensure that the minimum wall thickness of aluminum pipe is as follows:

Pipe

Diameter

Wall Thickness

Diameter

Wall Thickness

(inch)

(inch)

(mm)

(mm)

18

0.060

450

1.52

21

0.060

525

1.52

24

0.060

600

1.52

30

0.060

750

1.52

36

0.075

900

1.91

42

0.105

1050

2.67

48

0.105

1200

2.67

54

0.105

1350

2.67

60

0.135

1500

3.43

66

0.135

1650

3.43

9.1    Coupling bands shall have annular corrugations.

9.2    Coupling bands shall conform to 707.21.

14.1  Ensure that the certification and sampling conforms to 707.21.

707.25  Corrugated Aluminum Box Culverts.  Provide corrugated aluminum box culverts according to ASTM B 864/B 864M.

Ensure that all manufacturers are pre-approved.  Ensure that manufacturers not pre-approved submit a structural design criteria and analysis method to the Department before the project letting for approval.  The Department maintains a list of all pre-approved manufacturers.

Ensure that the manufacturer submits shop drawings and design calculations for review and written approval before manufacture.  Submit a minimum of seven copies of the drawings.  Allow a minimum of four weeks for approval.  Ensure that the shop drawings include the following:

A.     All structural design and loading information.

B.     All material specifications.

C.     All plan view.

D.     All elevation view.

E.      All headwall and wingwall attachment requirements.

F.      All dimensions.

G.     All maintenance of traffic phases.

H.     All plate size and dimensions.

The manufacturer may modify an approved shop drawing and resubmit for approval to the Department.

707.31  Corrugated Polyethylene Drainage Tubing.  Provide corrugated polyethylene drainage tubing according to AASHTO M 252 Type C, and CP. If Type S or SP is specified, provide corrugated polyethylene smooth lined pipe conforming to 707.33.

Only provide materials from manufacturers certified according to Supplement 1066.

707.32  Corrugated Polyethylene Drainage Pipe.  Provide conduits, coupling bands, and fittings according to AASHTO M 294, Type C.

Only provide materials from manufacturers certified according to Supplement 1066.

707.33  Corrugated Polyethylene Smooth Lined Pipe. 

Provide smooth lined corrugated polyethylene pipe, closed profile polyethylene pipe, couplings, and fittings conforming to AASHTO M 294, with the following modifications:

Provide Type S or Type D. If perforated is specified, provide Type SP.

1.1.1 Nominal sizes of 4 to 60 inches (100 mm to 1500 mm) are included.

7.2.1 In addition, nominal diameters of 4, 6, 8, and 10 inches (100, 150, 200, and 250 mm) are included.

7.2.2 For the additional nominal diameters listed for 7.2.1 the inner liner of Type S and SP pipe, and both inner and outer walls of Type D pipe shall have the following minimum thicknesses:

Diameter

Inner Wall Thickness

(inch)

(mm)

(inch)

(mm)

4

100

0.020

0.50

6

150

0.020

0.50

8

200

0.025

0.60

10

250

0.025

0.60

7.4    For the additional nominal diameters listed for 7.2.1 the pipe shall have a minimum pipe stiffness at 5 percent deflection as follows:

Diameter

Pipe Stiffness

(inch)

(mm)

(P/I/I)

(N/m/mm)

4

100

50

340

6

150

50

340

8

200

50

340

10

250

50

340

7.8.5 In addition, couplings for corrugated pipe shall be bell and spigot or bell-bell couplings, or clamp-on bands, for all sizes up to and including 36-inch (900 mm) diameter.

          Couplings for Type D pipe shall be a bell-bell or bell and spigot coupling. The coupling may be welded on one end of each length of pipe by means of a full circumferential weld. Stitch welds are not permitted.

          Couplings for pipe diameters 42 inches (1050 mm) and larger shall be bell-bell or bell and spigot.

11.1.3  In addition, pipe with diameters 4 through 10 inches (100 through 200 mm) inclusive may be marked “AASHTO M252”.

12.1  Only provide materials from manufacturers certified according to Supplement 1066.

707.41  Smooth-Wall Polyvinyl Chloride Underdrain Pipe.             Provide smooth wall perforated and non-perforated PVC plastic pipe and fittings according to ASTM F 758, Type PS 46 minimum, with the following modifications:

7.2.4 Perforated pipe shall have a minimum of four rows of perforations.

Furnish materials according to the Department’s Qualified Products List (QPL).

707.42  Polyvinyl Chloride Corrugated Smooth Interior Pipe.  Provide PVC corrugated smooth interior pipe, joints and fittings according to ASTM F 949, with the following modifications:

5.2.4 Perforated pipe may be specified.

Furnish materials according to the Department’s Qualified Products List (QPL).

707.43  Polyvinyl Chloride Profile Wall Pipe.  Provide PVC open profile wall pipe and fittings with integral bell joints according to ASTM F 794, with the following modifications:

7.2.4 Only molded or fabricated fittings conforming to the requirements of Specification F 794 may be used.

7.5    Ensure a pipe stiffness of 46 or greater.

Furnish materials according to the Department’s Qualified Products List (QPL).

707.45  Polyvinyl Chloride Solid Wall Pipe.  Provide PVC solid wall pipe and fittings with nominal size of 4, 6, 8, 10, 12 and 15-inch (100, 150, 200, 250, 300 and 375 mm) diameter according to ASTM D 3034, SDR 35, with the following modifications:

10.1  The retest provisions do not apply.

Furnish materials according to the Department’s Qualified Products List (QPL).

707.46  Polyvinyl Chloride Drain Waste and Vent Pipe.  Provide PVC drain, waste, and vent pipe and fittings according to ASTM D 2665, with the following modifications.

8.1    The retest provisions do not apply.

Furnish materials according to the Department’s Qualified Products List (QPL).

707.47  ABS and Polyvinyl Chloride Composite Pipe.  Provide ABS and PVC composite pipe and fittings according to ASTM D 2680, with the following modifications.

11.1  The retest provisions do not apply.

13.1  Furnish certified test data as defined in 101.03 to the Engineer.

707.48  Polyvinyl Chloride Large-Diameter Solid Wall Pipe. Provide PVC solid wall pipe and fittings according to ASTM F 679, with the following modifications:

8.1    The retest provisions do not apply.

Furnish materials according to the Department’s Qualified Products List (QPL).

707.51  ABS Drain Waste and Vent Pipe.  Provide ABS schedule 40 plastic drain, waste and vent pipe and fittings according to ASTM D 2661, with the following modifications:

6.4.1 Perform inspection at the project site.

9.18.1  The retest provisions do not apply.

10.1  Furnish certified test data as defined in 101.03 to the Engineer.

707.52  ABS Sewer Pipe.  Provide ABS sewer pipe and fittings according to ASTM D 2751, with the following modifications:

9.1    Perform inspection at the project site.

10.1  The retest provisions do not apply.

11.1  Furnish certified test data as defined in 101.03 to the Engineer.

707.62  Polypropylene Corrugated Single Wall Pipe. Provide polypropylene corrugated single wall pipe for storm sewer pipe from 6 to 30-inch diameters according to ASTM F 2736, with the following modification.

9.1    Provide a letter of certification to cover each shipment of material verifying that it meets specification requirements.

707.65  Polypropylene Corrugated Double Wall Pipe. Provide poly propylene corrugated double wall pipe for non-pressure sanitary sewer and storm sewer pipe from 6 to 30-inch diameters according to ASTM F 2736 and storm sewer pipe from 36 to 60-inch diameters according to ASTM F 2881 with the following modification.

9.1    Provide a letter of certification to cover each shipment of material verifying that it meets specification requirements.

707.69  Polypropylene Triple Wall Pipe. Provide polypropylene triple wall pipe and fittings for non-pressure sanitary sewer and storm sewer pipe from 30 to 60-inch diameters according to ASTM F 2764, with the following modification.

10.1  Provide a letter of certification to cover each shipment of material verifying that it meets specification requirements.

707.70  Welded and Seamless Steel Pipe.  Provide welded and seamless steel pipe according to ASTM A 53 or ASTM A 139/A 139M, Grade B, with the following modifications:

20.1  Perform inspection at the project site.  Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory.

Furnish materials according to the Department’s Qualified Products List (QPL).

708  PAINT

708.01  Inorganic Zinc Silicate Primer Paint.  Provide inorganic zinc silicate primer paint conforming to AASHTO M 300, Type I, and the following modification:

5.1  A green colorant approximately No. 34159 of FS 595C.

Follow the submittal requirements of Supplement 1084 to obtain approval of materials conforming to this specification.

 Once the Director approves the paint, the Department will not require further performance testing by the manufacturer unless the formulation or manufacturing process has been changed, in which case the Department will require new certified test results.

Furnish materials certified according to S 1084 and listed on  the Department’s Qualified Products List (QPL)

708.02  OZEU Structural Steel Paint.  This specification covers the formulation and testing of a three-coat structural steel paint system consisting of an organic zinc prime coat, an epoxy intermediate coat, and a urethane finish coat (OZEU).  Material requirements for the respective coats are as follows:

A.      General.  For each lot of all coatings, furnish a coated card (Drawdown card) that shows the color, gloss, and general appearance of the material covered by the lot.  Use a minimum card size of 3-inches by 5-inches.  The color must match the color card furnished for the Contract or order within visual limits determined by the Engineer.  In case of disagreement, provide test data according to ASTM D 2244 showing a color difference of no greater than 2.0,  ΔE* (CIE 1976 L*a*b*).

B.      Organic Zinc Prime Coat.  Provide an organic zinc prime coat consisting of a zinc dust filled, two or three-component epoxy polyamide, and selected additives as required.  The coating shall also meet the following:

1.      Physical Requirements.

a.      Total solids, % by weight of paint, ASTM D 2369.  70 percent minimum.

b.      Pigment, % by weight of total solids, ASTM D 2371. 83 percent minimum.

c.      Total zinc dust, % by weight of pigment. ASTM D 521. 93 percent minimum.

d.      Total zinc, % by weight of total solids (by calculation) ASTM D 521.  77 percent minimum.

e.      Total solids, % by volume, ASTM D 2697.  45 percent minimum.

f.       Color.  Greenish gray, approximating FS-595C-34159, visual comparison.

g.      Pot life.  SSPC-Paint 22, Section 5.5 with the following exception: 6 hours minimum at 77+/-3 °F (25+/-2 °C)  with no evidence of gellation.  The coating will be in a free-flowing condition and easily sprayed.

2.      Qualitative Requirements.

a.      Mixing.  Section 6.1, SSPC-Paint 20 using only a high shear (Jiffy) mixer.

b.      Storage Life.  Section 6.3, SSPC-Paint 20.

c.      Mudcracking.  Section 7.1, SSPC-Paint 20.

3.      Material Quality Assurance.  Analysis for each component.

Material Quality Assurance will conform to the requirements of Supplement 1084.

C.      Epoxy Intermediate Coat.  Provide a two-part epoxy intermediate coat composed of a base component and curing agent suitable for application over the zinc rich primer.

The base component shall contain an epoxy resin together with color pigments, mineral fillers, gellant, leveling agent, and volatile solvents.  The curing agent component will contain a liquid polyamide resin and volatile solvent.  The coating shall also meet the following:

1.      Physical Requirements.

a.      Color.  White, meeting or exceeding, FS-595C-37875 according to ASTM E 1347.

b.      Components.  Two, mixed before application.

c.      Volume solids, ASTM D 2697.  50 percent minimum.

                   d.      Pot life.  SSPC-Paint 22, Section 5.5 with the following exception: 6 hours minimum at 77+/-3 °F (25+/-2 °C)  with no evidence of gellation.  The coating shall be in a free-flowing condition and easily sprayed

e.      Curing time.

(1)     Set-to-touch, ASTM D 1640.  4 hours, maximum at 77 °F (25 °C).

(2)     Dry-to-recoat, ASTM D 1640.  24 hours, maximum at 77 °F (25 °C).

(3)     Full cure.  7 days, maximum at 50 °F (10 °C).

No pick-up when rubbed with a cloth soaked in Methyl Ethyl Ketone.

f.       Fineness of grind, ASTM D 1210.  Hegman 3 minimum.

g.      Volatile Organic Compounds (VOC), maximum, ASTM D 3960.  2.83 lb/gal(340 g/L), as applied.

2.      Material Quality Assurance.  Material Quality Assurance will conform to the requirements of Supplement 1084.

D.      Urethane Finish Coat.  Provide a two-component urethane finish coat composed of a polyester and/or acrylic aliphatic urethane and suitable for use as a finish coat over the white epoxy polyamide intermediate coat.  The coating shall also meet the following:

1.      Physical Requirements.

a.      Finish, Specular gloss, ASTM D 523. Use Fed. Std. 595C-16440 Gray: 70 % minimum after 3000 hours weathering resistance.  Color change less than 2.0 ΔE*, (C.I.E 1976 L*a*b*) ASTM D2244.

b.      Volume solids, ASTM D 2697.  42 percent minimum.

c.      Curing time, at 77 °F (25 °C) and 50% RH.  Set-to-touch, ASTM D 1640:  30 minutes, minimum; 4 hours, maximum.

d.      Pot life.  SSPC-Paint 22, Section 5.5 with the following exception: 4 hours minimum at 77+/-3 °F (25+/-2 °C)  with no evidence of gellation.  The coating shall be in a free-flowing condition and easily sprayed

e.      Volatile Organic Compounds (VOC), maximum, ASTM D 3960.  2.83 lb/gal(340 g/L), as applied.

f.       Colors.

(1)     Specified.[2]

Brown

FS-595C, 10324

Green

FS-595C, 14277

Blue

FS-595C, 15526

[2]  Contractor’s choice unless specified on plans

(2)     Elective. As specified on the plans.

g.      Gloss requirements, ASTM D 523.

Full gloss

minimum 80% unless specified on the plans

Semi-gloss

30 to 45%

Lusterless (Matte)

maximum 6%

2.      Material Quality Assurance.  Material Quality Assurance will conform to the requirements of Supplement 1084.

Performance Requirements.  Test the coating system, which consists of the organic zinc prime coat, the epoxy intermediate coat, and the urethane topcoat, prior to use.

Prepare three panels for each of the specified tests according to ASTM D 609, except provide a minimum thickness of 1/8 inch (3 mm) and use ASTM A 36/A 36M hot rolled steel.  Blast clean (using coal slag abrasive) the surface to equal, as nearly as is practical, the standard Sa 2 1/2 of ASTM D 2200 (Steel Structures Painting Council SSPC-SP10 meets this requirement).  Ensure that the surface has a nominal height of profile of 1 to 3.5 mils (25 to 88 mm) verified by using appropriate replica tape.  Coat and cure the panels according to the manufacturer’s printed instructions.  Provide a dry film coating thickness for the system to be tested as follows:

Organic Zinc:

3.0 to 5.0 mils (75 to 125 mm)

Epoxy:

5.0 to 7.0 mils (125 to 175 mm)

Urethane:

2.0 to 4.0 mils (50 to 100 mm)

The coating system shall pass each of the following tests:

A.      Fresh Water Resistance Test (ASTM D 870).  Scribe the panels according to ASTM D 1654 to the depth of the base metal in the form of an “X” having at least 2-inch (50 mm) legs, and immerse panels in fresh tap water at 75 ± 5 °F (25 ± 3 °C).  After 30 days of immersion, examine the panels to verify that they show no rusting and that the coating shows no blistering, softening, or discoloration.  Rate blistering according to ASTM D 714.

B.      Salt Water Resistance Test (ASTM D 870).  Scribe the panels as specified in “A” above, and immersed panels in a water solution of 5 percent sodium chloride at 75 ± 5 °F (25 ± 3 °C).  After 7, 14, and 30 days of immersion, examine the panels to verify that they show no rusting and that the coating shows no blistering or softening.  Rate blistering according to ASTM D 714.  Replace the sodium chloride solution with a fresh solution after examination at 7 and 14 days.

C.      Weathering Resistance Test.  Test the panels according ASTM D 4587, Method D, using Ultra Violet A 340 bulbs.  Place the panels on test at the beginning of a wet cycle.  After 3000 hours of continuous exposure, examine the panels to verify that they show no rusting and that the coating shows no blistering or loss of adhesion.  Perform the 60 degree specular gloss measurements on the sprayed panels utilized for this test.  Average the three initial measurements (one per panel) together.  Also, average the three final measurements together.

D.      Salt Fog Resistance Test.  Scribe the panels as specified in “A” above, and test them according to ASTM B 117.  After 3000 hours of continuous exposure, examine the coating to verify that it shows no loss of bond and that it shows no rusting or blistering beyond 1/16 inch (2 mm) from the center of the scribe mark.  Rate blistering according to ASTM D 714.

E.      Adhesion Test, ASTM D 4541 Type IV.  Test the panels according to the following:

1.      Lightly sand the coating surface and aluminum dolly, and apply a quick set adhesive.

2.      Allow adhesive to cure overnight.

3.      Scribe the coating and adhesive around the dolly before testing.

4.      Make a minimum of 4 trials to failure, and report the 4 trials.  Ensure that each trial is greater than 400 pounds per square inch (2.8 MPa).  Reject trial if fracture at the primer-blast interface occurs.

Prequalification.  Before approval, submit copies of the manufacturer’s certified test data showing that the coating system complies with the performance requirements of this specification to the Laboratory  Ensure that the certified test data also states the following physical properties for each coating:  Density, pounds per gallon (g/mL); Solids, percent by weight; Solids, percent by volume; Viscosity; Drying time; and VOC content, pounds per gallon (g/mL).

Use an independent testing laboratory, approved by the Laboratory, to develop the test data.  Include with the test data the brand name of the paint, name of manufacturer, number of lots tested, and date of manufacture.

Once the Director approves the coating, the Department will not require further performance testing by the manufacturer unless the formulation or manufacturing process has been changed, in which case the Department will require new certified test results.

Sampling.  The Laboratory will establish acceptance variances.

Furnish materials certified according to S 1084 and listed on  the Department’s Qualified Products List (QPL).

709  REINFORCING STEEL

709.00  Epoxy Coated Reinforcing Steel.  Provide epoxy coated reinforcing steel according to ASTM A 775/A 775M, with the following modifications:

5.1  Ensure that steel reinforcing bars to be coated conform to 709.01, 709.03, or 709.05, and are free of oil, grease, or paint.

5.2  Ensure that the coating material meets the requirements listed in Annex A1 and is a color that facilitates inspection of the installed bar.  The color is subject to approval of the Director.

5.3  Sample required.

8.3.1  Evaluate the adhesion of the coating by bending production coated bars around a mandrel of specified size according to the bending tables in ASTM A 615 (ASTM A 615M) or ASTM A 996 (ASTM A 996M) as applicable.  Perform the bend test for adhesion of the coating at a uniform rate, and ensure that it takes up to 90 seconds to complete.  Place the two longitudinal deformations in a plane perpendicular to the mandrel radius, and ensure that the test specimens are at thermal equilibrium between 68 and 86 °F (20 and 30 °C).

12.1  Perform tests, inspection, and sampling at a site specified by the Director.  Sampling for testing requires three 30-inch (1 m) samples for each bar size, for each coating lot, and for each heat of steel reinforcing bars.

14.1  Report of test results required. 

Where reinforcing bar cages for prestressed concrete beams are fabricated by tack welding, patch the areas damaged by the tack welding according to ASTM A 775, Section 11, permissible Amount of Damaged Coating and Repair of Damaged Coating.

709.01  Deformed and Plain Billet Steel Bars for Concrete Reinforcement.  Provide deformed and plain billet steel bars for concrete reinforcement according to ASTM A 615 (ASTM A 615M), with the following modification:

13.1  Where positive identification of a heat can be made, perform one tension test and one bend test from each bar designation number of each heat in the Lot.  Where identification of the heat is not practical, perform one tension test and one bend test for each bar designation number in each lot of 10 tons (10 metric tons) or fraction thereof.

Furnish certified material according to Supplement 1068.

709.03  Rail Steel Deformed and Plain Bars for Concrete Reinforcement.  Provide rail steel deformed and plain bars for concrete reinforcement according to ASTM A 996/A 996M.

Furnish certified material according to Supplement 1068.

709.05  Axle Steel Deformed and Plain Bars for Concrete Reinforcement.  Provide axle steel deformed and plain bars for concrete reinforcement according to ASTM A 996/A 996M.

Furnish certified material according to Supplement 1068.

709.08  Cold-Drawn Steel Wire for Concrete Reinforcement.   Provide cold drawn steel wire for concrete reinforcement according to ASTM A 82 or ASTM A 1064, with the following modification:

7.2  Completely cover galvanized wire with a coating of pure zinc of uniform thickness, so applied that it will adhere firmly to the surface of the wire.  Ensure that the minimum weight of zinc coating is 0.8 ounces per square foot (244 g/m²) of surface as determined by ASTM A 90.

Furnish certified material according to Supplement 1068.

709.09  Fabricated Steel Bar or Rod Mats for Concrete Reinforcement.  Provide fabricated steel bar or rod mats for concrete reinforcement according to ASTM A 184/A 184M, with the following modifications:

4  Use deformed bars.

4.1  Provide longitudinal bars conforming to Grade 60 of 709.01, 709.03, or 709.05.

4.2  Provide longitudinal bars according to 709.01, Grade 60.  Provide transverse bars according to 709.01.

Furnish certified material according to Supplement 1068.

709.10  Welded Steel Wire Fabric For Concrete Reinforcement.   Provide welded steel wire fabric for concrete reinforcement according to ASTM A 185 or ASTM A 1064.

Furnish certified material according to Supplement 1068.

709.11  Deformed Steel Wire for Concrete Reinforcement.   Provide deformed steel wire  for concrete reinforcement according to ASTM A 496 or ASTM A 1064.

Furnish certified material according to Supplement 1068.

709.12  Welded Deformed Steel Wire Fabric for Concrete Reinforcement.   Provide welded deformed steel wire fabric for concrete reinforcement according to ASTM A 497 or ASTM A 1064.

Furnish certified material according to Supplement 1068.

709.13  Coated Dowel Bars.  Provide coated dowel bars according to AASHTO M 254, with the following modifications:

4.1  The core material will consist of steel according to 709.01, 709.03, or 709.05.

Coat all surfaces of dowel bars. Suitably re-coat ends of dowel bars that have been cut to length after coating or have not had the uncoated ends coated during manufacturing or fabrication. Prepare surface and patch uncoated bar ends with material equivalent to the original epoxy coating.

If the Contractor elects to use basket supports for positioning of the above dowel bars as specified in 451.08.B or as shown on the plans, provide a fusion-bonded epoxy coated basket dowel bar assembly.  Repair uncoated areas with surface preparation and patching material equivalent to the original epoxy coating.

Suitably repair coating on the dowel bars or baskets damaged during installation.

Do not expose coated dowels to weather or sunlight for a period exceeding 180 days.

Furnish certified material according to Supplement 1068.

709.14  Epoxy-Coated Steel Wire and Welded Wire Fabric for Reinforcement.  Provide epoxy coated steel wire and welded wire fabric for reinforcement according to ASTM A 884, with the following modifications:

5.1  Ensure that plain or deformed steel wire or welded wire fabric to be coated conform to 709.08, 709.10, 709.11, or 709.12, and is free of oil, grease, or paint.

8.1  Ensure that the coating thickness conforms to Type A.  Provide dry film thickness of 5 to 12 mils (0.13 to 0.31 mm).

8.4  Test coated steel wire or welded wire fabric at the manufacturer’s plant before shipment or at other sites as designated by the Laboratory.

Furnish certified material according to Supplement 1068.

709.15  Plastic Supports for Reinforcing Steel.  Conform to Supplement 1125.

709.16  Galvanized Reinforcing Steel Option for Bridge Structure Spirals.   As an option to 709.00 provide galvanized reinforcing steel for the spiral bars only in round column and drilled shaft reinforcing steel cages.  Galvanized steel will conform to ASTM A767, Class 1. The galvanized coated reinforcing steel will meet all other requirements of 509.

The galvanized coating will be applied after the reinforcing has been fabricated. If the galvanized surface becomes damaged during handling in the field, repairs will conform to ASTM A780.

Where a sample is requested, provide a replacement splice conforming to the lap length requirements for epoxy coated reinforcing.

Furnish certified material according to Supplement 1068.

710  FENCE AND GUARDRAIL

710.01  Barbed Wire.  Furnish barbed wire according to ASTM A 121, Type Z, Class 3 Galvanizing, or ASTM A 585, Type I, with the following modifications:

A.      ASTM A 121, Type Z, Class 3.

6.3.1  Ensure that the weight of coating for various gages of wire composing the strands and barbs are not less than  0.80 ounces per square foot (244 g/m²) of surface.

7.1  Furnish No. 12 1/2, 13 1/2 or 15 1/2 steel wire gage barbed wire.  Ensure that the barbs are four point round steel wire spaced 5 inches (130 mm) center-to-center.

9.1  Select one sample, according to Section 9.2, from each 50 spools or fraction thereof.

11.1  Perform inspection at the project site. 

Furnish certified material according to Supplement 1067.

B.      ASTM A 585, Type I.

12.3  Does not apply.

14.1  Perform inspection at the project site.

Furnish certified material according to Supplement 1067.

710.02  Woven Steel Wire Fence, Type 47.  Furnish woven steel wire fence according to ASTM A 116, Type Z, Class 3 galvanizing, with the following modifications:

7.1  Ensure that the fence fabric is design number 1047-6.9.

11.1  Perform inspection at the project site.

In addition, ensure that all hardware and attachments are galvanized according to 711.02.

Furnish certified material according to Supplement 1067.

710.03  Chain-Link Fence.  Furnish chain-link fence according to AASHTO M 181, with the following modifications:

3.1  Furnish posts, gate frames, and post braces, made of Type I or Type III material.  Furnish Type I material conforming to the requirements of Table 710.03-1.  Furnish Type III material conforming to the requirements of Table 710.03-2.

          Fasten the fabric to the posts using either aluminum alloy or galvanized steel bands or wires.  Furnish wires that have a 0.148-inch (3.7 mm) minimum diameter and a zinc coating or steel fasteners that are not less than 0.8 ounces per square foot (244 g/m²).

          Furnish stretcher bars that have a 3/4 ´ 3/16-inch (19 ´ 5 mm) cross-section or an equivalent cross-section with a length equal to full height of fabric.

          Furnish steel truss rods that have a steel 3/8-inch (9.5 mm) diameter or equivalent cross-section and that have suitable adjustment.

TABLE 710.03-1  STEEL POSTS, GATE FRAMES, And POST BRACES,

Usage –

nominal

fence height

6 ft or less

Section

Thickness

Outside

Diameter or

Dimensions

(in)

Weight

Nominal

lb/ft

Tolerance

(+/- %)

Minimum

Yield

Strength

(psi)

Line posts

Grade 1 Pipe

2.375

3.65

10

30,000

Grade 2 Pipe

2.375

3.12

10

50,000

C-Section

2.250 ´ 1.700

2.78

10

50,000

H-Section

2.250 ´ 1.700

3.26

10

50,000

End, corner pull posts

Grade 1 Pipe

2.875

5.79

10

30,000

Grade 2 Pipe

2.875

4.64

10

50,000

Gate Posts, for nominal width of gate (single or one leaf of Double):

Up to 6 ft incl.

Grade 1 Pipe

2.875

5.79

10

30,000

Grade 2 Pipe

2.875

4.64

10

50,000

Over 6 to 13 ft incl.

Grade 1 Pipe

4.000

9.11

10

30,000

Grade 2 Pipe

4.000

6.56

10

50,000

Over 13 to 18 feet incl.

Grade 1 Pipe

6.625

18.97

10

30,000

Over 18 feet

Round

8.625

28.58

10

30,000

Gate frames

Grade 1 Pipe

1.900

2.72

10

30,000

Grade 2 Pipe

1.900

2.28

10

50,000

Tension Wire,[1] post braces

Grade 1 Pipe

1.660

2.27

10

30,000

Grade 2 Pipe

1.660

1.84

10

50,000

Roll-form

1.6250 ´ 1.250

1.35

10

50,000

Round tubing

1.660

1.38

10

50,000

[1]   When tension wire is specified, it will be of 0.177 in diameter.

TABLE 710.03-1M  STEEL POSTS, GATE FRAMES, And POST BRACES,

Usage – nominal fence height 1.8 m or less

Section

Thickness

Outside Diameter or Dimensions

(mm)

Weight

Nominal

(kg/m)

Minimum

Tolerance

(+/- %)

Yield

Strength

(MPa)

Line posts

Grade 1 Pipe

60

5.4

10

209

Grade 2 Pipe

60

4.6

10

345

C-Section

57 ´ 43

4.1

10

345

H-Section

57 ´ 43

4.9

10

345

End, corner pull posts

Grade 1 Pipe

73

8.6

10

209

Grade 2 Pipe

73.00

6.9

10

345

Gate Posts, for nominal width of gate (single or one leaf of Double):

Up to 1.8 m incl

Grade 1 Pipe

73.00

8.6

10

209

Grade 2 Pipe

73.00

6.9

10

345

Over 1.8 to 4 m incl.

Grade 1 Pipe

102.00

13.6

10

209

Grade 2 Pipe

102.00

9.8

10

345

Over 4 to 5.5 m incl.

Grade 1 Pipe

168.00

28.2

10

209

Over 5.5 m

Round

219

42.5

10

209

Gate frames

Grade 1 Pipe

48

4.0

10

209

Grade 2 Pipe

48

3.4

10

345

Tension Wires,[1]

   post braces

Grade 1 Pipe

42

3.4

10

209

Grade 2 Pipe

42

2.7

10

345

Roll-form

41 ´ 32

2.0

10

345

Round tubing

42

2.1

10

345

[1]   When tension wire is specified, it will be of 4.5 mm diameter.

Furnish ornamental cap post tops made of steel, malleable iron or cast iron.  Furnish them with a hole suitable for through passage of the top rail.  Ensure that they fit snugly to the post, have a means of attaching securely to the post, and exclude moisture from tubular posts. Furnish swing type gates complete with latches, stops, keepers, hinges, locks, and fabric.  Cover them with fabric matching the fence.  Furnish hinges of adequate strength to support the gate and that do not twist or turn under action of the gate.  Locate plunger bar type latches at the full gate height in a manner that will engage the gate stop.  Forked latches may be used for single gates less than 10 feet (3 m) wide.  Furnish lockable latches.  Furnish stops that consist of a flush plate with anchor placed in concrete to engage the plunger bar of the latch.  Other approved types of stops may be used for single gates less than (10 feet) 3 m wide.  Keepers are substantial devices for securing and supporting the free end of the gate in open position.

          Furnish top rail couplings consisting of the outside sleeve type at least 6 inches (150 mm) long.  Ensure that a minimum of 20 percent of the coupling has an internal heavy spring to take up expansion and contraction.

          Furnish gate frames that are assembled by welding, using properly designed, formed sheet, or sandcast fittings.  Cover the gates with fabric matching the fence.

          Furnish offset type hinges.  Furnish galvanized latches, stops, and keepers made of malleable iron, except for plunger bars that may be galvanized tubular or bar steel according to Section 6.2.

          Furnish flat stretcher bars in 3/4 ´ 1/4-inch (19 ´ 6 mm) sections.

          Furnish self-centering outside rail couplings that are 6 inches (150 mm) long.

          Furnish tie wire that has a 0.148-inch (3.7 mm) minimum diameter and that meets an aluminum alloy.

          Furnish wrought or cast turnbuckles.

          Furnish truss and brace rods with an 3/8-inch (9.5 mm) outside diameter or equivalent cross-section.

          Furnish beveled brace bands in 1 ´ 1/8-inch (25 ´ 3 mm) section.

          Furnish bolts with an anodic coating at least 2 mil (5 mm) in thickness, chromate sealed.

11.1.  Ensure that the size of the fabric conforms to 0.148-inch (3.7 mm) nominal diameter of coated wire, 2-inch (50 mm) mesh.

14.1  Table 8.  Type I Zinc-Coated Steel Chain Link Fabric will have Class D weight of coating.

15.5  Ensure that the vinyl covering is of a uniform medium green color.

19.1  Perform inspection at the project site. 

32.2  Does not apply.

32.3.3.2.  Increase the minimum weight of interior coating to an average of 0.9 ounces per square foot (275 g/m²) and not less than 0.8 ounces per square foot (244 g/m²) on an individual specimen.

TABLE 710.03-2  DIAMETERS OR PLAIN END, SCHEDULE 40 ALUMINUM ALLOY PIPE

The weights and dimensions are as specified in ANSI H 35.2.

Nominal Pipe Size

Material

(in)

(mm)

Brace rails

1 1/4

32

Gate frames and rail couplings

1 1/2

40

Line posts

2

50

End and corner posts

2 1/2

65

Gate posts single or one leaf of double:

Gate opening

(ft)

(m)

(in)

(mm)

To 6

To 1.8

2 1/2

65

Over 6 to 12

Over 1.8 to 3.7

3 1/2

90

Over12 to 18

Over 3.7 to 5.5

6

150

Over 18 to 32

Over 5.5 to 9.8

8

200

A 8'-8" line post may be substituted in lieu of the line post shown on standard drawings Chain Link Fence 1.1, 7-28-00 and Walk Gates F-3.2, 7-28-00.  This will be accomplished by reducing the 4'-0" depth as necessary to accommodate the shorter posts. All other dimensions shown in the standard drawings shall remain unchanged

Furnish certified material according to Supplement 1067.

710.06  Deep Beam Rail.  Furnish deep beam rail according to AASHTO M 180, Type II, Class A, with the following modifications:

5.1  Perform inspection at the project site.

5.2.1  When a field check of coating thickness shows insufficient coating thickness or shows insufficient coating weight, sample and test the guardrail.

9.1.2  The minimum check limits for both triple and single-spot tests apply.

Furnish certified material according to Supplement 1042.

710.09  Wire Rope Rail.  Furnish wire rope rail according to AASHTO M 30, Class A, Type I rope, with the following modification:

9  Perform inspection at the project site. 

Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory.

710.11  Fence Posts and Braces.  Furnish round wood posts conforming to 710.12 and 710.14.  Furnish dimension timber, posts, and lumber for braces and stream crossings that are sound, straight, free from unsound or loose knots, splits and shakes, and that are treated according to 712.06.

Furnish steel line posts according to ASTM A 702, with the following modifications:

5.6.2  Furnish fasteners or clamps that have a 0.120-inch (3 mm) diameter and that are galvanized according to ASTM A 116, Type Z, Class 3.

5.6.1  Supply each post with a sufficient number of fasteners or clamps.

6.2  Ensure that the post lengths are as designated.

7.1  Furnish galvanized line posts and anchors according to 711.02.

7.2  Delete.

9.  Perform sampling according to 712.06.

Furnish certified material according to Supplement 1067.

710.12  Square-Sawed and Round Guardrail Posts.  Furnish pressure treated square-sawed and round guardrail posts according to 710.14 and 712.06.  Cut posts from growing timbers that are free from unsound or loose knots and rot and from injurious or excessive shake, and season checks that exceed 1/4 inch (6 mm) in width.

  Ensure that the sweep does not exceed 1 inch (25 mm) for the length of the post.  Peel round posts their entire length, removing all outer and inner bark and leather fiber by shaving the surface.  Trim knots even with the post, and saw both ends of the post square.

Furnish round posts for the follow species only:

Douglas Fir:
Knot diameter for posts of Douglas Fir shall not exceed 51 mm (2 in.). Ring density for the species shall be at least 6 rings-per-inch as measured over a 76 mm (3 in.) distance. The diameter of the Douglas Fir posts shall be 184 mm (7¼ in.) at the ground line with a upper limit of 203 mm (8 in.).

Southern Pine:
Knot diameter for posts of Southern Pine shall not exceed 64 mm (2½ in.). Ring density for the species shall be at least 4 rings-per-inch as measured over a 76 mm (3 in.) distance. The diameter of the Southern Pine posts shall be 190 mm (7½ in.) at the ground line with a upper limit of 210 mm (8¼ in).

Ponderosa Pine:
Knot diameter for posts of Ponderosa Pine shall not exceed 102 mm (4 in.). Ring density for the species shall be at least 6 rings-per-inch as measured over a 76 mm (3 in.) distance. The diameter of the Ponderosa Pine posts shall be 203 mm (8 in.) at the ground line with an upper limit of 222 mm (8¾ in.).

Furnish square sawed posts that are free from injurious cross grain and sapwood. 

Species

White Pine

Maximum Slope of Grain

1 in 15

Nominal Width of Face

6" [152]

8" [203]

Shakes,
Checks,
and Splits

Green

1" [25]

1 3/8" [35]

Seasoned

1 1/2" [38]

2" [51]

Maximum Wane

1" [25]

1 3/8" [35]

Maximum Allowable

Knots

Narrow Face

Middle 1/3 of Length

1 3/8" [35]

1 5/8" [41]

End (1)

2 3/4" [70]

3 1/4" [83]

Sum in Middle ½ of Length (2)

11" [279]

13" [330]

Wide Face

Edge Knot in Middle 1/3 of Length

1 3/8" [35]

1 5/8" [41]

Edge Knot at End (1)

2 3/4" [70]

3 1/4" [83]

Centerline

1 3/8" [35]

1 7/8" [48]

Sum in Middle Half of Length

5 1/2" [140]

7 1/2" [190]

Furnish certified material according to Supplement 1072.

710.14  Pressure Treated Guardrail and Fence Posts, Braces, and Blocks.  Furnish pressure treated guardrail and fence posts, braces, and blocks according to AASHTO M 168 and 710.11, 710.12, and 712.06.

Furnish certified material according to Supplements 1042 and 1072.

710.15  Steel Guardrail Posts.  Furnish steel guardrail posts in the sections and lengths as specified.  Ensure that they are made of copper bearing steel when so specified.  Furnish steel according to ASTM A 36/A 36M.  Furnish galvanized posts according to 711.02.

Furnish certified material according to Supplements 1042.

710.16  Guard Posts.  Furnish pressure treated wood posts according to 710.14 Furnish posts that are either 5 ´ 6-inch (125 ´ 150 mm) sawed square or 5 1/2-inch + 1/2-inch (138 mm) diameter round when measured 30 inches (0.75 m) from the top.  Furnish posts that are 5 feet, 3 inches (1.6 m) in length and are embedded such that 30 inches (0.75 m) remains exposed.  Ensure that the center-to-center spacing is spaced at 6 feet (1.8 m) intervals, unless otherwise shown on the plans.

Furnish certified material according to Supplements 1042.

711  STRUCTURAL STEEL AND STRUCTURE INCIDENTALS

711.01  Structural Steel.  Furnish structural steel conforming to  ASTM A 709, Grade 36 (A36), 50 (A572),  50W (A588), or 70W.

Ensure that materials designated to meet notch toughness requirements have a minimum longitudinal Charpy V-Notch (CVN) energy absorption value as listed below.  Sample and test according to ASTM A 673/A 673M.  Use the (H) frequency of heat testing and provide the test data as required by 501.06.

ASTM Designation

Thickness and
Connection Method

Value Min CVN

A709 Gr. 36 (A36, A36M)

Up to 4 in (102 mm) mechanically fastened or welded

15 ft-lb @ 40 °F

(20 J @ 4 °C)

A709 Gr. 50 (A 572/A 572M),

A709 Gr. 50W (A 588/A 588M)

Up to 4 in (102 mm) mechanically fastened

15 ft-lb @ 40 °F [1]

(20 J @ 4 °C)

A709 Gr. 50 (A 572/A 572M),

A709 Gr. 50W (A 588/A 588M)

Over 2 to 4 in (51 to 102 mm) welded

20 ft-lb @ 40 °F [1]

(20 J @ 4 °C)

A709 Gr. 50 (A 572/A 72M),

A709 Gr. 50W (A 588/A 588M)

Up to 2 in (51 mm) welded

15 ft-lb @ 40 °F [1]

(20 J @ 4 °C)

A709 Gr. 70W

Up to 4 in (100 mm) mechanically fastened or welded

25 ft-lb @ -10 °F [1]

(34 J @ -23 °C)

[1]  If the yield point of the material exceeds 65 ksi (448 MPa), the temperature of the CVN value for acceptability should be reduced by 15 °F (8.3 °C) for each increment, or part of increment, of 10 ksi (69 MPa) above 65 ksi (448 MPa).

711.02  Galvanized Steel.  Furnish galvanize steel according to ASTM A 123 after cutting, bending, and welding.  At the discretion of the Engineer, replace, re-galvanize, or repair damaged galvanized material.  If a repair is authorized, perform work according to ASTM A 780 except the Department will not allow aerosol spray applications of paints containing zinc dust.

Furnish bolts, nuts, washers, and similar threaded fasteners that are galvanized according to ASTM A 153 or F2329.  These items may be mechanically zinc coated according to ASTM B 695, Class 50.  Except for ASTM A 325 (ASTM A 325M) bolts, electrogalvanizing may also be used if the coated item meets the thickness coating requirements of ASTM A 153 or F2329.

711.03  Steel for Piling.  Furnish steel for H-piling conforming to ASTM A 572 Grade 50 / A 572M Grade 345.  Furnish steel for sheet piling according to ASTM A 328/A 328M. Furnish steel for cast-in-place reinforced concrete piles conforming to ASTM A 252, Type 2.

711.04  Cold Rolled Steel.  Furnish cold rolled steel according to ASTM A 108, Grades 1016 through 1030 for pins, rollers, trunnions, and other similar parts.

711.07  Steel Castings.  Furnish steel castings according to ASTM A 27/A 27M, Grade 65-35 or Grade 70-36, or  AASHTO M103, or ASTM A 148, Grade 90-60, with the following modification:

Ensure that steel castings are free from pouring faults, sponginess, cracks, blow holes, and other defects in positions affecting their strength and value for the service intended.  No sharp, unfilleted angles or corners are allowed.

711.08  Arc-Welding Electrodes and Fluxes.  The following applies to all steel, except for exposed bare ASTM A 242/A 242M and ASTM A709 Grade 50W (A 588/A 588M) steels.  For exposed bare ASTM A 242/A 242M and A709 Grade 50W (A 588/A 588M) applications, see Table 711.08-1.

A.      Manual shielded metal-arc welding.

1.      AWS A5.1 Low Hydrogen Only

2.      AWS A5.5 Low Hydrogen Only

B.        Submerged Arc Welding

1.      AWS 5.17⁵

2.      AWS 5.23⁵

C.      Gas metal-arc welding,   AWS A 5.18⁵

D.      Flux cored arc welding, AWS A5.20⁵

Table 711.08-1

Filler metal requirements for exposed bare applications of

ASTM A 242/A 242M and ASTM A709 Grade 50W (A 588/A 588M) steel.

Welding Process

Shielded metal arc

Submerged arc [5]

Gas metal arc or

Flux cored arc [2],[4], [5]

AWS A5.5

AWS A5.23

AWS A5.28 and 5.29

E8015, 8016, or 8018 electrodes that deposit weld metal meeting C1, C1L, C2, C2L, C3, or W analysis

All electrode-flux combinations that deposit weld metal with a Ni1, Ni2, Ni3, Ni4, or W analysis  [2],[3]

All electrode-flux combinations that deposit weld metal with a Ni1, Ni2, Ni3, Ni4, or W analysis

[2]  Deposited weld metal will have a minimum impact strength of CVN 20 ft-lb (27 J) at 0 °F (-18 °C) (only applied to bridges).

[3]  The use of the same type filler metal having next higher mechanical properties as listed in AWS specification is permitted.

[4]  Deposited weld metal will have a chemical composition the same as that for any one of the weld metals in this table for the shielded metal arc welding process.

[5]  In conformance with those classifications allowed under AWS D1.5 Bridge Welding Code, Tables 4.1 and 4.2.

The Laboratory will issue a list of approved electrodes and combinations of shielding.  The Laboratory will include electrodes in the list when certified test data submitted by the manufacturer is found in compliance with the specified requirements.  The certification will cover either process qualification or quality control tests.  To qualify, such tests must be made within one year before the period covered.  For each submission of certified test data, include the manufacturer’s statement that it will advise the Laboratory immediately of any change in materials or processing used in the manufacture of the electrodes made within one year from the date of the tests.

When electrodes to be used are not included in the Laboratory’s list of approved electrodes and combinations of shielding, submit certified test data as described above for each lot showing compliance with the specified requirements.

711.09  High-Strength Steel Bolts, Nuts, and Washers.  Furnish high-strength steel bolts, nuts, and washers according to ASTM A 325 (ASTM A 325M), with the following modification:

11  If necessary for approval, obtain samples from material delivered to the project site or at other locations designated by the Laboratory.

Furnish bolts for steel use in bare unpainted applications according to A 325 (A 325M), Type 3.

When galvanized bolts, nuts, and washers are specified, mechanical galvanizing is permitted.

Use galvanized bolts to fasten steel that has received an inorganic zinc prime coat according to 514.

Furnish high-strength steel bolts, nuts, and washers that also meet the requirements of Supplement 1080.

Provide samples to the Laboratory for acceptance.

711.10  Machine Bolts.  Furnish machine bolts according to ASTM A 307, with the following modification:

If necessary for approval, obtain samples from material delivered to the project site or at other locations designated by the Laboratory.

Mechanical galvanizing is permitted.

711.12  Gray Iron Castings.  Furnish gray iron casting according to ASTM A 48, Class 30B, with the following modifications:

12  Two or more test bars will accompany each lot of castings or; one pair of test bars may represent castings shipped to two or more projects provided the lot number or date cast are cast or anchored in both the bars and castings.  The identifying data or castings shall not interfere with the use of the casting.

9  In addition, ensure that castings are free from pouring faults, sponginess, cracks, blow holes, and other defects in positions affecting their strength and value for the service intended.  Ensure that the castings are generously filleted at angles and the arrises are sharp and perfect.

17  Ship test bars with the lot or make test bars representing the lot available to the Laboratory at the place of manufacture or warehouse.

711.13  Ductile Iron Castings.  Furnish ductile iron castings according to ASTM A 536, with the following modifications:

8.1  In addition, ensure that castings are free from pouring faults, sponginess, cracks, blowholes, and other defects in positions affecting their strength.  Ensure that the castings are generously filleted at angles and arrises are sharp and perfect.

10.1  Send a keel block or Y-block specimen made according to ASTM A 536 with the shipment for each heat number, ladle number, and date of casting.

14.1  Submit a certification stating that the test bars shipped with the castings were prepared according to the specified requirements.

711.14  Gray Iron and Ductile Iron Castings.  Furnish gray iron and ductile iron castings according to AASHTO M 306, Class 35B, with the following modifications:

Test bars are required as outlined in 711.12 and 711.13.  In addition, submit certified test data for monthly proof load testing to the Laboratory with each inspection of castings from that month.

Design Approval.  Submit designs for cast frames, grates and covers for manholes, catch basins and inlets that vary from the standard construction drawings to the Department for approval.  Manufacturers will seek approval for such non-standard designs well in advance of a projects sale date.

711.15  Sheet Copper.  Furnish sheet copper according to ASTM B 370.

711.16  Phosphor Bronze Plate.  Furnish phosphor bronze plate according to ASTM B 100.

711.17  Cast Bronze.  Furnish cast bronze according to ASTM B 22, Copper Alloy No. C91100, with the following modification:

Finish cast plates to plane surfaces and finish one plate of a pair at right angles to the other plate of the pair.

711.18  Leaded Bronze.  Furnish leaded bronze according to ASTM B 584, Copper Alloy No. C93700, with the following modification:

Finish cast plates to plane surfaces and finish one plate of a pair at right angles to the other plate of the pair.

711.19  Sheet Lead.  Furnish sheet lead according to ASTM B 29.

711.20  Aluminum for Railings.  Furnish aluminum other than permanent mold castings that conform to the following requirements:

Portion of Railing

ASTM Designation

Alloy

Condition or

Temper (B296)

Sand castings

B 26/B 26M

356.0

T6

Shims

B 209 (B 209M)

1100

0

Washers

B 209 (B 209M)

Clad 2024

6061

T4

T6

Sheet and plate

B 209 (B 209M)

6061

T6

Drawn seamless tubes

B 210

6061 or 6063

T6

Bars, rods, wire

B 211 (B 211M)

6061

T6

Bolts, set screws

B 211 (B 211M)

2024 [1]

6061

T4

T6

Nuts

B 211 (B 211M)

6061

6262

T6

T9

Extruded bars, rods, shapes

B 221 (B 221M)

6061 or 6063

6351

T6

T5

Extruded tubes

B 221(B 221M)

6061 or 6063

6351

T6

T5

Pipe

B 241/B 241M

6061 or 6063

T6

Rivets

B 316(B 316M)

6061

T6

[1]  Will have an anodic coating.

For permanent mold castings for bridge railing posts, provide aluminum according to AASHTO M 193.

711.21  Preformed Bearing Pads.  Composition.  Furnish preformed bearing pads consisting of a fabric and rubber body.  Ensure that the pad is made with new, unvulcanized, natural and/or synthetic rubber, and unused cotton and/or synthetic fabric fibers in proper proportion to maintain strength and stability.

Physical Properties.  The required surface hardness, expressed in standard rubber hardness figures, is 80 ± 10 Shore Durometer.  The minimum ultimate break down limit of pads under compressive loading is 10,000 pounds per square inch (69 MPa).  Furnish pads to specified dimensions and accurately locate and cleanly cut all bolt holes.

Furnish materials according to the Department’s Qualified Products List (QPL).

711.22  Buried Liner Waterproofing Membrane.  Furnish buried liner waterproofing membrane according to ASTM D 7176-06, with the following modification:

Only 4.1.2 through 4.1.6 is approved.

Furnish materials according to the Department’s Qualified Products List (QPL).

711.23  Elastomeric Bearings.  Furnish bearing pads and elastomeric bearings conforming to AASHTO Standard Specifications for Highway Bridges, Division II, Construction, Chapter 18, Section 18.4.5.1 Grade 3 requirements.  Fabricate elastomeric bearing pads according to Sections 18.5.6.1 and 18.5.6.2.  Test pads and bearings according to 18.7.1, 18.7.2.1, 18.7.2.3, 18.7.2.5, 18.7.2.6, 18.7.3, 18.7.4.5, and 18.10.3.  Include testing in the price bid for the bearings. Furnish certified material according to Supplement 1081.

Furnish bearing pads and laminated bearings consisting of neoprene cast in molds under pressure and heat.  A plain elastomeric bearing pad and steel load distribution plate combination is classified as a laminated elastomeric bearing.  Obtain test specimens according to ASTM D 3182 or ASTM D 3183.  Where test specimens are cut from the finished product, a 20 percent variation from the original physical properties is allowed.  The use of compounds of nominal hardness between the values shown in Table 711.23-1 is permitted and the test requirements interpolated.

Table 711.23-1

Physical Properties

Grade

50

60

70

Hardness, Durometer A, ASTM D 2240.

50 ± 5

60 ± 5

70 ± 5

Tensile Strength, min psi (MPa), ASTM D 412

2500 (17)

2500 (17)

2500 (17)

Elongation at break, min %

400

350

300

Accelerated Tests to Determine Long-Term Aging Characteristics, Over-Aged 70 hrs at 212 °F (100 °C), ASTM D 573:

Hardness, points change, max

15

15

15

Tensile strength, % change, max

-15

-15

-15

Elongation at break, % change, max

-40

-40

-40

Ozone 1 ppm in air by volume 20% strain, 104 °F (40 °C) ASTM D 1149, 100 hrs

   (Samples to be solvent wiped before test to remove any traces of surface impurities)

No

cracks

No

cracks

No

cracks

Compression set 22 hrs/212 °F (100 °C) ASTM D 395, Method B, % max

35

35

35

Adhesion, bond made during vulcanization ASTM D 429 Method B, lb/in (kN/m)

40 (7.0)

40 (7.0)

40 (7.0)

Furnish bearing pads that are individually molded, cut from previously molded strips or slabs, or extruded and cut to length.  Mold laminated bearings together into an integral unit with all edges of internal steel laminates covered by a 1/8-inch (3 mm) minimum thickness of elastomer.  Fill indentations or grooves on the exterior surface of the bearings caused by external laminate restraining devices to a 1/8 inch (3 mm) minimum cover by a revulcanized patch; or by a silicon caulk conforming to Federal Specifications TT-S-001543A; or by an approved equal.  Ensure that the bearing manufacturer patches the bearings.

Ensure that the external connection or distribution plates of laminated bearings are the same material as the attached structural steel and are similarly cleaned and coated.  Furnish internal plates according to ASTM A 709 grade 36  or A1011/A1011M, SS Grade 36 or Grade 40.  Minimum thickness for the internal plates is 0.074 inch (1.88 mm).  Debur all plates.

The bearing manufacturer will furnish certified test data for the elastomer, base plate, steel laminates, and proof load.

The bearing manufacturer will produce one sample bearing for each bridge structure in the project plans.  Ensure that the sample bearing for each bridge structure is of the same design and materials as the bearings furnished for that bridge structure.  The bearing manufacturer will ship the completed sample bearings to an independent testing laboratory for destructive testing for the following physical properties:

Hardness, Durometer A

ASTM D2240

Tensile Strength

ASTM D412

Elongation at Break

ASTM D412

Adhesion bond made during vulcanization

ASTM D429, Method B

Ensure that the bearing manufacturer submits to the project the certified test data for the sample bearings from the independent testing laboratory with the bearing manufacturer’s certified test data for the elastomer, base plate, steel laminates, and proof load.

711.24  Waterproofing Fabric.  Furnish waterproofing fabric according to ASTM D 173.

Furnish materials according to the Department’s Qualified products List (QPL). 

711.25  Type 2 Membrane Waterproofing.

Physical Properties

Thickness ASTM D 1777

60 mils (1500 mm) min.

Width

36 inches (914 mm) min.

Pliability [180° bend over 1/4 inch (6 mm) mandrel @ -25 °F (-32 °C)] ASTM D 146

No Effect

Elongation ASTM D 412 (Die C)

300% min

Puncture Resistance-Membrane ASTM E 154

40 lb (18 kg) min.

Permeance (Grains/ft²/hr/in Hg)
ASTM E 96, Method B

0.1 max.

Water Absorption (% by Weight) ASTM D 570

0.2 max.

Adhesion to concrete ASTM D 903

5.0 min.

Submit certified test data and letter of certification to the Engineer.

Furnish materials according to the Department’s Qualified Products List (QPL).

711.26  Structural Timber, Lumber and Piling.  Furnish structural timber, lumber and piling according to 712.06, and AASHTO M 168, with the following modification:

Air-dry or kiln-dry timber and lumber to a moisture content not to exceed 19 percent by weight.  Size and grade will conform to American Lumber Standards.

Use only structural timber, lumber, and piling meeting the certification requirements of Supplement 1072.

711.27  Prestressing Steel Strands.  Furnish prestressing steel strands according to ASTM A 416, with the following modification:

11  Sample and inspect as directed by the Laboratory.

711.28  Cellular Polyvinyl Chloride Sponge.  Furnish cellular PVC sponge according to AASHTO M 153, Type I, and with a minimum density of 20 pounds per cubic foot (320 kg/m³).

Furnish materials according to the Department’s Qualified Products List (QPL).

711.29  Type 3 Membrane Waterproofing.  Furnish Type 3 membrane waterproofing conforming to the following requirements.

Physical Properties

Thickness

0.135 inches (3.43 mm) min.

Width

36 inches (914 mm) min.

Weight

0.8 lb/ft2 (3.875 kg/mm²) min.

Tensile strength (machine direction) ASTM D 882

Modified [1]

275 lb/in (48.1 N/mm)

200 psi (13.8 MPa)

Tensile strength ASTM D 882 (90°

machine direction)

Modified [1]

150 lb/in (26.2 N/mm)

1000 psi (6.9 MPa)

Elongation at break ASTM D 882, Modified [1]

100%

Brittleness ASTM D 517

Pass

Softening point (mastic) ASTM D 36

200 °F (93 °C) min.

Peel adhesion ASTM D 413 [1]

2.0 lb/in (0.35 N/mm)

Cold flex ASTM D 146
2 ´ 5 inch (50 ´ 125 mm) specimen-180° bend over 2 inch (50 mm) mandrel

No cracking

Heat stability
2 ´ 5 inch (50 ´ 125 mm) specimen vertically suspended in a mechanical convection oven 2 hr @ 190 °F (88 °C)

No dripping or delamination

[1]  12 inches (300 mm)/minute test speed and 1 inch (25 mm) initial distance between the grips.

Submit certified test data and letter of certification to the Engineer.

Furnish materials according to the Department’s Qualified Products List (QPL).

711.30  Aluminum for Steps.  Furnish aluminum for steps according to ASTM B 221 (ASTM B 221M), Alloys 6061-T6 or 6005-T5.

Furnish materials according to the Department’s Qualified Products List (QPL).

711.31  Reinforced Propylene Plastic Manhole Steps.  Furnish reinforced propylene plastic manhole steps conforming to the details shown on the plans.

Furnish steel rod according to 709.01, Grade 60 that is continuous through the entire length of legs and tread.  The steel may be coated according to ASTM A 934/A 934M.  Ensure that the manufacturer furnishes written certification.  Furnish propylene plastic according to ASTM D 4101, Table B 33430.  Ensure that the manufacturer furnishes certified test data for the propylene plastic used in each lot of steps.

Furnish materials according to the Department’s Qualified Products List (QPL).

712  MISCELLANEOUS

712.01  Expansion Shield Anchors.  Furnish anchors conforming to the dimension requirements of the project plans and the following:

A.      Type A. Federal Specification  A-A-1923A, and  A-A-55614.

B.      Type B. Federal Specification  A-A-1924A.

The supplier or producer of the anchors will provide a certification showing certified test results of the proof load required in the Federal Specifications.

Furnish materials according to the Department’s Qualified Products List (QPL).

712.02  Calcium Chloride.  Furnish calcium chloride according to ASTM D 98. 

Furnish materials according to the Department’s Qualified Products List (QPL).

712.03  Sodium Chloride.  Furnish sodium chloride according to ASTM D 632, Type I, Grade 1, with the following modification:

4  Total Chlorides (NaCl, CaCl₂, and MgCl₂ as NaCl based on dry weight) not less than 97 percent.

712.04  Lime and Lime Kiln Dust.

A.      Furnish hydrated lime for masonry purposes according to ASTM C 207, Type S.

B.      Furnish quick lime for soil stabilization that is certified according to Supplement 1087 and listed on the Department’s Qualified Products List (QPL) and according to ASTM C 977, with the following modification:        

4.2.1 Particle size of Quick Lime – Quick lime shall all pass the No. 4 (4.75 mm) sieve.

C.      Furnish lime kiln dust for soil stabilization that is certified according to Supplemental 1087.  Lime kiln dust is a by-product of making lime. Furnish lime kiln dust that meets the following requirements.  Perform chemical analysis of the lime kiln dust according to ASTM C 25.

Combined total calcium oxide and magnesium oxide

50 % minimum

Available calcium hydroxide (rapid sugar test, ASTM C25),
plus total MgO content calculated to be equivalent Ca(OH)₂

30 % minimum

Loss on ignition (carbon dioxide plus moisture, combined and free on as-received basis)

40 % maximum

Free water (as-received basis)

4 % maximum

Sulfur as SO₃

10 % maximum

Sieve analysis.

Sieve Size

Minimum Percent Passing

No. 4       (4.75 mm)

95

No. 30     (600 µm)

90

No. 100   (150 µm)

75

Submit test results for the above requirements for every 100 tons (90 metric tons) of lime kiln dust supplied to the Department.  If multiple tests were performed, include the average and standard deviation with the results.

712.06  Preservative Treatment for Structural Timber, Lumber, Piling, Posts, Braces, and Blocks.

A.      General.  Furnish structural timber, lumber, and pilings according to 711.26, and posts, braces, and blocks according to 710.14, except that moisture may be removed from the untreated lumber at the time of preservative treatment.  Ensure that structural timber, lumber, piling, posts, and braces conform to the current AWPA standards and this subsection.  The minimum retention for blocks is 0.40 pounds per cubic foot (6.4 kg/m³).

B.      Materials.  Furnish timber preservatives according to AASHTO M 133.

C.      Preparation for Treatment.  Sort the material into one kind or designated group of kinds of wood and into pieces of approximately equal size and moisture and sapwood content.  Separate material to ensure contact of treating medium with all surfaces.

D.      Framing.  Conduct all adzing, boring, chamfering, framing, graining, mortising, and surfacing before treatment.

E.      Incising.  Incise lumber 3 inches (75 mm) or more thick on all four sides.  Incise lumber less than 3 inches (75 mm) thick on the wide faces only, except as shown on the plans.

Incise Douglas fir with a minimum dimension of 2 inches (50 mm) using a suitable power-driven machine before treatment.  Do not incise Douglas fir rails and rail posts.

Use the spacing and shape of the cutting teeth and the method of incising necessary to produce a uniform penetration.  The minimum required depths of the incisions are as follows:

Size[1]

Minimum depth of incision, inch (mm)

2 ´ 12

(50´300)

3/8

(9)

3 ´ 12

(75´300)

7/16

(11)

4 ´ 12

(100´300)

1/2

(13)

8 ´ 10

(200´250)

9/16

(14)

10 ´ 12

(250´300)

5/8

(16)

12 ´ 12

(300´300)

3/4

(19)

[1]  Intermediate size in proportion.

F.      Amount of Preservative.  The required net retention in any charge is no less than 90 percent of the quantity of preservative specified, but the average retention by the material treated under any contract or order and the average retention of any five consecutive charges are required to be at least 100 percent of the quantity specified.  Ensure that the minimum amounts of preservative retained conform to AASHTO M 133 and the requirements set forth in the referenced AWPA Standard.  Treat all species of structural timber, lumber, piling, posts, and blocks according to the current AWPA standards.

G.     Acceptance.  Accept only structural timber, lumber, piling, posts, braces, and blocks according to Supplement 1072. 

712.09  Geotextile Fabrics.   Furnish fabric composed of strong rot-proof polymeric fibers formed into a woven or non-woven fabric. Products must be tested by the National Transportation Product Evaluation Program (NTPEP). The Department will determine acceptance of Type A, B, C and D fabric according to data obtained in the most current NTPEP report – Laboratory Results of Evaluations on Geotextiles and Geosynthetics. The NTPEP testing results must meet or exceed the requirements listed in Table 712.09-1. For all tests except Ultraviolet Exposure, the products Minimum Average Roll Values (MARV), as published in the NTPEP report, must also meet or exceed the requirements listed in the table. If no MARV value is published in the NTPEP report, the manufacturer must submit to the Department certified test data showing the MARV values for the product will meet or exceed the requirements listed in Table 712.09-1.

For Type E material, supply fabric conforming to the requirements of AASHTO M288, Section 10, Table 8. The Department will accept Type E material based on certified test data.

All minimum strengths shown are in the weakest principal direction.

Ensure that the fabric is free of any treatment that might significantly alter its physical properties.

During shipment and storage, wrap the fabric in a heavy-duty protective covering to protect it from UV deterioration, direct sunlight, dirt, dust, and other debris.

Furnish materials according to the Department’s Qualified Products List (QPL).

Table 712.09-1

Property

Test Method

Required Value

Type A: Underdrains and Slope Drains

Minimum tensile strength

ASTM D 4632

80 lb

355 N

Minimum puncture strength [1]

ASTM D 6241

140 lb

625 N

or ASTM D 4833

25 lb

110 N

Minimum tear strength

ASTM D 4533

25 lb

110 N

Apparent opening size

ASTM D 4751

   Soil Type-1: Soils with 50% or less passing
  No. 200 (75 mm) sieve

AOS £ 0.6 mm

   Soil Type-2: Soils with 50 to 85% passing
  No. 200 (75 mm) sieve

AOS £ 0.3 mm

Minimum permittivity

ASTM D 4491

0.5 sec⁻¹

Type B: Filter Blankets for Rock Channel Protection

Minimum tensile strength

ASTM D 4632

200 lb

890 N

Minimum elongation

ASTM D 4632

15%

Minimum puncture strength [1]

ASTM D 6241

440 lb

1955 N

or ASTM D 4833

80 lb

355 N

Minimum tear strength

ASTM D 4533

50 lb

220 N

Apparent opening size

ASTM D 4751

AOS £ 0.6 mm

Minimum permittivity

ASTM D 4491

0.2 sec⁻¹

Type C: Sediment Fences

Minimum tensile strength

ASTM D 4632

120 lb

535 N

Maximum elongation

ASTM D 4632

50%

Minimum puncture strength [1]

ASTM D 6241

275 lb

1225 N

or ASTM D 4833

50 lb

220 N

Minimum tear strength

ASTM D 4533

40 lb

180 N

Apparent opening size

ASTM D 4751

AOS £ 0.84 mm

Minimum permittivity

ASTM D 4491

0.01 sec⁻¹

Ultraviolet exposure strength retention [2]

ASTM D 4355

70%

Type D: Subgrade-Base Separation or Stabilization

Minimum tensile strength

ASTM D 4632

180 lb

800 N

Maximum elongation

ASTM D 4632

50%

Minimum puncture strength [1]

ASTM D 6241

385 lb

1715 N

or ASTM D 4833

70 lb

310 N

Minimum tear strength

ASTM D 4533

70 lb

310 N

Apparent opening size

ASTM D 4751

Same as Type A

Permittivity

ASTM D 4491

0.05 sec⁻¹

[1]  ASTM D6241 is now the standard puncture resistance test required by AASHTO and NTPEP. NTPEP will continue to publish product data, tested under ASTM D4833, until the product is retested under ASTM D6241.

[2]  Provide certified test data to the Department. Include strength retention data at 0, 150, 300, and 500 hours

712.10  Prefabricated Edge Underdrain.  Furnish prefabricated edge underdrain consisting of a polymeric core with a minimum thickness of 1 inch (25 mm) wrapped in fabric according to 712.09, Type A.  Ensure that the underdrain is flexible, rectangular in shape, and of hollow construction.  Use core material that is resistant to petroleum-based chemicals, naturally occurring soil chemicals, and road de-icing agents.  The core material will have sufficient flexibility to withstand bending and handling during installation without damage.  The core will provide a minimum of 100 square inches (0.064 m²) unobstructed (one side only) drainage area per 1 foot (0.3 m) of width.  Side walls of the core will have at least 5 percent open area to permit unobstructed flow through the filter and wall to the core.  The required minimum compressive strength of the prefabricated edge drain is 6000 pounds per square foot (290 kPa) with a maximum 20 percent compression in a parallel plate compression test (ASTM D 695).  The minimum (single side) core flow capacity is 10 gallons per minute per foot of width for a 0.1 gradient at 10 pounds per square inch bladder load according to ASTM D 4716.  Furnish the manufacturer’s certified test results as specified 101.03.

712.11  Temporary Erosion Control Mats Materials.  Unless specifically itemized, furnish any of the type mats listed below.  Provide certified test data for each shipment of material.

A.      Type A Temporary Erosion Control Mat.  Conform to the following:

1.      A machine-produced mat consisting of 100 percent agricultural straw covered on the top with a polypropylene netting having an approximate 1/4 ´ 1/4 inch to 1/2 ´ 1/2 inch (6 ´ 6 mm to 13 ´ 13 mm) mesh, and sewn together with biodegradable or photodegradable thread.

2.      A consistent thickness with the straw evenly distributed over the entire area of the mat.

3.      A minimum mat width of 6.5 feet (2 m).

4.      An average mat weight of 0.5 pound per square yard (270 g/m²) ± 10 percent.

5.      A netting weight of approximately 1 pound per 1000 square feet (5 kg/1000 m²).

B.      Type B Temporary Erosion Control Mat.  Conform to the following:

1.      A machine-produced mat consisting of 100 percent agricultural straw covered on the top with a photodegradable polypropylene netting having an approximate 1/2 ´ 1/2 inch to 5/8 ´ 5/8 inch (13 ´ 13 mm to 16 ´ 16 mm) mesh and on the bottom with a photodegradable polypropylene netting having an approximate 1/4 ´ 1/4 inch to 1/2 ´ 1/2 inch (6 ´ 6 mm to 13 ´ 13 mm) mesh, sewn together with biodegradable or photodegradable thread.

2.      A consistent thickness with the straw evenly distributed over the entire area of the mat.

3.      A minimum mat width of 6.5 feet (2 m).

4.      An average mat weight of 0.5 pound per square yard (270 g/m²) ±10 percent.

5.      A top netting weight of approximately 3 pounds per 1000 square feet (15 kg/1000 m²) and a bottom netting weight of approximately 1 pound per 1000 square feet (5 kg/1000 m²).

C.      Type C Temporary Erosion Control Mat.  Conform to the following:

1.      A machine-produced mat consisting of 70 percent agricultural straw and 30 percent coconut fiber covered on the top with a photodegradable polypropylene netting having an approximate 5/8 ´ 5/8 inch (16 ´ 16 mm) mesh and on the bottom with a photodegradable polypropylene netting having an approximate 1/4 ´ 1/4 inch (6 ´ 6 mm) mesh, sewn together with cotton thread.

2.      A consistent thickness with the straw and coconut fiber evenly distributed over the entire area of the mat.

3.      A minimum mat width of 6.5 feet (2 m).

4.      An average mat weight of 0.5 pound per square yard (270 g/m²) ± 10 percent.

5.      A top netting weight of approximately 3 pounds per 1000 square feet (15 kg/1000 m²) and a bottom netting weight of approximately 1 pound per 1000 square feet (5 kg/1000 m²).

E.      Type E Temporary Erosion Control Mat.  Conform to the following:

1.      A machine-produced mat consisting of 100 percent coconut fiber covered on the top and bottom with an ultraviolet stabilized polypropylene netting having an approximate 5/8 ´ 5/8 inch (16 ´ 16 mm) mesh, and sewn together with polyester thread.

2.      A consistent thickness with the coconut fiber evenly distributed over the entire area of the mat.

3.      A minimum mat width of 6.5 feet (2 m).

4.      An average mat weight of 0.5 pound per square yard (270 g/m²) ± 10 percent.

5.      An  ultraviolet stabilized polypropylene netting with a weight of approximately 3 pounds per 1000 square feet (15 kg/1000 m²).

F.      Type F Temporary Erosion Control Mat.  Conform to the following:

1.      A uniform open plain weave of undyed and unbleached single jute yarn.

2.      Loosely twisted yarn not varying in thickness by more than one-half its normal diameter.

3.      Furnish mats in rolled strips with:

a.      A minimum length of 50 yards (46 m).

b.      A width of 48 inches ± 1 inch (1.2 m ± 25 mm).

c.      Warp ends width 81 ± 3.

d.      Weft ends per yard (meter) 41 ± 3 (49 ± 3).

e.      An average weight of 1.22 pounds per linear yard (0.6 kg/m) ± 10 percent.

G.     Type G Temporary Erosion Control Mat.  Conform to the following:

1.      A machine-produced mat consisting of wood excelsior, 80 percent of which is at least 8 inches (200 mm) in length.

2.      Excelsior cut from wood that is properly cured to achieve adequately curled and barbed fibers.

3.      A consistent thickness with the fiber evenly distributed over the entire area of the mat.

4.      For use in ditches or channels, cover the top and bottom of the excelsior with lightweight netting entwined with the excelsior for maximum strength and ease of handling, or cover the top only with heavyweight netting machine sewn on maximum 2 to 4-inch (51 to 102 mm) centers along the longitudinal axis of the material.  For all other applications, cover the top with lightweight netting entwined with the excelsior for maximum strength and ease of handling.

5.      Regardless of application, lightweight netting consists of either netting having a maximum 3 ´ 1 inch (75 ´ 25 mm) weave, twisted craft [check spelling] paper yarn having a high web strength or biodegradable plastic.

6.      Mat widths of 24, 36, 48, or 78 inches (0.6, 0.9, 1.2, or 2 m) or greater, ±1 inch (±25 mm).

7.      Mat rolls of more than 90 feet (27.5 m) in length.

8.      A mat weight of not less than 0.72 pound per square yard (390 g/m²) constant weight, air dry.

I.       Type I Temporary Erosion Control Mat.  Conform to the following:

1.      Extruded polymeric plastic net having a mesh opening of approximately 3/4 ´ 3/4 inch (20 ´ 20 mm).

2.      A netting with an average weight of 3 pounds per 1000 square feet (15 kg/1000 m²) ± 10 percent and a minimum tensile strength of 15 pounds over a 3-inch width (67 N over a 77 mm width) in the weakest principal direction.

712.12  Tied Concrete Block Mat.  Furnish materials tested to ASTM D6460. The Department will determine acceptance of Type 1, 2, and 3 based on independent third party test data.  The acceptable stability threshold shear values are:

Type 1:     3 lbf/ft²     (140 Pa)

Type 2:     5 lbf/ft²     (240 Pa)

Type 3:     7 lbf/ft²     (340 Pa)

Furnish products according to the Departments Qualified Products List (QPL).

712.13  Articulating Concrete Block Revetment System.  Furnish materials according to ASTM D6684 and tested according to ASTM D7277.  The Department will determine acceptance of Type 1, 2, 3 based on independent third party test data. The acceptable stability threshold shear values are:

Type 1:     17 lbf/ft²   (810 Pa)

Type 2:     20 lbf/ft²   (960 Pa)

Type 3:     23 lbf/ft²   (1100 Pa)

Furnish products according to the Departments Qualified Products List (QPL).

712.14  Detectable Warning Devices Furnish materials conforming to the following requirements:

Products must be compliant with the Americans with Disabilities Act (ADA).

Products will be designed to be physically embedded into concrete and be of a color that visually contrasts with the concrete.    Do not use black as a color.

Products may be manufactured from materials of cast iron, stainless steel, polymer concrete, reinforced polymer composite, or granite.  Products may be designed as either one time installation products or replaceable products. 

Surface applied, stamped concrete, concrete, and brick products will not be permitted.

Detectable Warning Devices will be provided with a minimum 5 year written warranty with at least the following: 

1. The installed device will remain ADA compliant for the term of the warranty period. 

2. During the warranty period at least 85% of the truncated domes on installed device will remain entirely intact.

3. The installed device will remain securely affixed to and flush with the concrete substrate.

4. Any surface coating applied to the installed product will remain in place and color fast.

5. At no cost to the Department, the manufacturer will replace the product, including all installation costs, if during the 5 year warranty period the product fails to comply with the above warranty requirements.  Any new device installed under the warranty will meet the requirements of this specification

As part of the Department Acceptance process for inclusion on the Qualified Product’s List (QPL) submit the proposed warranty to the Department along with material samples, dimensional drawings, and written installation procedures.

Upon acceptance by the Department the materials will be listed on the QPL

Furnish materials according to the Department’s Qualified Product List (QPL)

Begin warranty period upon Contract acceptance.

At the preconstruction meeting provide the Engineer with the written warranty signed by the executive officer of the manufacturing company

720  DELINEATOR MATERIALS

720.01  Reflectors. For bridge parapet bracket or bridge rail bracket, furnish rectangular reflectors that are a minimum size of 3 × 6 inches (75 × 150 mm) and that consist of reflective sheeting according to 730.192 or 730.193 adhered to an aluminum plate. Furnish white, yellow, or red reflectors as specified. Furnish aluminum plate for reflectors according to ASTM B 209 (B 209M), 6061-T6 with a minimum thickness of 0.060 inch (1.5 mm).

For ground mounted delineators, furnish rectangular reflective sheeting according to 730.192 or 730.193 that is a minimum size of 3 × 6 inches (75 × 150 mm) adhered to a flexible post. Furnish white, yellow or red reflectors as specified.

For surface mounted delineators, furnish a 3-inch (75 mm) wide band of reflective sheeting according to 730.192 or 730.192 adhered completely around a flexible post. Furnish white or yellow reflectors as specified.

Furnish materials according to the Department’s Qualified Products List (QPL).

720.03  Flexible Posts. Conform to Supplement 1020.

Furnish materials according to the Department’s Qualified Products List (QPL).

721  RAISED PAVEMENT MARKER MATERIALS

721.01  Raised Pavement Marker Castings.   Ensure that the casting is nodular iron according to ASTM A 536, hardened to 51-55 RC, snow plowable in the two opposing longitudinal directions and designed to accommodate a replacement prismatic retroreflector.

Furnish materials according to the Department’s Qualified Products List   (QPL).

721.02  Prismatic Retroreflector and Adhesive.  Furnish reflectors that contain one or two prismatic reflective faces to reflect incident light from a single or opposite directions.  Furnish reflectors with nominal dimensions of 4 ´ 2 ´ 0.48 inch (100 ´ 50 ´ 12 mm). Ensure that the reflector fits securely in the recessed area and does not protrude above the profile of the casting.

 Furnish manufacturer recommended retroreflector adhesive to bond the prismatic retroreflectors to casting.

Furnish materials according to the Department’s Qualified Products List (QPL).

721.03  Casting Adhesive.  Casting adhesives will follow a two-step acceptance procedure.

Step 1 will be materials testing and a flow test.

A.      Furnish adhesive material conforming to AASHTO M 237, Type IV, except that the viscosity is 200 to 900 poise at 77 + 2 °F (25 + 1 °C) and the unit weight is 11.3 to 11.9 pounds per gallon (1.35 to 1.43 kg/L).

B.      For materials conforming to the above requirements provide samples of the adhesives to the Department for flow testing. The casting adhesive flow test will meet the ranges in Table 721.03-1.

The flow test procedure is:

1.      In a standard 2 × 4 block of pine wood (3.5 in wide × 1.5 in deep × 22 in long) cut a channel in the block that is 3/4 in wide by 1/2 in deep with a dado blade. The channel will run longitudinally 22 inches long in the center of the 3.5 inch wide face of the wood block. Use tape to block off the ends of the channel.

2.      Condition epoxy (Part A and Part B) and the wood block for a minimum of 4 hours at each of the three different temperatures (77, 100, and 120 °F).

3.      Mix Part A and Part B epoxy separately for 15 seconds.

4.      Mix Part A epoxy with Part B epoxy, at the manufacturer’s required ratio, for 1.5 minutes. The total amount of sample mixed will equal 40 mL.

5.      Temporarily dam off 6.5 inches of the channel at one end of the wood block. Keep the wood block flat and level with the channel side facing up.

6.      Pour mixed product into the blocked off end of the channel for 30 seconds. The product should fill this blocked off volume. Remove the temporary dam.

7.      Immediately place wood block with the epoxy filled channel on a 15 percent grade incline, with epoxy placed at the top of the slope.

8.      Immediately start a stop watch.

9.      Stop the watch when the material completely stops flowing in the channel.

10.    The time and length the epoxy traveled down the channel need to meet the requirements of Table 721.03-1.

11.    This test will be run at each of the three established temperatures.

Table 721.03-1

Temperature

77 °F

(25 °C)

100 °F

(38 °C)

120 °F

(49 °C)

Distance (D) traveled down 15% incline (inches)

10 ≤ D ≤ 18

12 ≤ D ≤ 20

12 ≤ D ≤ 20

Time (T) for epoxy to stop flowing on 15% incline (minutes)

5 ≤ T ≤ 14

2 ≤ T ≤ 9

1 ≤ T ≤ 4

Step 2 will include a Department controlled field application and performance test

The epoxy adhesive will be field evaluated on two ODOT roadway projects in north eastern Ohio. One roadway will be new asphalt pavement and the other will new concrete or concrete that is less than 20 years old. The test sections on each roadway will be a minimum of 2 miles long and carry a minimum of 30,000 ADT. It will be the responsibility of the epoxy manufacturer to find routes in Ohio that meet these requirements and have them installed, at no cost to the Department, as a part of an existing ODOT contract. The casting adhesive will be evaluated after one year of service. Removal of any casting from the roadway after one year will be considered failure of the epoxy adhesive. If no castings are removed from the roadway and the product meets the requirements listed above, the epoxy adhesive will be granted Conditional Approval.

If the product continues to perform satisfactorily after 4 years, the product will be moved to Full Approval. If at any time during Conditional Approval status, the epoxy adhesive fails to perform to the satisfaction of the Department, it will be removed from Conditional Approval status and from further consideration.

Approved and Conditionally Approved materials will be incorporated on the Department’s QPL. Only furnish materials listed on the Department’s QPL.

725 HIGHWAY LIGHTING MATERIALS

725.01  General.  Furnish luminaires, conduits, wire, switch gear and other electrical hardware that are listed with Underwriters Laboratories.

Ensure that each item of manufactured electrical apparatus as a unit has a durable nameplate identifying the manufacturer and manufacturer’s product identification. 

Only provide samples when required by the Laboratory.

725.02  Wire and Cable.  Ensure that each nonshielded wire or cable rated 0-2kV is single conductor, stranded copper with cross-linked thermosetting polyethylene insulation, nonjacketed, meets the requirements of ICEA S-95-658/NEMA WC70 and is of UL Type RHH-RHW-USE except for conductors 10 AWG and smaller for which those with insulation meeting the requirements of UL Type XHHW may also be used.

Ensure that each non-shielded wire or cable rated 5000 volts (2400 volts working under the 2005 NEC) is single conductor, stranded copper with chemically cross-linked polyethylene insulation, nonjacketed, meets the requirements of ICEA S-96-659/NEMA WC71 and of UL Type MV-90 dry.

Ensure that each cable’s identification device defining its use is either a tag tied onto the cable or a band applied around the cable.  Ensure that cable tags are of copper, brass or plastic (except for tags within switch and device cabinets which shall be nonconducting) 1/32 inch (0.8 mm) minimum in thickness permanently fastened to the cables by means of cable tying straps.  Ensure that cable identifying bands are approximately 1/32 inch (0.8 mm) thick wrap completely around the cable and closed securely.  Ensure that each tag or band is marked using 1/4 inch (6 mm) minimum height embossed or engraved letters. 

Ensure that conductors shall be marked “CKT” followed by the circuit designation shown on the plans and that grounding conductors are marked “GND” and that neutral conductors are marked “NEU” and that hot conductors are marked “Line“ followed by “1” or “2” for single phase power or “Phase“ followed by “A“ or “B“ or “C“ for three phase power.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.03  Unit Type Duct-Cable Systems  Ensure that factory made cable-in-duct has conductors as specified, that the duct is high density polyethylene Type III, Class C, Category 5, Grade 34 conforming to NEMA TC-7 and that the duct has the manufacturer’s name and the year of manufacture included in the marking.

Conductors and neutrals will conform to 725.02.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.04  Rigid Galvanized Steel Conduit and Fittings  Ensure that rigid galvanized steel conduit complies with the requirements of ANSI C 80.1 and UL 6 Type I and that each length of conduit bears the UL label. Furnish fittings that comply with the requirements of ANSI/NEMA FB 1 AND ANSI/UL 514B.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.051 Polyvinyl Chloride Conduits and Fittings. Furnish polyvinyl chloride conduit EPC-40-PVC conforming with NEMA Standard TC 2 for normal above ground or below ground installation, either concrete encased or direct burial.  Use fittings conforming to NEMA Standard TC-2 references.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.052 Polyethylene Conduits and Fittings. Furnish polyethylene conduit EPEC-40-HDPE conforming to NEMA Standard TC 7 for below ground only installation, whether concrete encased or direct burial. Use fittings conforming to ASTM D3350.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.06  Polymer Concrete Pull Boxes  Ensure that the polymer concrete pull box and cover is of aggregate bound with a polymer resin.  Ensure that the body of the box is of one piece construction.  Ensure that all surfaces of the box and cover are smooth and that the cover has a molded slip resistant surface.  Ensure that the cover is slip resistant and is labeled in clearly legible block letters 1 to 2 inches (25 to 50 mm) in height integral to the cover with the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE“ to designate the circuit(s) contained.  Ensure that the cover closely fits the opening and is secured by stainless steel bolts and hardware and that the threaded holes into which the cover bolts fasten are of open bottom design.  Ensure that the box and cover meet the structural requirements of Society of Cable Telecommunications Engineers Tier 15.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.07  Plastic Pull Boxes  Ensure that the plastic pull box and cover is of high density ultraviolet stabilized molded polyethylene with a box wall thickness of at least 1/4 inch (6 mm). The box depth may be obtained through the use of extensions or stacking. Ensure that the cover is slip resistant and has in clearly legible block letters 1 to 2 inches (25 to 50 mm) in height integral to the cover the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate the circuit(s) contained.  Ensure that the cover closely fits the opening and is secured by stainless steel bolts and hardware and that the threaded holes into which the cover bolts fasten are of open bottom design.  The box shall meet the structural requirements of Western Underground Committee Guide 3.6.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.08  Portland Concrete Pull Boxes.

A.      Pull Box.  Ensure that the Portland concrete pull box is constructed of reinforced portland cement concrete.  When the box is precast, provide pull boxes from suppliers certified to Supplement 1073.  Ensure that the pull box cover is constructed according to 725.08B and as shown on the plans.

B.      Pull Box Covers.  Furnish metal pull box covers that conform to the following requirements:

1.      Furnish 1/2-inch (13 mm) thick steel plate for the steel cover conforming to 711.01 with a 1/2-inch (13 mm) minimum flange around the edge and galvanized to conform to 711.02.  Display on the steel cover or on an attached brass or stainless steel plate (tag) clearly legible block letters 1 to 2 inches (25 to 50 mm) in height with the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate the circuit(s) contained.  Ensure that the word designating the use is in raised letters that are either integral to the steel cover or integral to a brass or stainless steel plate 1/16 inch (1.6 mm) in thickness securely mechanically attached to the steel cover at the four corners of the tag and at intervals 2 to 3 inches (50 to 75 mm) along the perimeter between corners.

2.      Furnish gray iron or ductile iron with a minimum thickness of 3/8 inch (9 mm) conforming to 711.14.  Certification is required.  Ensure that the word “TRAFFIC,” “LIGHTING”, “ELECTRIC,” or “TELEPHONE” is cast in the top surface of the cover forming letters 1 to 2 inches (25 to 50 mm) in height.

725.10  Junction Boxes.  Ensure that the junction boxes are iron castings hot-dip galvanized in accordance with 711.02. Ensure that the junction boxes meet the requirements of NEMA ICS-6-Type 3.  When a drilled and tapped conduit entry is stipulated, ensure that the junction box has adequate wall thickness and that a boss has been cast into the box if necessary.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.11  Luminaires

A.      Optical System. Furnish a luminaire set to the photometric distribution stipulated in the plan and that the distribution along with the settings required to produce it are clearly indicated on a durable label affixed to the interior of the housing in a position readily apparent and easily read by a worker lamping the luminaire.

Furnish a luminaire with a borosilicate glass refractor free of striations and imperfections and embossed to clearly indicate the street side when the refractor may be installed in more than one position.  Ensure the refractor is held firmly in the housing, but is easily removed without the use of special tools.

Furnish a luminaire with an aluminum reflector with a specular polished reflective surface free from scratches.  Ensure the reflector is held firmly in the housing, but is easily removed without the use of special tools.

Furnish a luminaire with a socket for mogul base lamps where there is a choice of size for the application at hand.

Furnish a lamp socket with a large center contact spring providing a firm contact with the lamp base and lamp grips to prevent the lamp from loosening.  Ensure that the shell is shrouded in porcelain and that the wiring terminals and contacts are identified.

Ensure that socket position adjustments have positive indexing such as holes, lugs or notches and are not slots with infinite settings.

Ensure that socket adaptors are not necessary and not used.

B.      Lamps. Furnish a luminaire that has been provided with a lamp of the type and wattage specified and that each lamp has a clear glass envelope, a date recording feature and does not have any ballasting or starting components.

Furnish high pressure sodium lamps that are first line, high quality lamps having heat resistant clear glass envelopes with a quartz arc tube interior with horizontal initial lumens and approximate hours of life not be less than the values shown in Table 725.11-1.

TABLE 725.11-1

ANSI

WATTS

Horizontal Lumens
Initial

Economic Life
Hours

S62

70

5,800

14,000

S54

100

9,500

14,000

S56

150

16,000

16,000

S66

200

22,000

16,000

S50

250

27,500

16,000

S67

310

37,000

16,000

S51

400

50,000

16,000

S52

1,000

130,000

16,000

Furnish high pressure sodium lamps that produce a minimum of 80 percent of the initial lumen output at the end of economic life.

Furnish metal halide lamps that are first line, high quality lamps having heat resistant clear glass envelopes with a quartz arc tube interior with horizontal initial lumens and approximate hours of life not less than the values shown in Table 725.11-3.

TABLE 725.11-3

ANSI

WATTS

Horizontal Lumens
Initial

Economic Life
Hours

M57

175

14,000

4,000

M58

250

18,000

4,000

M59

400

32,000

10,000

M47

1,000

95,000

7,500

Furnish metal halide lamps that produce a minimum of 65 percent of the initial lumen output at the end of economic life.

Furnish low pressure sodium lamps that are first line, high quality lamps having heat resistant clear glass envelopes with a quartz arc tube interior with horizontal initial lumens and approximate hours of life not less than the values shown in Table 725.11-4.

TABLE 725.11-4

WATTS

Lumens
Initial

Economic Life
Hours

35

4,000

16,000

55

8,000

16,000

90

13,500

16,000

135

22,500

16,000

180

33,000

16,000

Furnish materials according to the Department’s Qualified Products List (QPL).

C.      Ballast. Ensure that the ballast is of an integral design contained within the luminaire housing.

If the ballast is to be wired line to line or phase to phase, ensure that the ballast has an isolated primary winding. 

Furnish a ballast (in conjunction with the starter in the case of high pressure sodium lamps) capable of starting and operating the lamp at ambient temperatures as low as -20 °F (-30 °C).

At circuit voltage of nominal plus or minus 10 percent or the ballast manufacturer’s stated range if greater, ensure that the ballast can start (in conjunction with the starter in the case of high pressure sodium lamps) and operate the lamp within the lamp’s ANSI operating parameters for the full design life of the lamp.

Furnish a ballast capable of operation with the lamp in an open or short circuit condition for six months without significant loss of ballast life.

Furnish a starter of encapsulated solid state design capable of withstanding the temperatures encountered in the ballast compartment of the luminaire.

Ensure that the starter provides a timed pulsing with sufficient follow through current to completely ionize and start all lamps that meet published ANSI standards.

Ensure that the starter has push-on type electrical terminations and is field replaceable with no adjustment necessary for proper operation.

Ensure that there is a barrier type terminal block for connection of the incoming electrical circuit.

D.      Housing. Furnish a housing of cast aluminum.

Ensure that the housing has a flat area on the top side on which a level may be placed and read by a worker leveling a mounted luminaire on an erected support.

Ensure that the door(s) providing access to the optical and electrical components have hinges and latches of corrosion resistant materials that remain securely closed during operation.

Ensure that the silicone rubber, ethylene propylene terpolymer, dacron felt or other durable gaskets and seals supplied by the manufacturer either as part of the basic luminaire or as options are in good condition and properly installed at the socket entry, between the refractor and reflector and any other location where such gaskets or shields are part of the luminaire and options.

Ensure that the exterior finish of the luminaire is a light gray color unless otherwise specified.

Furnish a glare shield of aluminum or opaque plastic material when specified. Furnish a shield supplied by the manufacturer of the luminaire.

E.      Conventional Luminaries. Ensure that the luminaire housing doors may be opened, closed, removed or installed without the use of tools.

Ensure that the clamp for the slip-fit mounting accommodates both 1 1/4 inch (32 mm) and 2 inch (50 mm) nominal pipe mounting bracket.  Ensure that a stop is provided as part of the housing to prevent over insertion of the bracket into the housing.  Ensure that the clamp engages at least 4 1/2 inches (115 mm) longitudinally along the arm of the bracket arm between the extremes of a minimum of two clamping points.  Ensure that the mounting clamp provides for leveling of the luminaire to the specified transverse and longitudinal position with respect to the roadway.

Ensure that the luminaire is equipped with a device indicating the direction and amount of tilt over a range of zero to five degrees in any direction with indications at level, three degree tilt and five degree tilt all accurate to one half degree.  Ensure that the indicating device is clearly readable in daylight from a distance of 50 feet (15 m) and in no way alters or reduces the amount of light from the luminaire.  Ensure that the indicating device is constructed of a transparent container having one horizontal surface which is curvilinear in any vertical cross section for supporting an indicator and a damping fluid.  Ensure that the damping fluid is a liquid which shall be suitable for operation at -40 °F (-40 °C) and that the transparent container is fabricated from clear ultraviolet-inhibited acrylic or similar material.

Ensure that the glare shield will cut off the upward component of light and that it does not reduce the total output of the luminaire more than 3 percent.

Ensure that the luminaire has a label or decal indicating the type of source and wattage rating.  Ensure that, with the luminaire installed in its normal operating position, the label or decal is clearly legible in daylight at a distance of 50 feet (15 m).  Ensure that the labeling is in accordance with the provisions of NEMA Publication OD-150 or EEI Publication TDJ-150.

Ensure that the complete conventional luminaire assembly including the lamp and all options including, when required, the glare shield does not weigh more than 75 pounds (34 kg).

Furnish materials according to the Department’s Qualified Products List (QPL).

F.      Wall Mounted Underpass Luminaires. Ensure that the assembly is weatherproof and sealed against dust.

Ensure that a wire entry for the incoming power is provided on both of the vertical side surfaces of the housing, that each entry is drilled and tapped for 3/4-inch (19 mm) conduit and that the unused entry is properly closed with the screw type plug supplied by the manufacturer.

Ensure that the luminaire housing doors may be opened, closed, removed or installed without the use of special tools.

Ensure that the housing can be mounted onto a vertical flat surface by means of cap screws or bolts through the wall side of the housing.

Ensure that the luminaire has the option for protecting the glass refractor with a guard or shield that is integral to the luminaire and does not have to be removed to gain access to the lamp or ballast.

Furnish materials according to the Department’s Qualified Products List (QPL).

G.     High Mast / Low Mast Luminaires. Ensure that luminaires with a symmetric distribution shall have an initial intensity of no more than 100 candela per 1000 lamp lumens at nadir and no more than 325 candela per 1000 lamp lumens at angles between 55 and 65 degrees above nadir.

Ensure that luminaires with an asymmetric distribution or a long and narrow distribution shall have an initial intensity of no more than 175 candela per 1000 lamp lumens at nadir and no more than 425 candela per 1000 lamp lumens at angles from 66 through 73 degrees above nadir.

Ensure that the output efficiency of the luminaire shall be not less than 65 percent of the bare lamp lumens.  The luminaire shall emit at least 25 percent but no more than 35 percent of the bare lamp lumens at vertical angles of at least 60 degrees above nadir but no more than 90 degrees above nadir.

Ensure that no portion of the arc tube of the lamp shall be viewable at angles of 70 degrees or more above nadir.

Ensure that the photometric distribution is produced by an optical assembly consisting of a reflector alone or in combination with a refractor which redirects the output of a lamp mounted in a socket therein and that the reflector and refractor (if used) are each of a one piece design.

Ensure that the optical assembly is field rotatable to align the light distribution horizontally independent of the orientation of the arm supporting the luminaire.

Ensure that a luminaire for use with a 1000 watt lamp has an auxiliary lamp support that engages the outer end of the lamp envelope.

Ensure that the luminaire is of substantial design adequate to operate at mounting heights up to and including 150 feet (45 m) and wind velocities up to and including 90 mph (145 km/h).

Ensure that the luminaire mounts by means of a slip fit onto a horizontal 2-inch (50 mm) pipe and that the luminaire’s integral mounting provides adjustment for leveling but remains secure and does not twist about the mounting pipe of the bracket when subjected to the vibration and wind loads of the installation.

Ensure that the maximum weight of the complete luminaire does not exceed 75 pounds (34 kg) and the maximum projected area does not exceed 3.5 square feet (0.3 m²).

Furnish materials according to the Department’s Qualified Products List (QPL).

725.12  Polyethylene, Fiberglass Reinforced, Pull Box with Polymer Concrete Cover and Support Ring  Ensure that the pull box body is of fiberglass reinforced high density ultraviolet stabilized molded polyethylene with a polymer concrete cover support ring and polymer concrete cover.  Ensure that the body of the box is of one piece construction.  Ensure that the body of the box has a wall thickness of at least 1/4 inch (6 mm).  Ensure that the cover support ring is permanently integrated into the box.  Ensure that the cover is slip resistant and has in clearly legible block letters 1 to 2 inches (25 to 50 mm) in height integral to the cover the word “TRAFFIC”, “LIGHTING”, “ELECTRIC” or “TELEPHONE” to designate the circuit(s) contained.  Ensure that the cover closely fits the opening and is secured by stainless steel bolts and hardware and that the threaded holes into which the cover bolts fasten are of open bottom design.  Ensure that the box and cover meet the structural requirements of Society of Cable Telecommunications Engineers Tier 5.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.15  Circuit Cable Connections and Terminations. Ensure that each connector or terminator is of the same voltage rating as the wire being connected or terminated except that 600 volt connectors may be used with 5000 volt (secondary service) cable used in 600 volt service for the highway lighting circuits.

Ensure that each connector or terminator is a compression style which fully encloses the conductor(s) and is of high strength copper alloy not a metal other than copper which has been plated. Ensure that each connector used for a “butt” splice is a sleeve type with a “stop” in the center.

A.      Termination of Oversize Wire. Ensure that each cable terminal of each device can properly accommodate the size of the wire being terminated. If a terminal of adequate size cannot be furnished, ensure that a short length of smaller wire is connected to the oversize conductor through the use of a proper butt style crimp connector or a terminal block, that no strands have been cut back in the oversize conductor to make the connection and that the smaller wire is rated to carry the full ampacity of the circuit protection device.

B.      Fused Pull-Apart Connection. Ensure that each fused pull-apart cable connector kit is a molded synthetic rubber housing consisting of a female line side with two ports and a male load side with one port containing a socket type fuse holder wherein the fuse also acts as the pin for the load connection which is designed to break the circuit when the two halves of the connector body are separated.  Ensure that the assembled kit is rated for direct burial and exposure to sunlight.  Ensure that the metal parts of connector are of copper with a conductivity of 90 percent, have individual compression connections for each wire on the line side, have a crimp connection for the wire on the load side and have annular spring on the socket for each end of the fuse.  Ensure that the fuse holder is for a standard midget 13/32 × 1 -1/2-inch (10 × 38 mm) fuse.  Ensure that the fuse is rated 600 VAC, 100,000 AIC and does not have a glass body.  Ensure that each cable port is sized for the wire or cable entering the entering the port and that there is a closure for the second line port if it is not to be used.

C.      Unfused Pull-Apart Connection. Ensure that each unfused pull-apart cable connector kit is a molded synthetic rubber housing consisting of a female line side with two ports and a male load side with one port containing a line side socket and load side pin making a connection which is designed to break the circuit when the two halves of the connector body are separated.  Ensure that the assembled kit is rated for direct burial and exposure to sunlight.  Ensure that the metal parts of connector are of copper with a conductivity of 90 percent, have an individual compression connection for each wire on the line side, have a crimp connection for the wire on the load side, and have an annular spring on the socket for the pin.  Ensure that each cable port is sized for the wire or cable entering the port and that there is a closure for the second line port if it is not to be used.

D.      Unfused Bolted Connection. Ensure that each unfused re-enterable cable connector kit is a rigid molded plastic sleeve closed on each end by a molded synthetic rubber female end housing having one or two ports as needed containing space in which the connection is made by crimping a lug onto each wire and then bolting all of the lugs together.  Ensure that the assembled kit is rated for direct burial and exposure to sunlight. Ensure that the metal parts of connector are of copper with a conductivity of 90 percent and that each connecting bolt has a self-locking nut.  Ensure that each wire enters through a port sized for the wire and that there is a closure for the port if it is not to be used.

E.      Unfused Permanent Connection. Ensure that each cable splicing kit is a rigid transparent molded body having as many as two ports on each which allows the completed splice to be completely encapsulated by filling the mold with a resin compound. Ensure that the actual conductor connections are made using one time use compression connectors and that each wire or cable enters the mold through its own port.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.16 Ground Rods. Ensure that each ground rod is 1 inch (25 mm) in diameter and 10 feet (3 m) in length with a driving point on the lower end.  If of other than circular cross section, ensure that the periphery of the rod is 3.2 inches (80 mm) or more.  Ensure that the rod is of solid construction and is either stainless steel jacketed steel, copper clad steel or hot dipped galvanized steel in accordance with ASTM A 153, Class B-1.

Ensure that the rod bears a label denoting that it is UL listed.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.19 Power Service Components. Furnish the materials and equipment comprising a service pole, including service equipment, that meets the following requirements.

A.      Service Entrance Conduit. Ensure that the service entrance or riser conduit is rigid galvanized steel with a rain tight galvanized steel service entrance head (weatherhead) threaded to fit the conduit containing a composition insert for three conductors.

B.      Service Disconnect. Ensure that the service disconnect is a properly rated fused switch of the ampacity specified and solid neutral. Ensure that the service fuses are cartridge fuses on the load side of the switch.

C.      Lighting Contactor. Ensure that the lighting contactor is of the open type electromagnetically held.

Ensure that control of the contactor is through a photocell connected through a “HAND-OFF-AUTOMATIC” selector switch accessible only with the contactor enclosure open.  Ensure that the control circuit is a separate circuit with its own protection.

D.      Lighting Circuit Protection. Ensure that separate protection is provided on the load side of the lighting contactor for each lighting circuit and that such protection will open all line or phase conductors of the respective circuit should a fault occur on any one line or phase conductors.

E.      Photoelectric Cell. Ensure that the photoelectric control is a twist-lock plug-in, utility grade, solid state, cadmium sulfide type of the proper voltage, rated for 1000 watts maximum load, with integral surge protection, a fail-safe mode in which the lighting circuits will remain energized, and a hermetically sealed case. Ensure that the nominal “turn on” level is 1 footcandle (10 lux) vertical and that the nominal “turn-off” level is 6 footcandles (65 lux) vertical with tolerances of 20 percent for the specified values.  Ensure that the photocell has a time delayed response that will not respond to flashes of light from lightning, headlights of passing vehicles or emergency vehicle strobes and beacons.  Ensure that the photoelectric control mounting bracket has a EEI-NEMA locking-type receptacle.

F.      Switchgear Enclosure. Ensure that components are mounted on a removable back panel of 14 gage or heavier enameled steel rather than directly on the back wall of the enclosure and that the back panel mountings do not penetrate the walls of the enclosure.

Ensure that a neutral terminal bar of adequate ampere rating and with holes in number and of size to terminate each conductor separately is provided in each enclosure where neutral conductors are to be terminated.  Ensure that an equipment grounding conductor terminal bar of adequate ampere rating and with holes in number and of size to terminate each conductor separately is provided in each enclosure where grounding conductors are to be terminated.  When there is no code or utility company prohibition, a combination neutral and equipment grounding conductor bar may be furnished.

Ensure that an enclosure containing a disconnect switch with an external operating handle allows that handle to be padlocked in either the “OFF” or the “ON” position.

Ensure that the enclosure containing the service disconnect switch has an interlock to prevent the door from being opened when the switch is in the “ON” position

Ensure that the enclosure provides for padlocking the door. 

Ensure that each switchgear enclosure is a NEMA ICS-1-110.15 Type 4 fabricated from No. 16 gage or heavier AISI Type 302 or 303 annealed stainless steel with fully welded seams and a brushed finish.

All fasteners used in assembly of the enclosures shall conform to ASTM A 320/A 320M (AISI-300 series).

G.     Wiring Schematic, Wiring Diagram, Placards. Furnish both a schematic diagram and a wiring diagram of the entire power service from the power company service transformer secondary connection through the lighting branch circuit connections in triplicate with two copies delivered to the project and the third copy placed in the service disconnect enclosure.  The Engineer will ensure that one of the two copies delivered to the project is filed with the project records and the other is delivered to the maintaining agency .

Ensure that each placard to be attached to an apparatus enclosure is of multiple layers of plastic thermally bonded together to provide a plate of at least 1/8 inch (3 mm) in thickness with engraved plain block letters at least 1/2 inch (12 mm) in height.  Ensure that placards designating the function of the apparatus contained in an enclosure or other such information are of white letters on a black placard.  Ensure that placards warning of high voltage possibly present in an enclosure or other such warning are of white letters on a red placard.

H.     Customer Service Pole. Furnish a wood pole that complies with Supplement 1072.  Ensure that the pole and any cross arms or pole key is Southern Pine or Western Red Cedar, full length, pressure treated in compliance with specifications of the American Wood Preservers Association using either creosote or pentachlorophenol.  Ensure that the retention of preservative in Southern Pine is 7.5 pounds (120 kg) of creosote by assay or 0.38 pounds (6 kg) of pentachlorophenol by lime-ignition assay per cubic foot (cubic meter) of wood.  Ensure that the retention of preservative in Western Red Cedar is 16 pounds (256 kg) of creosote by assay or 0.8 pounds (13 kg) of pentachlorophenol by lime-ignition assay per cubic foot (cubic meter) of wood.  Ensure that the pole is 35 feet (10.5 m) minimum in length and Class 4 or heavier and conforming to ANSI 05.1 Specifications and Dimensions for wood poles. Ensure that the pole is reasonably straight without pronounced sweep or short crooks.

Ensure that all pole hardware, including racks, braces, straps, guy anchors, guy wire, clamps, bolts, nuts, washers, screws, nails, etc. is hot dip galvanized in accordance with 711.02.

Ensure that the grounding conductor is fastened to the pole with copper clad, rolled point staples of adequate size.

Ensure that the grounding conductor molding is either wood or plastic, in sections not less than 8 feet (2.4 m) long, of sufficient width and groove depth to completely enclose the grounding conductor.

Ensure that each pole anchor is of malleable iron or galvanized steel, 6 inch (150 mm) minimum diameter, two-way or four-way expanding type. Ensure that each anchor rod is 5/8 inch (16 mm) minimum diameter, 8 feet (2.4 m) minimum length galvanized steel with thimble eye. Ensure that each guy wire is 3/8 inch (10 mm) minimum diameter, conforming to ASTM A 475, galvanized steel.

725.20  Multiple Cell Polyvinyl Chloride Conduit and Fittings. Ensure that the multiple cell conduit consists of inner ducts conforming to NEMA TC-8 type DB in an outer conduit conforming to NEMA TC-2 (type EPC-40 or EPC-80 as specified except that size shall be the true inside diameter) in a factory preassembled unit.  Ensure that fittings are factory made couplings that couple inner ducts and the outer conduit simultaneously, maintain the continuity and indexing of the inner ducts and are of a push fit design mechanically locked in place.

Furnish materials according to the Department’s Qualified Products List (QPL).

725.21  Luminaire Supports. Ensure that the complete luminaire support from the luminaire(s) down through the connection to the foundation or other structure to which the luminaire support is attached conforms to the requirements of AASHTO’s Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals.  Ensure that the combined stress ratio above the first field joint is greater than the combined stress ratio at the base of the pole.

The design wind speed for all areas of the State shall be 90 mph (145 km/h).

The Department may require various tests including destructive tests at either the factory or on site prior to acceptance of a support in which case the Department’s representative will supervise the Contractor and/or manufacturer as the appropriate entity performs the tests on supports selected at random by the Department from the lot produced for the project.  Ensure that any support damaged by the testing is replaced at no additional cost to the Department.

Ensure that the support identification labels are adhesive labels with silver white reflective characters on a reflective green background meeting the requirements of 730.18.

Furnish certified luminaire supports according to Supplement 1091

A.      Light Poles. Ensure that the deflection of the pole from vertical when placed under the load of the bracket arm, and a weight of 75 pounds (35 kg) in place of each luminaire does not exceed an angle of 1 degree 10 minutes when tested in accordance with Supplement 1025 and that certified copies of the results obtained from the deflection tests are furnished the Laboratory.

A pole and arm constructed from either aluminum or steel but not a combination of the two may be furnished.

Ensure that each bracket arm is made from straight or tapered stock round or ovaliptic in cross section not less in size than 2 inch (50 mm) nominal pipe.

Ensure that the luminaire end of each bracket arm has an outside diameter equal to 2 inch (50 mm) pipe, is straight for a distance of eight inches (203 mm), with the longitudinal axis canted not less than 1 degree and not more than 4 degrees above horizontal.

Ensure that the bracket has an internal raceway with a minimum internal diameter of 1 3/32 inches (28 mm) free of projections and obstructions, which, when assembled to the shaft, will permit installation of luminaire supply conductors without insulation damage and which will not require bending the conductors to a radius less than 3 inches (75 mm).

Ensure that the pole does not have more than two sections, that the shorter section of a sectional is at the top and that the shorter section of a sectional pole is not less than 10 feet (3 m) in length.  Ensure that the pole sections are joined by telescoping the bottom of the upper section over the top of the lower section for a minimum length of 1 1/2 times the external diameter of the bottom of the upper section, driving the joint tight, and securing by through bolting with a stainless steel hex head bolt of a minimum diameter of 5/8 inch (16 mm).

Ensure that a pole section does not have more than one longitudinal, automatically electrically welded seam and no transverse seams.  Ensure that the longitudinal welded seam is neat and uniform in appearance, that the weld is not less than the thickness of the base material and that the bead height does not exceed 1/16 inch (2 mm).  Ensure that the wall thickness is uniform throughout, except at the weld bead. Ensure that the cross section of the pole is circular, or multi-sided with no less than eight sides and that the difference between the major and minor diameters of poles of circular cross section or the difference between the maximum and minimum distances across corners for poles of multi-sided cross section, measured at any point along the longitudinal axis, does not exceed 3/16 inch (5 mm).

Ensure that steel poles are tapered tubes with a true continuous taper not less than 0.06 inches per foot (1.5 mm per 300 mm) and not more than 0.16 inches per foot (4.0 mm per 300 mm).

Ensure that aluminum poles, either spun or cold rolled, are a true continuous taper except for the top and bottom sections which may be straight, that no more than 40 percent of the total shaft length is straight, and that the average rate of shaft taper including straight portions of the shaft is not less than 0.06 inches per foot (1.5 mm per 300 mm) and not more than 0.16 inches per foot (4.0 mm per 300 mm).

Ensure that the full design strength of the pole shaft section in bending can be transmitted through the base plate into the transformer base or the anchor bolts without permanent bending of the base plate or failure of the pole shaft to base plate connection.

Ensure that there is a “J” hook inside the pole just below the top on which to hang the pole and bracket cable support assembly.

Ensure that nonstructural castings for aluminum poles, including the pole cap are of ASTM B 26/B 26M or B 108, Alloy S 5 A, Condition F.

Ensure that steel poles and bracket arms are hot dipped galvanized after fabrication in accordance with the requirements of 711.02.

Furnish aluminum poles and bracket arms in natural aluminum with a satin brushed surface. 

Ensure that each light pole is identified by a raised or engraved marking applied to the edge of the base plate which identifies the manufacturer and the year that the pole was manufactured and that such marking remains legible after the pole has been galvanized.

Ensure that bolts, nuts, washers and other fasteners used to assemble the light pole are of galvanized steel conforming to 711.02, stainless steel conforming to ASTM A 320/A 320M (AISI-300 series) or silicon bronze conforming to ASTM B 98M (B 98).

Ensure that each non-frangible steel transformer base is capable of transmitting the design dead, live, ice and wind loads of the light pole to be mounted on it to the foundation without failure or permanent deformation, has a flush door permanently attached by means of a top-mounted continuous stainless steel hinge, and is made from steel conforming to ASTM A36/A 36M hot dip galvanized after fabrication.

Ensure that each frangible aluminum transformer base is capable of transmitting the design dead, live, ice and wind loads of the light pole to be mounted on it to the foundation without failure or permanent deformation, has a flush aluminum door permanently attached by means of a top-mounted continuous stainless steel hinge, and bears easily found and read durable labeling as to which AASHTO frangibility criteria the base meets. Ensure that the base has been tested and accepted by the FHWA as complying with the 1985 AASHTO frangibility requirements

Ensure that the bolts and nuts used to fasten the base plate of the pole to the transformer base are heavy hex conforming to ASTM A 307 and galvanized in accordance with 711.02.  When either the top or the bottom of an aluminum transformer bases is to be fastened against non-galvanized steel, ensure that both the steel and the aluminum mating surfaces have been coated with a heavy film of zinc rich paint.

Ensure that the anchor bolts are steel with 55,000 psi (380 Mpa) minimum yield strength, that the threaded ends of the bolts and nuts are galvanized in accordance with 711.02 for at least 2 inches (50 mm) beyond the threads and that the nuts are capable of developing the full strength of the anchor bolt and are galvanized in accordance with 711.02.

B.      Light Towers. Ensure that the structural design of the light tower is based on a load of six luminaires or the actual number of luminaires to be installed whichever is greater.  Ensure that the structural design of the light tower is based on each luminaire weighing 75 pounds (34 kg) and having an effective projected area of 3.5 square feet (0.3 m²) or the actual weight and effective projected area of each luminaire whichever is greater.  Ensure that the structural design of the light tower is based on the head frame assembly with lowering device weighing 340 pounds (154 kg) and having a projected area of 5.3 square feet (0.5 m²) or the actual weight and effective projected area of the head frame and lowering device whichever is greater.

Ensure that the luminaire lowering device (consisting of the luminaire ring, the head frame, the winch, the power cables and all miscellaneous mechanical and electrical equipment mounted in or on the pole) and the pole are compatible with each other.

1.      Luminaire Ring. Ensure that the luminaire ring assembly is fabricated from steel which conforms to ASTM A 36/A 36M and that the ring is fitted with a separate 2 inch (50 mm) nominal steel pipe mounting arm directly attached to the ring for each luminaire.

Ensure that the luminaire ring is supported by three wire ropes equally spaced around the ring.  Ensure that the three wire ropes are of the same material and construction.  Ensure that the wire rope for this purposed is 3/16 inch (5 mm) minimum diameter and either galvanized steel hoisting cable or aircraft grade stainless steel control cable composed of 7 strands of 19 wires each. Ensure that each wire rope support cable is connected to the ring by a corrosion resistant device that will allow the connection to develop the full breaking strength of the wire rope while permitting ready adjustment of the length of the wire rope to level the ring.  Ensure that the ring is equipped with a minimum of three spring loaded roller tipped centering arms equally spaced around the ring that are in continuous contact with the pole shaft and that the guide arm rollers are of a nonabrasive, water resistant material.

Ensure that the luminaire ring is equipped with three positive latching devices equally spaced around the ring that latch to the head frame supporting the ring in the raised position allowing tension to be removed from the lifting cables. Ensure that all moving parts of each latching device are part of the ring portion of the latch assembly and that each latch assembly incorporates a reflectorized flag that is clearly discernible from the ground when the ring is latched to the head frame.  Ensure that the latching sequence shall not exert a horizontal force sufficient to cause an excess of 4 g’s acceleration upon the luminaires.

Ensure that the luminaire ring is equipped with a NEMA 4 corrosion resistant junction box for the connections between the main power cord bringing power to the ring and the separate power cords for each luminaire.  Ensure that each power cord has copper conductors of adequate size and insulation, that each power cord is of suitable construction, and that each power cord enters the junction box through a weather tight cord connector. Ensure that there is a cord support capable of withstanding a load of 1 1/2 times the weight of the main power cord without damage to the cord transmitting the weight of the main power cord directly to the ring.  Ensure that there is a weather tight power inlet on the luminaire ring which allows the main power cord in the base of the tower to connect to the ring when the ring is in the lowered position.  Ensure that the junction box is equipped with a 600 volt class terminal block for the connections between the main power cord, the luminaire power cords and the power inlet cord.  Ensure that each luminaire ring is identified by a raised or engraved marking applied in a prominent location which identifies the manufacturer and the year that the ring was manufactured and that such marking remains legible after the ring has been galvanized

2.      Head Frame Assembly. Ensure that the head frame is fabricated from steel which conforms to the requirements of ASTM A 36/A 36M. Ensure that the head frame assembly is equipped with pulleys for the wire ropes hoisting cables and rollers for the main power cord to the luminaire ring.  Ensure that each hoisting cable sheave has a tread diameter of at least 20 times the cable diameter for galvanized cable and 25 times the cable diameter for stainless steel cable, that the groove for the hoisting cable has a semi-circular in cross section with a radius of one-half the cable diameter plus 1/64 inch (0.4 mm), that the sheave has an oil-impregnated bronze bushing and that the shaft on which the sheave turns is of stainless steel.  Ensure that the rollers for power cord run on AISI 304 stainless steel shafts between cold-rolled steel plates. Ensure that bending radius of the power cord is not less than 7 inches (180 mm).  Ensure that keeper bars have been provided over the power cord and ring support cables to keep them in their respective tracks.  Ensure that a guide is provided to separate the individual cables as they pass between the head frame and the top of the pole.  Ensure that the head frame mechanism is protected from the weather by a domed cover of either copper free spun aluminum or fiberglass.  Ensure that each head frame is identified by a raised or engraved marking applied in a prominent location which identifies the manufacturer and the year that the head frame was manufactured and that such marking remains legible after the head frame has been galvanized.

3.      Transition Plate. Ensure that there is a transition plate between the ring support cables and the main hoisting cable.  Ensure that the luminaire ring support cables are secured to the transition plate by shop applied, swage-type fittings designed to develop a connection strength equal to the breaking strength of the cable and prevent abrasion of the cable by the transition plate.  Ensure that there is a cord support capable of withstanding a load of the weight of the main power cord plus a wind load on the cord equal that of a 30 mph (48 km/h) wind perpendicular to the full length of the cord without damage to the cord connecting the main power cord to the transition plate.

4.      Hoisting Winch. Ensure that the winch is of cast iron and steel construction with an integral enclosed lubricant bathed worm and gear drive having a reduction great enough to be self-locking.  Ensure that the winch has a pulling capacity at least five times greater than that required to lift the load.  Ensure that the winch drum diameter is not less than 4 inches (100 mm), that the drum flange diameter is at least 3 inches (75 mm) greater than the diameter of the drum.  Ensure that there is a cable guide or follower to prevent cable buildup at the ends of the winch drum. Ensure that the support plate for the winch bears a durable tag which identifies the manufacturer, manufacturer’s model and year of manufacture for the lowering device.

5.      Winch Drive Unit (Portable Power Unit). Ensure that the winch drive unit is powered by a heavy duty reversing drill motor, minimum 560 W (3/4 horsepower) rating, 120 volt.  Ensure that there is a mechanical slip clutch torque limiter incorporated into the output shaft and that there is a placard on the portable winch drive unit giving the settings and instructions for care of the torque limiter.   Ensure that there is a separately packaged dry type isolated winding transformer included to permit operation of the drill motor from the lighting circuit by plugging into the luminaire power cord outlet in the base of the tower.  Ensure that the cord outlet and plug for connecting the motor to the transformer are NEMA L5-15 devices.   Ensure that he hoisting rate is between 15 and 25 feet per minute (4 and 8 m/min).  Ensure that the hand control switch incorporates 20 feet (6 m) of cable to allow operation of the lowering device from a position away from the pole and not beneath the ring and luminaires. Ensure that each winch drive unit frame is identified by a raised or engraved marking applied in a prominent location which identifies the manufacturer and the year that the portable power winch drive unit was manufactured and that such marking remains legible after final finish has been applied to the frame.

6.      Connection of Tower to Lighting Circuit. Ensure that there is a separate terminal block for each conductor of the supply circuit in the base of the tower, and that there are enough spaces on the blocks to allow the incoming circuit to split into three outgoing directions in addition to the feed to the tower itself.  Ensure that the terminal block has set screw style terminations, sized for 4 AWG - 1/0 AWG for the incoming and outgoing lighting circuit and 12 AWG - 10 AWG for the tower wiring.  Ensure that there is a circuit breaker in a NEMA 4 enclosure located electrically after the terminal blocks for the lighting circuit and before the power cord leading up the tower to the luminaires.  Ensure that the breaker enclosure is internally mounted and that the breaker is readily accessible through the tower hand hole.  Ensure that the circuit breaker is a bolt on design, sized at 15 amperes with a minimum interrupting capacity of 14,000 amperes for 480 volt circuits or sized at 20 amperes with a minimum interrupting capacity of 10,000 amperes for 240 volt circuits and is of a single handle rather than a tied handle design with one pole for each line or phase conductor. Ensure that cord connector, plug and inlet on the ring for electrical power to the luminaires are NEMA L8-20 devices for 480 volt systems or are NEMA L6-30 devices for 240 volt systems.

7.      Operating Manual. Furnish a complete manual including instructions on installation, operation and maintenance for each type of the following: lowering device, winch assembly and portable power winch drive unit.

8.      Shaft. Ensure that shaft of the tower is of not more than four round or multi-sided tapered steel sections for towers up to and including 100 feet (30 m), five sections for towers over 100 feet (30 m) up to and including 120 feet (37 m), and six sections for towers over 120 feet (37 m).  Ensure that the shaft is of steel having a minimum yield strength of 55,000 psi (379 MPa).  Ensure that the shaft sections are joined by telescoping the bottom of the upper section over the top of the lower section for a minimum length of 1 1/2 times the external diameter of the bottom of the upper section or two feet (0.6 m) whichever is greater and driving the joint tight.  Ensure that the sections have been pre-fitted and match-marked at the factory. Ensure that the inside surface of the shaft is relatively smooth and that there are no more than two longitudinal welds which shall be made by automatic electric arc welding.  Ensure that the longitudinal seam welds have complete penetration, are of uniform density, are no thinner than the shaft material and not more than 20 percent thicker than the shaft material.  Ensure that the base plate is fabricated from steel which conforms to the requirements of ASTM A 36/A 36M and that the shaft is joined to the base plate using the American Welding Society prequalified joint TC-U4a-S or TC-U4c-GF.  Ensure that the hand hole in the shaft is properly reinforced to avoid stress risers and that the reinforcements are welded to the shaft using a joint and techniques designed to insure total penetration plus an outside fillet equal to the thickness of the shaft material.  Ensure that all welds in the shaft satisfy AWS D 1.1 Structural Welding Code Article 9.25.3 for tensile stress when tested either by the ultrasonic method or by an approved alternate method, and that certified results are furnished to the Laboratory.  Ensure that the door is fabricated from the same type steel as the shaft, is attached with a continuous stainless steel hinge having non-removable stainless steel hinge pins, fits the opening closely, and is securely held shut.  Ensure that there are provisions for padlocking the handhole door closed and that each tower has been furnished with a vandal resistant padlock having a bronze or brass lock body and a corrosion-protected steel shackle keyed to the key number specified by the maintaining agency.  Ensure that there are two holes, tapped 1/2-13, 180 degrees apart provided at the base of the tower for the grounding conductors.  Ensure that the shaft shall be hot dipped galvanized after fabrication in accordance with the requirements of 711.02.  Ensure that each shaft is identified by a raised or engraved marking applied to the edge of the base plate which identifies the manufacturer and the year that the shaft was manufactured and that such marking remains legible after the pole has been galvanized.

9.      Anchor Bolts and Nuts. Ensure that each anchor bolt is steel conforming to ASTM F1554, Grade 55, and galvanized in accordance with 711.02. at least 2 inches (50 mm) beyond the threads.  In lieu of a bent end, an anchor bolt with the lower end threaded and inserted into a steel plate of approved size and thickness which has been drilled and tapped to receive the anchor bolt may be furnished.  Ensure that the nuts used with each anchor bolt are capable of developing the full strength of the anchor bolt.

725.22  Plastic Caution Tape. Furnish tape that is an inert material, approximately 6 inches (150 mm) wide composed of polyethylene plastic, highly resistant to alkalis, acids or other chemical components likely to be encountered in soils.  Furnish tape that is bright red with identifying printing “ELECTRIC” in black letters on one side only.  Furnish tape in continuous rolls with the identifying lettering repeated continuously the full length of the tape.

726         Barrier Reflector MATERIALS

726.01  Barrier Reflectors. Furnish concrete barrier, retaining wall and bridge parapet reflector body housings that are made of acrylic or polycarbonate plastic, or corrosion resistant metal. Ensure that the minimum reflective surface area of the reflector is 7 square inches (4400 mm²).

Furnish white reflectors that reflect the following minimum candela of light at the indicated observation angles for each 1 foot-candle (10.76 lx) of incident light at the indicated entrance angles. Furnish amber reflectors that reflect at least 60 percent of these values.

MINIMUM SPECIFIC INTENSITY, cd/10.76 lx

Entrance angle

Observation Angle

0.2°

2.0°

-4°

62

0.25

15°

52

0.18

The entrance angle is measured in the horizontal plane between the direction of incident light and normal to the face of the reflector. The observation angle is measured in the vertical plane between the observer’s line of sight and the direction of light incident to the reflector face.

Furnish guardrail blockout reflectors that are a minimum size of 4.5 × 10 × 0.125 inches (112.5 × 250 × 3.1 mm) and made of corrosion resistant metal with 1/4" (6 mm) predrilled mounting holes. One or both sides shall be covered with a minimum 4.5 × 5 inches (112.5 × 125 mm) of Type G, H or J reflective sheeting.

Furnish materials according to the Department’s Qualified Products List (QPL).

730  TRAFFIC SIGN AND SUPPORT MATERIAL

730.01  Steel Tube and Pipe.  Furnish steel tube and pipe according to ASTM A 53, Grade B or ASTM A 501, except provide tubing for truss and end frame diagonals according to 711.01.

730.015  U-Channel Posts.  Furnish U-channel posts fabricated from steel into a characteristic cross-section that may be used alone or paired to form a heavier post by being bolted together back to back.  Furnish posts with a uniform cross section for their full length.  Cut posts square to a length tolerance ±1 inch (±25 mm) and ensure that posts do not have ragged or sharp edges, or cracks or other imperfections affecting strength or durability.  The back of the posts may be flat or contain raised longitudinal ribs.

Furnish posts meeting the deflection criteria of Supplement 1075.  Furnish posts manufactured from rail or billet steel according to ASTM A 499, Grade 60.

Furnish posts with a nominal weight before punching or galvanizing as follows:

Post Size Number

Weight  lb/ft (kg/m)

Tolerances %

1

1.12 (1.7)

-3.5, +10.0

2

2.00 (3)

-3.5, +10.0

3

3.00 (4.5)

-3.5, +10.0

Furnish posts with 3/8-inch (10 mm) diameter holes accurately punched on the centerline spaced at 1-inch (25 mm) centers beginning not more than 1 1/8 inches (30 mm) from the top of the post through the entire length, to allow bolting the posts back to back, without redrilling, using 5/16-inch (8 mm) diameter bolts.  Furnish posts that have been galvanized after punching according to 711.02.

Furnish materials according to the Department’s Qualified Products List (QPL).

730.016  Square Posts.  Furnish square posts fabricated from steel according to ASTM A 1011 with a minimum yield strength of 60,000 pounds per square inch (415 MPa), with 7/16-inch (11 mm) diameter die-cut knockouts or open holes spaced on 1-inch (25 mm) on the centerline of all four sides, in true alignment and opposite each other.  Furnish posts with the dimensional requirements conforming to the Department’s standard drawings.  Furnish posts that have been finished with one of the following methods:

A.      Both inside and outside of the post are hot-dip galvanized according to ASTM A 653 G-235.

B.      The outside of the post has a zinc coating of 0.80 ounce per square foot (244 g/m²) followed by chromate conversion coating and a cross-linked polyurethane acrylic coating.  The inside of the post has a zinc organic coating.

Furnish materials according to the Department’s Qualified Products List (QPL).

730.017 Wooden Box Beams.  Furnish wooden box beams fabricated from 1/10 or 1/8 inch (2.54 or 3.18 mm) thick laminated veneers with the grain oriented parallel to the length of the finished beam and the veneers glued together in a continuous process with lap or scarf joints connecting successive veneers in each layer staggered throughout the thickness of the beam.  A 45 degree miter shall be used for the corner joints.  The adhesive used shall be a phenol-formaldehyde which conforms to ASTM D 2559.  The beams shall be pressure treated with a pentachlorophenol preservative meeting AWPA Standard C33, with a minimum preservative retention of 0.60 lb/ft³ (9.6 kg/m³) of pentachlorophenol.

730.02  Steel Anchor Bolts and Nuts.  Furnish anchor bolts made of steel conforming to ASTM F1554 Grade 105, galvanized according to 711.02 at least 2 inches (50 mm) beyond the threads, with the end either bent or with a drilled and tapped steel plate.  Furnish leveling nuts and anchor nuts capable of developing the full strength of the anchor bolt.

Furnish materials according to the Department’s Qualified Products List (QPL).

730.03  Steel Poles and Arms.  Furnish poles and arms made of steel with a minimum yield strength of 52,000 pounds per square inch (359 MPa) and galvanized according to 711.02.

Furnish certified material according to Supplement 1093

730.04  Base and Arm Plates.   Furnish support or pole anchor bases and arm attachment plates fabricated from steel plate according to ASTM A 36 (A 36M) or ASTM A 572 (A 572M), Grade 42.  Weld plates to supports, poles, or arms both inside and outside with fillet or full penetration welds equal to the wall thickness, or by AWS prequalified welding joints TC U4a-S or TC U4c-GF.  The Contractor may use a cast steel base of equivalent strength.

Furnish certified material according to Supplement 1093.

730.05  Handhole Covers.  Furnish handhole covers for poles and overhead sign supports made of 0.109-inch (2.7 mm) galvanized steel or 0.125-inch (3 mm) nominal aluminum alloy.

Furnish certified material according to Supplement 1093.

730.06  Pole Caps.  Furnish pole caps made of aluminum, galvanized ferrous metal, or zinc die casting.

Furnish certified material according to Supplement 1093.

730.07  Arm Caps.  Furnish arm caps made of steel that cover at least 50 percent of the end area.

Furnish certified material according to Supplement 1093.

730.08  Steel Hardware.  Furnish bolts 5/8-inch (16 mm) diameter or larger according to ASTM A 325 (A 325M).  Furnish bolts and screws less than 5/8-inch (16 mm) diameter according  to SAE J429, Grade 5.  Furnish nuts of all size, except anchor nuts and leveling nuts, according to SAE J995, Grade 2.  Furnish flat washers according to ANSI B18.22.1.  Furnish lock washers according to ASME B18.21.1.  Furnish U-bolts according to ASTM A 307.  Furnish all hardware that is hot-dipped galvanized according to ASTM A 153 or mechanically galvanized according to ASTM B 695, Class 50.

Furnish certified material according to Supplement 1092 or 1093.

730.09  Stainless Steel.  Furnish any AISI 300 or 400 series stainless steel.

Furnish certified material according to Supplement 1093.

730.10  Stainless Steel Hardware.  Furnish stainless steel hardware according to ASTM A 320/A 320M (AISI 300 series).  Furnish bolts, screws, nuts, washers, handhole cover chains, and U-bolts that are passivated commercial grade.

Furnish certified material according to Supplement 1092 or 1093.

730.11  Aluminum Sheet and Plate.  Furnish sheets for extrusheet panels according to ASTM B 209 (B 209M), 3003-H18, or 5052-H38.  Furnish sheets for flat sheet and overlay signs, and sign post reflectors, according to ASTM B 209 (B 209M), 3004-H38, 5052-H38, or 6061-T6.  Furnish plates for sign support structures according to ASTM B 209 (B 209M), 6061-T6.

Furnish certified material according to Supplement 1092 or 1093.

730.12  Aluminum Extrusions.  Furnish extruded panels and extrusions for extrusheet panels according to ASTM B 221 (B 221M), 6063-T6.  For sign support structures, provide rolled or cold finished bar, rod, and wire according to ASTM B 211 (B 211M), 6061-T6; provide extruded bars, rods, shapes, and tubes according to ASTM B 221 (B 221M), 6061-T6.

Furnish certified material according to Supplement 1092 or 1093.

730.13  Aluminum Tube and Pipe.  Furnish seamless pipe and seamless extruded tube according to ASTM B 241/B 241M, 6061-T6.  Furnish extruded structural pipe and tube according to ASTM B 429, 6061-T6.

Furnish certified material according to Supplement 1092 or 1093.

730.14  Aluminum Castings.  Furnish sand castings according to ASTM B 26/B 26M, 356-T6 or T7.  Furnish permanent mold castings according to ASTM B 108, 356-T6 or T7.

Furnish certified material according to Supplement 1092 or 1093.

730.15  Aluminum Forgings.  Furnish forgings according to ASTM B 247 (B 247M), 6061-T6.

Furnish certified material according to Supplement 1092 or 1093.

730.16  Aluminum Welding Rods.  Furnish welding rods according to AWS ER-4043.

730.17  Aluminum Hardware.  Furnish hardware according to:

ASTM Designation

Alloy

Condition/Temper

Bolts and screws

B 211 (B 211M)

2024

6061

T4

T6

Studs-welded

B 211 (B 211M)

1100

H16

Nuts-hex

B 211 (B 211M)

6061

6262

T6

T9

Nuts-lock

B 211 (B 211M)

2017

T4

Washers-flat

B 209 (B 209M)

Clad 2024

6061

T4

T6

Lock washers

B 211 (B 211M)

7075

T6

Rivets-solid

B 316/B 316M

6053

6061

T6

T6

Rivets-blind

B 316/B 316M

2017

2117

5052

F

F

F

In addition, provide break-mandrel aluminum blind rivets with a stainless steel or aluminum mandrel.

Furnish certified material according to Supplement 1092.

730.18  Reflective Sheeting Type F.   Furnish sheeting according to ASTM D 4956, Type I, including supplemental requirement S1.

730.19  Reflective Sheeting Type G.  Furnish Type G reflective sheeting according to Supplement 1049, and according to ASTM D 4956, Type III or IV, including supplemental requirement S1.

Furnish materials according to the Department’s Qualified Products List (QPL).

730.191 Reflective Sheeting Reboundable.  Furnish reboundable reflective sheeting according to Supplement 1049, and according to ASTM D 4956, Type III, IV, VIII, IX or XI, including supplemental requirements S1 and S2, with watermarks or other identification marks inconspicuously incorporated into the face of the sheeting on a repeating pattern if necessary to distinguish the sheeting from other similarly appearing sheetings.

Furnish materials according to the Department’s Qualified Products List (QPL).

730.192  Reflective Sheeting Type H.  Furnish Type H reflective sheeting according to Supplement 1049, and according to ASTM D 4956, Type VIII including supplemental requirement S1.

Furnish materials according to the Department’s Qualified Products List (QPL).

730.193  Reflective Sheeting Type J.  Furnish Type J reflective sheeting according to Supplement 1049, and according to ASTM D 4956, Type IX or XI, including supplemental requirements S1.

Furnish materials according to the Department’s Qualified Products List (QPL).

730.20  Nonreflective Acrylic Opaque Sheeting.  Furnish non-reflective acrylic opaque sheeting according to ASTM D 4956, except provide sheeting that does not incorporate any optical elements.

 730.22 Silk Screen Inks.  Furnish opaque and transparent process color inks used in the silk screen process that the manufacturer of the reflective sheeting accepts and warrants according to Supplement 1049.  Use inks that provide a tough, durable film of uniform thickness and appearance on the sign surface.  Furnish transparent process color inks used in the reverse screen process according to the Daytime Color Specification Limits table in ASTM D 4956.

730.23  Transparent Acrylic Electronic Cuttable Films.  Furnish transparent acrylic electronic cuttable films the manufacturer of the reflective sheeting warrants according to Supplement 1049.  Use films that provide a uniform appearance on the sign surface.  Furnish films according to the Daytime Color Specification Limits table  in ASTM D 4956.

731  SIGN LIGHTING AND ELECTRICAL SIGNS MATERIAL

731.03  Changeable Message Sign, Electrical Type.

A.      General.  Electrical changeable message signs consist of units or groups of units containing arrangements of pixels that use electrical circuitry to display different messages.

Place signs in weatherproof cabinets.  Integrate control logic units, load switches, monitor feedback circuits, power supply, etc., within the sign cabinet or mount within a separate weatherproof enclosure as required.

B.      Message Type.  Furnish electrical changeable message signs of the limited message or unlimited message type.

Limited message signs contain pixels in an arrangement so that by the energizing of selected pixels two or more messages may be displayed.

Unlimited message signs contain pixels arranged in full matrix or alphanumeric type modules positioned side-by-side to provide line units of the specified length.  Ensure that the line units are capable of displaying messages containing letters and numerals, limited only by the number of characters that can be accommodated.  Ensure that the line units are capable of continually displaying alternating messages.

Furnish materials according to the Department’s Qualified Products List (QPL).

C.      Display Type.  Furnish electrical changeable message signs consisting of lamp, light emitting diode, fiber optic, light reflecting, or hybrid types.

Lamp type changeable message signs consist of individual incandescent bulbs.

Light emitting diode changeable message signs consist of groups of individual light emitting diodes that, acting together, form individual character pixels.

Fiber optic changeable message signs consist of fiber optic bundles that transmit light from a remote source to form individual pixels.

Light reflecting changeable message signs consist of individual light reflecting panels.

Hybrid changeable message signs consist of individual light reflecting panels, each augmented by a light emitting pixel of the specified type.  Ensure that the light emitting pixels are displayed when the corresponding reflecting panel is in the exposed position, and concealed or de-energized when the corresponding reflecting panel is in the unexposed position.

Furnish materials according to the Department’s Qualified Products List (QPL).

731.05  Internally Illuminated Fixed Message Sign.  Furnish internally illuminated fixed message signs of the required legend and that consist of an opaque housing with a face of translucent plastic.  If specified, provide double faced signs.  Illuminate signs using interior lamps located so the sign face is uniformly lighted.

Furnish signs either with the legend on the exterior surface to maintain legibility when unlighted due to power failure, or with the legend on the interior surface so as to be invisible when the sign is unlighted.  Apply the legend using black silk screening or by direct applied characters to white sign faces, unless otherwise specified.  Design the sign faces for quick removal for maintenance, and provide faces with a safety chain or like device.  If specified, shield the sign faces with sunscreens, louvering, or visors.

Furnish housings made of corrosion-resistant material that is cast, extruded, or formed.  Furnish mounting hubs that are similar to traffic signal design.  Furnish weatherproof signs that have drainage weepholes.

Furnish the sign with the appropriate hardware for mounting by span wire, mast arm, pedestal top, or pole type bracket arms.  Include fluorescent type lamps with ballast.

Furnish materials according to the Department’s Qualified Products List (QPL).

731.06  Sign Flasher Assembly.  Furnish beacons consisting of single traffic signal sections with 8 or 12-inch (200 or 300 mm) yellow lenses.   Ensure that the flasher control unit flashes the beacons at a rate for each beacon of between 50 to 60 times per minute with the light period from one-half to two-thirds of the total cycle.  Furnish flasher control units that have all solid state components and that meet NEMA TS-1, part 6.  House control units within a weatherproof corrosion-resistant enclosure with a lockable door.  Include the LED lamps.

Ensure that the manufacturer of LED beacons is listed on the Department’s Qualified Products List (QPL) for LED signal lamps.

Furnish materials according to the Department’s Qualified Products List (QPL).

731.07  School Speed Limit Sign Assembly.  Furnish yellow beacons that are 8 inches (200 mm) or 12 inches (300 mm).  Ensure that the flashers flash the beacons alternately at a rate for each beacon of 50 to 60 times per minute with the light period from one-half to two-thirds of the total cycle.  Furnish flashers that have all solid state components and that meet NEMA TS-1, part 6.  Ensure that the backing members with hardware are compatible with the method of support.

Ensure that the manufacturer of LED beacons is listed on the Department’s Qualified Products List (QPL) for LED signal lamps.

 Furnish materials according to the Department’s Qualified Products List (QPL).

731.08  Flexible Conduit.  Furnish galvanized steel flextube conduit with a waterproof PVC jacket according to UL 360 for wiring of lighted signs.  

Furnish materials according to the Department’s Qualified Products List (QPL).

731.10  Timer with Enclosure.  Furnish a timer that allows automatic sign operation for a minimum of 8 times per day and for selected days of the week.  Furnish a solid state timer with a back-up battery to maintain timekeeping and program memory for at least 48 hours.  Furnish a battery with a design life of 10 years under field conditions when power failures over the 10-year period would accumulate to 100 days.  If installed outdoors, house the timer within a lockable, weatherproof, corrosion-resistant enclosure.  Furnish each enclosure with at least one padlock complying with 631.06.

Furnish materials according to the Department’s Qualified Products List (QPL).

732  TRAFFIC SIGNAL MATERIAL

732.01  Vehicular Signal Heads, Conventional.  Ensure that vehicular traffic signal heads conform to the ITE “Vehicle Traffic Control Signal Heads” standard. In conformance with the above standard, provide signal heads that are of cast nonferrous corrosion resistant metal.

Traffic signals consist of specified assemblies of optical sections containing 12-inch (300 mm) diameter lens opening, a housing, a door frame with stainless steel hinge pins and latching device, visor, wiring, and includes LED lamp in accordance with 732.04. Retention hardware for LED lamps, if sharing threaded hole with visor hardware, shall consist of minimum 1/2-inch (13 mm) long, set screw with retaining tab and captive wingnut or hex nut. All hardware shall be stainless steel and set screw shall be inserted into signal section door using visible, semi-permanent threadlocking compound. All hardware used to join optical sections together shall be stainless steel.

Furnish signal heads with required mounting hardware.  Furnish signal face orientation to traffic by serrated rings or other devices on housing sections and mounting hardware.  Permit adjustment in increments not greater than 5 degrees of rotation and not affected by wind gusts when locked.  Furnish galvanized steel or aluminum spacers and drop pipes 1 1/2 inches (38 mm) nominal pipe size (1.90 inch (48 mm) actual diameter).  Ensure that disconnect hangers have at least twelve terminals unless a greater number is required Tethered heads shall use ¾-inch unpainted cast aluminum span wire clamps and cable entrance adapters with integral tri-studs (no tri-stud inserts), stainless steel hardware, and a single steel-reinforced mounting hole. Free-swinging heads shall use cast iron span wire clamps and cable entrance adapters with tri-studs. Tri-studs shall be secured to the head using stainless steel nylon-insert or distorted thread locknuts.  A neoprene gasket placed under the clamp washer in the top signal section shall effectively seal the entrance adapter on the signal to make a waterproof connection and shall have a minimum thickness of 3/32 inch.  The inside surface of the visors shall have a finish of flat black. All other exterior surfaces of the signal head and hardware shall have a finish of Federal Yellow or Gloss Black to closely agree with Federal Standard 595, Color 13655 or Color 17038, as specified in the plans. The coating system used shall be durable, uniform, and weather resistant.

For polycarbonate signal heads, obtain proper exterior colors by use of colored plastic rather than painting.

Furnish materials according to the Department’s Qualified Products List (QPL).

732.02  Vehicular Signal Heads, Optically Programmed, 12-inch (300 mm) Lens.  Ensure that the signal sections conform to applicable portions of the ITE standard and 732.01.  Furnish and mount optical sections with a 12-inch (300 mm) lens size alone or in combination with additional sections of optically programmed or conventional optics types to form signal faces and heads.  Furnish an optically programmed signal section that includes an LED lamp.

Balance adjusters, used only if specified, shall have a splined eyebolt design and splined external clamping body.  All assembly hardware shall be stainless steel.

  Furnish a visor with each signal section.

Cable entrance adapters shall be of the tri-stud type with stainless steel hardware.  A neoprene gasket placed under the clamp washer in the top signal section shall effectively seal the entrance adapter on the signal to make a weatherproof connection and shall have a minimum thickness of 3/32 inch (2.5 mm)..

  Furnish materials according to the Department’s Qualified Products List (QPL).

732.03  Vehicular Signal Heads, Optically Programmed, 8-inch (200 mm) Lens.  Optically programmed signal heads with 8-inch (200 mm) lenses consist of a conventional 8-inch (200 mm) signal housing, reflector and door; and an extension portion which is attached in place of a conventional lens and which contains a lens system capable of optical programming.  Furnish the conventional signal housing with reflector and wiring, and the optical programmable extension portion according to the applicable requirements of 732.01 and 732.02.

Furnish a cutaway visor with each signal section.  Ensure that the signal sections include LED lamp.

Furnish manufacturer’s certifications verifying material meets specifications requirements.

732.04  Signal Lamps.

A.      Optically Programmed and Pedestrian Signal Incandescent Lamps.  Ensure that optically programmed and pedestrian signal incandescent lamps conform to the ITE A Standard for Traffic Signal Lamps and Table 732.04-1.B.     Vehicular Signal Incandescent Lamps. The use of vehicular signal incandescent traffic signal lamps is no longer permitted..C.        Vehicular and Pedestrian Light Emitting Diode (LED) Lamps.  Prequalify vehicular and pedestrian LED lamps according to Supplement 1097.

Furnish LED signal lamp units that meet or exceed all the requirements of the current Institute of Transportation Engineers (ITE) publications - Vehicle Traffic Control Signal Heads (VTCSH) - Light Emitting Diode (LED) Circular Signal Supplement 2005; Pedestrian Traffic Control Signal Indications (PTCSI) - Part 2: Light Emitting Diode (LED) Pedestrian Traffic Signal Modules  and Vehicle Traffic Control Signal Heads -  Part 3: Light Emitting Diode (LED) Vehicle Arrow Traffic Signal Modules, unless otherwise stated herein.  .  LED module shall be certified by the Intertek LED Traffic Signal Module Certification Program, and each unit shall have a decal indicating Intertek certification.

All LED signal lamp units shall be the latest model currently in production and new.  Equipment no longer being manufactured shall not be accepted, even if it meets the following specifications.

LED signal lamp units shall conform to the following criteria:

1.      Physical and Mechanical Requirements

a.      The LED traffic signal lamp unit shall be designed as a retrofit replacement for existing incandescent signal lamps and shall not require any special tools for installation.  The 12" (300 mm) retrofit replacement LED traffic signal lamp unit shall fit into existing traffic signal housings built to ITE VTCSH standards without modifications.

b.      Installation of a retrofit replacement LED traffic signal lamp unit into an existing signal housing shall only require removal of the existing lens and incandescent lamp. The new unit shall fit securely in the housing door and connect to existing electrical wiring or terminal block by means of simple connectors. Removal of the reflector is optional.

c.      Each LED signal lamp unit shall be identified on the back side with the following:

(1)     Manufacturer’s name and trademark

(2)     Part number

(3)     Serial number (must be unique for each unit)

(4)     Voltage rating

(5)     Power consumption (watts and volt-ampere)

(6)     Vertical indexing indicator (i.e., “up arrow”, or the word “UP” or “TOP”) if specific orientation of the module  is required.

(7)     Date of manufacture (minimum information required - month & year)

Single units shall have identification markings as to the type and color of the module. Bi-Modals shall be marked with module type.

Each LED signal lamp unit shall have a label placed on the unit certifying compliance to ITE standards for color and luminance.

d.      The LED traffic signal lamp unit shall be a single, self-contained device, not requiring on-site assembly for installation into an existing traffic signal housing.

e.      The assembly and manufacturing process for the LED traffic signal lamp unit assembly shall be such as to assure all internal LED and electronic components are adequately supported to withstand mechanical shock and vibration from high winds and other sources.  The LED signal lamp shall survive 3 drops of 42 inches onto a smooth concrete surface without any loosening or breaking of internal components, or change in operation.

f.       The lens of the LED signal lamp unit shall be capable of withstanding ultraviolet light (direct sunlight) exposure for a minimum time period of five years without exhibiting evidence of deterioration.

g.      Ensure that lenses will withstand a 42-inch (1.0 meter) drop test, are a minimum of 1/8 inch (3 mm) thick, and are free of bubbles and imperfections.  The lenses shall be smooth on the outside with no external facets to prevent dirt and debris build up.

h.      Each LED traffic signal lamp unit shall comprise a UV stabilized polymeric outer shell, multiple LED light sources, and a regulated power supply.

i.       If red or yellow lenses are tinted, they shall match the wavelength (chromaticity) of the LED.  Do not furnish green tinted lenses.

j.       An optical assembly shall diffuse the light output and provide uniform illumination across the entire surface of the lens and eliminate the visibility of the individual LEDs to the observer.  The optical assembly shall be used for all ball modules and shall be optional on arrow and pedestrian modules.

k.      The LED traffic signal lamp unit shall be designed for universal installation in both span wire and standard/stationary pole mount applications.

l.       The Arrow pattern produced by the Arrow LED traffic signal lamp units shall conform to the VTCSH standard for color, size and shape. The Arrow LED traffic signal lamp units shall not require a specific orientation or have a variance in light output, pattern or visibility for any mounting orientation.

m.     LED pedestrian signal lamp units shall be designed as a retrofit replacement, modular or screw in unit for the message bearing surface of a 12" (300 mm) pedestrian traffic signal, type A-2, housing.

n.      The LED pedestrian signal lamp unit shall fit into existing pedestrian signal housings without the need to modify the housing. Installation of the retrofit replacement LED pedestrian signal lamp unit into an existing 12" (300 mm) pedestrian signal housing shall only require the removal of the existing message bearing surface, existing lamp components (i.e. lens, lamp module, gaskets, and reflector) and insertion of the retrofit replacement into the area once occupied by the removed assembly.

o.      The single pedestrian module shall be designed to display a full “HAND” icon and a full “Walking” Person icon that complies with standards for this (icon) symbol for the size specified.

p.      LED traffic signal lamp units shall be visible at 450 feet (137 meters) during sway conditions (extended view) until obscured by the visor.

q.      The module shall be designed to detect catastrophic loss of the LED load. Upon sensing the loss of the LED load, the module shall present a resistance of at least 250K Ohms across the input power leads within 300 msec.

r.       Turn-On and Turn-off time is less than 75 msec. Also, low voltage Turn-Off is less than 35 Volts.      

2.      Photometric Requirements

a.      The red and orange lamps shall be manufactured using AlInGaP (Aluminum-Indium-Gallium-Phosphide) technology or other LEDs with lower susceptibility to temperature degradation than AlGaAs (Aluminum-Gallium-Arsenic). AlGaAs LEDs will not be permitted. Green and yellow lamps shall be manufactured using Indium Gallium Nitride.   

b.      Each LED traffic signal lamp unit shall meet minimum laboratory light intensity values, color (chromaticity), and light output distribution as described in ITE   VTCSH – LED Circular Signal Supplement.

c.      Arrow LED traffic signal lamp units shall be designed so that when operated over the specified ambient temperature and voltage ranges, the signal is clearly visible and attracts attention for a distance of at least 1300 feet (400 meters) under normal atmospheric conditions..

d.      Measured chromaticity coordinates of LED traffic signal lamp units shall conform to the chromaticity requirements of the following table, for a minimum period of 60 months, over an operating temperature range specified in section AD@.  Each LED traffic signal lamp unit shall meet the minimum requirements for light output for the entire range from 80 to 135 volts.

Chromaticity Standards

Red

Y: not Y: not greater than 0.308 or less than 0.998 - x

Yellow

Y: not Y: not less than 0.411 nor less than 0.995 - x

nor less than 0.452

Green

Y: not Y: not less than 0.506 - 0.519x

nor less than 0.150 + 1.068x nor more than 0.730

e.      LED pedestrian signal lamp units shall be designed so that when operated over the specified ambient temperature and voltage ranges, the signal shall attract the attention of, and be readable to, a viewer (both day and night) at all distances from 10 feet (3 meters) to the full width of the area to be crossed.

f.       The measured chromaticity coordinates of LED pedestrian signal lamp units shall conform to the chromaticity requirements of Section 5.3, Color and the associated Figure C of the PTCSI standard, for a minimum period of 60 months, over an operating temperature range specified in section AD@.  Each LED traffic signal lamp unit shall meet the minimum requirements for light output for the entire range from 80 to 135 volts.

3.      Electrical

a.      Each unit shall incorporate a regulated power supply engineered to electrically protect the LEDs and maintain a safe and reliable operation.  The power supply shall provide capacitor filtered DC regulated current to the LEDs according to the LED manufacturer’s specification.

b.      The LED traffic signal lamp unit shall operate on a 60 Hz AC line voltage ranging from 80 volts RMS to 135 volts RMS.  The circuitry shall prevent flickering over this voltage range.  Nominal rated voltage for all measurements shall be 120 ± 3 volts RMS.

c.      All unit types shall be operationally compatible with the traffic signal equipment that each type is designed and intended to interface with. This equipment includes all controllers, conflict monitors, current monitors, switch pack and flashers currently in use by the Ohio Department of Transportation. The LED traffic signal lamp unit shall be operationally compatible with all TS-1, TS-2, 170 and 2070 controllers,  NEMA TS-1 conflict monitors (including so-called NEMA plus features such as dual indication detection and short yellow time detection); NEMA TS-2 Malfunction Management Units; and 33x cabinet Type 210ECL and 2010ECL conflict monitors (including red monitoring and so-called plus features such as dual indication detection and short yellow time detection) currently used by the Department.  In the case of conflicts between specifications, the latest ODOT specifications will control.

e.      Two, captive, color coded, 600 V, 20 AWG minimum jacketed wires, 3 feet (0.9 m) long, conforming to the National Electric Code, rated for service at 221  °F (105  °C), are to be provided for an electrical connection.

f.       The LED signal shall operate with a minimum 0.90 power factor.

g.      Total harmonic distortion (current and/or voltage) induced into an AC power cabinet bus by any sample of 10 signal lamp units shall not exceed 20 percent. This value may be calculated using the root-mean-square combination of the measured harmonic distortion from one sample LED signal lamp unit.

h.      LED signal lamp units and associated on-board circuitry shall conform to the requirements in Federal Communications Commission (FCC) Title 47, Sub Part B, Section 15 regulations concerning the emission of electronic noise.

i.       The LED signal lamp units shall incorporate circuitry to ensure that they show no evidence of illumination for input voltages below 35 volts.  LED signal lamp units shall be illuminated (unregulated illumination) for all input voltages higher than 45 volts AC but less than 80 volts AC.  They shall have fully regulated illumination for applied voltages of 80 volts through 135 volts AC.  Proof of the intended function of this circuitry shall be accomplished by connecting the lamps to a variable voltage source and slowly raising the applied voltage from zero volts up to 135 volts, and then slowly lowering the applied voltage from 135 volts to zero volts.

j.       Proposed LED signal lamp units shall be less than or equal to the base wattage shown below at 77 °F (25 °C).

Retrofit

Wattage

12@ R 12” Red Ball

12 or less

12@ Y 12” Yellow Ball

22 or less

12@ G 12” Green Ball

15 or less

12@ Y 12” Yellow Arrow

10 or less

12@ G 12” Green Arrow

l9 or less

4.      Environmental Requirements

a.      Green and red LED traffic signal lamp units shall be rated for use in the ambient operating temperature range of -40 °F to +166 °F (-40 °C to +74 °C). Yellow signal lamps shall be rated at a range of -13 °F to +77  °F (-25 °C to +25 °C).

b.      The unit shall consist of a housing that is a sealed watertight enclosure that eliminates dirt contamination and allows for safe handling in all weather conditions. The LED signal lamp unit shall be sealed against dust and moisture intrusion per the requirements of NEMA Standard 250-1991 for Type 4 enclosures to protect all internal LED and electrical components.

5.      Documentation Requirements.  Each LED traffic signal lamp unit shall be provided with the following documentation:

a.      Installation instructions.

b.      The manufacturer name, brand and model number of all LEDs used shall be provided, along with the LED manufacturer’s recommended drive current and degradation curves.

6.      Warranty.  The LED signal lamp unit shall be repaired or replaced by the manufacturer if it exhibits a failure due to workmanship or material defects within the first 60 months of field operation.

The LED signal lamp unit shall be repaired or replaced by the manufacturer if, when operating over the specified operating ambient temperature and voltage ranges, the unit does not meet or exceed all minimum luminous intensity requirements as defined in the specifications during the first 60 months of field operation.

The measured chromaticity coordinates of LED signal lamp units shall conform to the requirements for chromaticity in the specifications over the temperature range provided in the Specifications for the duration of the warranty period.

The manufacturer shall provide a written warranty against defects in materials, workmanship and luminous intensity for LED signal lamp units for a period of 60 months after installation of LED signal lamp units.  Replacement LED  signal lamp units shall be provided within 10 days after receipt of failed LED signal lamp units at no cost, except the cost of shipping the failed units.

An LED pedestrian signal lamp unit shall be repaired or replaced by the manufacturer if the signal lamp unit does not attract the attention of, or is not readable to, a viewer (both day and night) at all distances from 10 feet (3  meters)  to the full width of the area to be crossed when operated over the specified operating ambient temperature and voltage ranges.        

Furnish materials according to the Department’s Qualified Products List (QPL).

732.05  Pedestrian Signal Heads.  Furnish pedestrian signal heads that conform to the ITE Pedestrian Traffic Control Signal Indications.  Furnish signal heads that are complete units made up of two optical compartments with no leakage of light from one compartment to another.  Ensure that the signal heads alternately display the symbol of an upraised hand in Portland orange and the symbol of a walking person in white light.  Do not furnish outline style symbols.    Furnish material for housings that consist of cast or sheet, corrosion resistant, non-ferrous metal.  Adequately reinforce the housings.  Ensure that the lens frames are non-ferrous metal or polycarbonate material.

Ensure that the lenses are glass or ultraviolet and impact-resistant plastic and display the legend with translucent symbols within an opaque black background.

Seal the lens to the door frame by the use of a weatherproof seal.  Furnish an elastomeric gasket between the door frame and housing to ensure a dust and weatherproof seal.

Use a signal head design that provides adequate dissipation of heat.

Fit each compartment of pedestrian signal heads with a visor that is at least 7 inches (175 mm) in length or, in lieu of visors, protect the entire face with a sunshade fastened close to the lens.  Furnish a black grid sunshade fabricated of high impact resistant plastic with a nominal depth of 1 1/2 inches (38 mm) and consisting of horizontal members spaced at not more than 1/2-inch (13 mm) and vertical members spaced appropriately.

Furnish pedestrian signal heads with required mounting brackets.  Furnish either pipe type brackets or, when compatible with the mounting position required by the plans, two-piece hinged type brackets that support the signal head close to the pole.

Furnish 1 1/2-inch (38 mm) galvanized steel pipe brackets with necessary fittings and adapters, and that are one-way or two-way as required.  Orient the signal face to crosswalks by selective meshing of serration rings or other devices provided on housings and mounting brackets.  Make adjustment in increments not greater than 5 degrees of rotation and that is not affected by wind gusts when locked.

Furnish two-piece hinged brackets of cast aluminum with stainless steel hinge pins, and when closed will be secured by a tamperproof bolt.  Ensure that the mounting incorporates a terminal block for quick disconnect of field wiring.  Ensure that the mounting design permits attachment to the pole by banding, bolting or by lag screws in the case of wood poles.

Finish signal exterior surfaces black with enamel coating. Finish interior surfaces of visors flat black.

Furnish pedestrian signal head types according to Table 732.05-1.

TABLE 732.05-1

Signal Head Type

Symbol Height, Inches, (mm)

Light Source

A1

A2

6 (152)

9 (229)

LED

D2

9 (229)

LED

If specified, furnish the types listed below:

A.      Type A1.  Furnish a signal head that utilizes the housings of two 8-inch (200 mm) lens type vehicular traffic sections connected together to form a vertical unit.  Ensure that the sections have square lenses.  Ensure that the upper lens displays the symbol of an upraised hand in portland orange and the lower lens will display the symbol of a walking person in white . 

Furnish materials according to the Department’s Qualified Products List (QPL).

B.      Type A2.  Furnish a signal head that utilizes the housings of two 12-inch (300 mm) lens type vehicular traffic sections connected together to form a vertical unit.  Ensure that the sections have square lenses with the same symbol position as Type A1.  Furnish materials according to the Department’s Qualified Products List (QPL).

C.      Type D2.  Furnish a single housing signal head with a lens in one piece or in two sections, one for each message. Color and mask the lens to display in portland orange the symbol of an upraised hand from the left compartment and the symbol of a walking person in white from the right compartment. Install a lamp in each compartment. The upraised hand and the walking person symbols may be integral in the same compartment.

D.      Countdown. 

1.      Operation.

a.      Display driver shall be designed to allow individual LED failures without affecting other LEDs in the same display.

b.      The countdown timer shall be of the “smart” type, which continuously samples the timing intervals presented by the pedestrian signal load switch driver(s) in order to “learn” the programmed timing being used by the controller.

c.      During interval sampling time, the countdown timer numerical display shall be blank.

d.      Sampling time to determine interval settings shall take a maximum of two complete signal cycles.

e.      The unit shall be capable of displaying a countdown commencing at the onset of the pedestrian clearance interval and reaching zero at the end of the pedestrian clearance interval.

f.       Any interruption of the flashing pedestrian clearance display, e.g., preemption, timing plan change, during a countdown display shall immediately cause blanking of the countdown numerals.  The countdown timer shall “re-learn” the pedestrian clearance interval upon return to normal service after preemption or immediately following a change in walk clearance time associated with a timing plan change.

2.      Type A2.  The top section shall be identical to the 12 inch (300 mm) Type D2 pedestrian signal.  The bottom section shall consist of a countdown display in a 12 inch (300 mm) housing. 

3.      Type D2.  The left side of the signal section shall consist of an integral hand/walking person display.  The right side compartment shall contain the countdown display. 

Furnish materials according to the Department’s Qualified Products List (QPL).

732.06  Pedestrian Pushbuttons.  Furnish pushbuttons of sturdy construction that consist of a base housing and a removable cover.  Furnish components that provide a pushbutton with normally open contacts and that include all electrical and mechanical parts required for operation.

Ensure that the design of the pushbutton and its associated contacts and housing are sturdy and resistant to mechanical shocks and abuse.  Ensure that a concentrated force of 50 pounds (225 N) applied to the button or any exposed portion does not damage the unit or misadjusts the contacts.  Furnish a housing with a curved back surface for mounting on poles of various diameters.  Integrate the curved surface with the housing or supply an adapter with a flat back type housing.  Attach the cover assembly to the housing by stainless steel machine screws, resulting in a weatherproof and shockproof assembly.  Furnish a hole threaded for a 1/2-inch (13 mm) pipe in the housing for conduit attachment purposes.  Paint external surfaces yellow with enamel paint of Color 13655, Federal Standard 595 , unless specified otherwise in the Plans..

Ensure that the maximum force required to operate the pushbutton is 5 pounds (22.5 N).  Furnish a raised or flush pushbutton with a minimum of 2 inches at its smallest dimension.

Furnish pedestrian pushbutton signs that are a minimum of 0.07-inch steel or 0.10-inch aluminum.  Ensure that the legends and backgrounds are baked enamel paint for steel signs and enamel paint or non-reflective sheeting for aluminum signs.

    Furnish materials according to the Department’s Qualified Products List (QPL).

732.07  Loop Detector Units.

A.      NEMA TS-1.  Ensure that the loop detector units comply with the requirements of NEMA TS-1, section 15, with the following modifications.  Furnish shelf mounted loop detector units that are powered from 120 volts.  Use solid state isolated output units for all controller applications where directly connected to a solid state digital controller unit.  Ensure that the conductors in the cable harness for loop input pins are twisted three to five times per 1 foot (300 mm).

Ensure that the electrical connections for four-channel shelf-mounted units either are the 19-pin MS connector, as required by the foregoing specification, or consist of four connectors of the type required for single-channel shelf-mounted detector units.

If specified, design detector unit electrical connection plugs or wiring harness such that any multi-channel shelf-mounted detector unit may be readily replaced with single-channel detector units.  Accomplish this by furnishing only units with the connector type required for single-channel shelf-mounted detector units, or by wiring the controller back panel to single-channel harnesses which are, in turn, plug-connected to an adapter harness which is mated to the multi-channel connector of the detector unit.

Furnish loop detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent).  This display shall be a bar graph         or numerical display with at least eight (8) discrete levels indicated.

Furnish materials according to the Department’s Qualified Products List (QPL).

B.      NEMA TS-2.  Furnish loop detector units according to NEMA Standards TS-2.

Furnish loop detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent).  This display shall be a bar graph         or numerical display with at least eight (8) discrete levels indicated.

Furnish materials according to the Department’s Qualified Products List (QPL).

732.08  Loop Detector Units, Delay and Extension Type.  Ensure that the loop detector units of this type comply with the requirements of NEMA TS-1, section 15.  Furnish shelf-mounted loop detector units that are powered from 120 volts.  Use solid state isolated output units for all controller application where directly connected to a solid state digital controller unit.  When specified, apply the provisions of 732.07 for possible replacement of multi-channel units with single channel units.

Furnish loop detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent).  This display shall be a bar graph           or numerical display with at least eight (8) discrete levels indicated.

Furnish materials according to the Department’s Qualified Products List (QPL).

Furnish materials according to the Department’s Qualified Products List (QPL).

732.11  Signal Supports.  Furnish signal poles and mast arms that are tapered tubes of a true continuous taper.  Furnish tubes that are circular or regular polygons with six or more sides.  Ensure that any measurements of circular tube diameter at a specific point along the longitudinal axis do not vary by more than 3/16-inch (5 mm).  Ensure that the taper is between 0.54 and 1.3 percent.  A rectangular, rounded-corner aluminum Pole Identification Tag with minimum dimensions of 1 x 3 x 0.040 inches shall be attached to the pole at a height of 6 inches above the base plate.  The Pole Identification Tag shall be clearly and deeply stamped with the ODOT Standard Construction Drawing Number, Design Number, and the fabrication date of the pole (e.g., TC-81.21, DES. 12, 05-12) in characters with a minimum height of 3/8 in.  Attach to the pole with four stainless steel 3/16 inch rivets. 

Fabricate mast arms of the true continuous taper type in two portions joined by overlapping of sections with the overlap being at least 1 1/2 diameters as determined by the largest diameter of the outer portion.  Assemble the sections with a 5/8-inch (16 mm) minimum stainless steel or galvanized steel hex head through-bolt.

Ensure that there is not more than one longitudinal, automatically electrically welded seam on circular poles.  Ensure that the welded seams are neat and uniform in appearance and have a thickness not less than the base material and a bead height not exceeding 1/16-inch (2 mm).  Ensure that the wall thickness at each pole or arm cross-section is of uniform thickness, except at weld beads.  Do not place transverse seams or welds on true continuous taper type poles or arms.  Weld according to 513.17.

After fabrication, hot-dip galvanize poles and arms according to 711.02.

Do not use guy rods or truss-type arms.  Furnish poles and mast arms with attachment plates and gussets.  Assemble using high-strength bolts with the connection developing the full moment-resisting capability of the arm.  Do not allow the butt diameter of mast arms to exceed the nominal diameter of the pole at the point of attachment.

Fit poles with a welded-on cast or plate steel base designed to mount on an anchor bolt foundation and ensure that each pole includes the furnishing of anchor bolts and conduit ells for installation in the foundation.  Furnish at least one 2-inch (50 mm) diameter conduit ell for installation in each foundation.  Furnish conduit ells made from steel complying with 725.04; however, if they connect to non-metallic conduit, ensure that they are of the same non-metallic material. 

Use steel anchor bolts conforming to ASTM F1554, Grade 105 and galvanized according to 711.02.  Ensure that the galvanizing extends at least 2 inches (50 mm) beyond the threads.  Ensure that ends either are bent or have a drilled and tapped steel plate as shown on the plans.

Ensure that the poles include a handhole near the base oriented as required.  Reinforce the handhole with a welded-on steel frame with a grounding lug and fit it with a cover plate fastened by stainless steel screws.  Ensure that the poles also include a cable and wire support J-hook welded near the top and a removable pole cap.  Design poles and arms so their interiors conceal wiring and their mast arms include grommeted wire outlets for the signal heads.  Furnish hanger clamps with clevises on the mast arms for the signal heads as required.  Ensure that arm caps are made of steel and cover at least 50 percent of the end area.

Ensure that signal poles combining provisions for roadway lighting include an additional handhole located opposite the mast arm flange with the poles’ J-hook located above.

Furnish pedestrian pushbutton access holes and blind half couplings for controllers and pedestrian signal heads as required.  Plug any unused holes.

Furnish certified materials according to Supplement 1094.

732.12  Strain Poles.  Furnish signal strain poles for the attachment of span wire that are steel tapered tubes according to the requirements of 732.11. Ensure that all poles include a removable pole cap, and messenger wire clamps with clevis and shackle unless otherwise specified. A rectangular, rounded-corner aluminum Pole Identification Tag with minimum dimensions of 1 x 3 x 0.040 inches shall be attached to the pole at a height of 6 inches above the base plate.  The Pole Identification Tag shall be clearly and deeply stamped with the ODOT Standard Construction Drawing Number, Design Number, and the fabrication date of the pole (e.g., TC-81.21, DES. 12, 05-12) in characters with a minimum height of 3/8 in.  Attach to the pole with four stainless steel 3/16 inch rivets.

Furnish anchor bolt foundation type strain poles that include a welded-on cast or plate steel base, bolt covers, a handhole, and a J-hook, as required by 732.11, and that also include at least one 2-inch (50 mm) cable entrance with a weatherhead and a welded blind half-coupling.  Ensure that the poles include the furnishing of anchor bolts and conduit ells for installation in the foundation.  Furnish at least one 2-inch (50 mm) diameter conduit ell for installation in each foundation.  Furnish steel conduit ells that comply with 725.04; however, if they connect to non-metallic conduit, ensure that they are of the same non-metallic material.

Furnish certified materials according to Supplement 1094.

732.13  Wood Poles.  Furnish wood poles that conform to ANSI 05.1 “Specifications and Dimensions for Wood Poles”, that are made of Southern Pine or Western Red Cedar, and that are full-length pressure treated according to  725.19.

732.14  Down Guy Assemblies.  Furnish expanding or screw type anchors capable of withstanding a guy tension of 8000 pounds (35 kN) when installed in firm moist soil. Ensure that each anchor rod is 5/8-inch (16 mm) minimum diameter, 8 feet (2.4 m) minimum length galvanized steel with thimble eye.

Ensure that all pole and attachment hardware is hot dip galvanized in accordance with 711.02.

Furnish 3/8-inch (10 mm) minimum diameter guy wire that conforms to 732.18 and ensure that all accessories have a rated loading strength equal to or greater than the messenger wire minimum breaking strength.

Furnish porcelain strain insulators of the wet process type.

Furnish an 8 feet (2.4 m) minimum length guy guard made of impact and ultraviolet light resistant yellow plastic that is fastened to the guy wire.

Furnish materials according to the Department’s Qualified Products List (QPL).

732.15  Pedestals.  Fabricate pedestals for the support of traffic control equipment of 4-inch (100 mm) schedule 40 steel or aluminum pipe.  Fit the steel pipe with a welded-on base of plate or cast steel, or when specified thread the steel pipe into a gray cast iron transformer type base.  Furnish galvanized steel pedestals according to 711.02.  Thread aluminum pipe into an aluminum cast transformer type base.  Design pedestals to mount on an anchor bolt foundation and include the furnishing of anchor bolts and conduit ells for installation in the foundation.

Furnish materials according to the Department’s Qualified Products List (QPL).

732.16  Conduit Risers.  Ensure that risers have conduit and fittings according to 725.04 and the weatherhead is made of aluminum or galvanized ferrous metal and threaded.

732.17  Cable Support Assemblies.  Ensure that the cable grip used with cable support assemblies is of the proper size and strength for the cables and is of the flexible “closed” or “split with rod” type, of stainless steel or tin coated bronze, and equipped with a single “U” eye bale.  Ensure that the smallest cable grip permitted has a minimum rated breaking strength of 250 pounds (1.1 kN).

Ensure that the slings for cable supports are made from copper clad or galvanized multi-strand steel wire with an overall diameter of not less than 1/8-inch (3 mm) and a breaking strength of at least 400 pounds (1.7 N).  Use thimbles to form eyes at each end of the sling with grooves to match the wire.  Adjust the sling to the proper length with the wire at each thimble lapped and secured with split bolt clamps.

Furnish materials according to the Department’s Qualified Products List (QPL).

732.18  Messenger Wire  

A.      Wire. Furnish seven strand ASTM A475 Class B Utilities Grade or stronger messenger wire except 1/4-inch (6 mm) seven strand messenger wire must be High Strength Grade or stronger. Furnish 1/4-inch (6 mm) seven strand ASTM A475 Class B High Strength Grade or stronger tether wire. Furnish all wire per ASTM A475 with the following modifications:

18.2  Tags are not required on lengths less than 1000 feet (300 m).

B.      Accessories. For messenger wire ensure all accessories have a rated loading strength equal to or greater than 73 percent of the messenger wire minimum breaking strength. For breakaway tether installations, accessories within the turnbuckle-tensioned portion of the tether span shall have strength equal to or greater than 73 percent of the breaking strength of 1/4-inch, 7-strand ASTM A 475 High Strength Grade Wire rope, or 3460 pounds (15.4 kN). Other portions of the tether assembly shall use accessories strength equal to or exceeding the wire rope used in that portion. S-hooks shall be made of mild low-carbon galvanized steel and of the wire size indicated on the plans; larger wire sizes and higher-strength steel S-hooks shall not be substituted. Safety tie wire shall be 304 or 316 stainless steel, 1×19 stranded, 1/8-inch (3 mm) with stainless steel wire rope clips. If used, lead sheet to wrap tether wire in breakaway anchors shall be commercially pure lead of thickness 0.030 to 0.042 inches (0.75 to 1.0 mm).

Furnish materials according to the Department’s Qualified Products List (QPL).

732.19  Cable and Wire.  Furnish cable and wire meeting the requirements of Table 732.19-1 and rated at 600 volts with conductors of copper unless otherwise specified.  Ensure that the cable or wire jacket is indelibly marked at intervals of not more than 6 feet (2 m) with nomenclature stating the size, the type, the organization specifying the type, and the manufacturer’s name or trademark.

Furnish materials according to the Department’s Qualified Products List (QPL).

732.20  Power Service.  Furnish risers for power service that are 1 to 1 1/2-inch (25 to 38 mm) diameter conduit and fittings according to 725   Furnish weatherheads that are threaded and made of aluminum or galvanized ferrous metal.  Include a disconnect switch with enclosure.

732.21  Disconnect Switch with Enclosure.  Ensure that the switch enclosure is a UL listed watertight lockable stainless steel NEMA Type 4 supplied with the conduit hubs listed on the enclosure UL label.  Furnish an enclosure that contains as a minimum a single-throw, 2 pole, solid neutral, fused safety disconnect switch (or circuit breaker) UL listed as suitable for a service disconnect with a minimum capacity of 30-amperes at 240 VAC.  Ensure that the unit can be padlocked in both the “ON” and “OFF” positions.

    Furnish materials according to the Department’s Qualified Products List (QPL).

732.22  Backplates.  Furnish louvered backplates constructed of wrought sheet aluminum, according to ASTM B 209 (B 209M), 6061-T6, .050 inch (1.3 mm) minimum thickness.  Louvers shall be at least 8 percent of the total backplate area. Backplate base metal shall be anodized to maximize paint adhesion according to Mil-A-8625, Type II or Type I.  Furnish backplates painted on both sides with at least two coats of flat black alkyd enamel paint or polyester powder coat (no epoxy) closely matching FED-STD-595b-37038.  Furnish a backplate that extends 5 inches (125 mm) beyond the outside of the signal assembly on all sides. The overall outside shape of the installed backplate shall be rectangular.  The backplate shall allow no gaps between the backplate and the signal head or between signal sections.  A 2-inch (50 mm) wide continuous outside border of fluorescent yellow reflective sheeting shall be applied to the front of the backplate.  Border shall not be applied over the louvers. Reflective sheeting shall be Type H or J listed on the Department’s Qualified Products List. Prepare backplate surfaces in accordance with 630.04 prior to applying the reflective material. All assembly and mounting hardware shall be stainless steel conforming to 730.10. If used, machine nuts shall be thread-deforming or nylon locknuts.  Rivets shall not be used for mounting the backplate to the signal head.  A minimum of four mounting points shall be used on each signal section for attaching the backplate.  Furnish all mounting hardware.

TABLE 732.19-1 CABLE AND WIRE

Cable or Wire

Number of  Conductors

Wire Gage

Specification
or type

Conductor Type

Notes

Signal Cable

As specified

As specified

IMSA 19-1

IMSA 20-1

Copper,
color coded, stranded

Interconnect cable

As specified

As specified

IMSA 19-1

IMSA 20-1

Copper,
color coded, stranded

Twisted pairs as specified

As specified

RUS PE-39

IMSA 19-2

IMSA 20-2

Copper,
color coded, solid

Interconnect cable, integral, messenger type

As specified

As specified

IMSA 19-3

IMSA 20-3

Copper,
color coded, stranded

Twisted pairs as specified

As specified

IMSA 19-4

IMSA 20-4

Copper,
color coded, solid

[2]

Loop detector wire

Single conductor

14 AWG

IMSA 51-5

Copper, stranded

Loop detector lead-in cable

Two conductor

14 AWG

IMSA 50-2

Copper, twisted pair, stranded, shielded

Power cable

Two conductor

As specified

UL: RHH/RHW/ USE or HHW, cross linked polyethylene with an insulation thickness of 0.045 inch (1.14 mm) (min.)

Copper, stranded

[3]

Service cable

Two conductor (duplex)

As specified

Aluminum,[1] twisted, stranded

Ground Wire

Single conductor

UL: RHH/RHW/USE or XHHW, cross linked polyethylene

Copper, stranded

[4]

Loop detector lead-in cable, direct burial

As specified

12 or 14 AWG, or as specified

IMSA 19-6

IMSA 20-6

Copper, stranded

Loop detector lead-in cable, Integral messenger type

As specified

12 or 14 AWG, or as specified

IMSA 19-4

IMSA 20-4

Copper, stranded

Notes

[1]  Copper conductors may be substituted

[2]  ANSI/ICEA Cable shall have: Solid insulations, Full count color coding, 8-mil shield, and 772 kHz attenuation compliance. All other specifications are manufacturer’s option unless specified.

[3] Three-conductor cable may be specified.  Permitted substitution: 2 (or 3) single conductor cable.

[4]  Minimum size is equal to the power or service cable, whichever is larger.

733  Traffic Signal Controller Material

733.01  References and Definitions.

“NEMA TS-2,”  “Type TS-2/A2,” and “Type TS-2/A1” refers to equipment manufactured in conformance with the National Electrical Manufacturers Association (NEMA) Standards Publication No. TS-2.

“NEMA TS-1”  and “Type TS-1” refers to equipment manufactured in conformance with the National Electrical Manufacturers Association (NEMA) Standards Publication No. TS-1.

“Type 332” and “Type 336” refers to equipment manufactured in conformance with the California Department of Transportation (CalTrans) specifications titled “Traffic Signal Control Equipment Specifications” and “Transportation Electrical Equipment Specifications“, including all addenda.

“Type 2070” refers to equipment manufactured in conformance with the California Department of Transportation (CalTrans) specifications titled “Transportation Electrical Equipment Specifications”, including all addenda.

“CalTrans QPL” refers to the California Department of Transportation (CalTrans) “Qualified Product List” for traffic signal equipment.

“IP” refers to equipment conforming to the Internet Protocol Suite communication protocols defined by the Internet Engineering Taskforce RFC 1122. 

733.02  Controller Units.

A.      General Requirements.  Ensure that each controller unit contains internal time based coordination and, if used in a hardwired coordination system, provide an internal communication device or transceiver for connection to interconnect cables including multi-conductor 120 volt cables, twisted pair low voltage cables or fiber optic cables as shown on the plans.

If used in a closed loop system, ensure that the local intersection controller contains all of the software features necessary to operate with the system requirements given in 733.06 and 733.07.  Furnish the necessary communications capability for isolated local intersections when part of the monitoring and control system described in 733.08.

When the signal timing and phasing configuration shown on the plans requires a pre-timed operation, ensure that the controller unit meets all requirements of this section and can also be configured in a pre-timed, sequential phase, fixed interval mode.

Furnish controller memories that are nonvolatile and do not require batteries or other sources of energy to retain data while power is removed from the controller.

B.      Software.  Furnish a communication port for connection to a laptop computer for database upload/download.  Furnish software for the personal computer to completely program all features of the controller unit.  Unless otherwise shown on the plans, provide the controller unit with software that provides the following features even if not used by the signal phasing operation shown on the plans:

1.      NEMA 8 phase, dual ring capability with four pedestrian movements, 4 overlaps, and the ability to program an exclusive pedestrian movement.  Ensure that the controller is capable of being programmed for sequential phasing operation.  All controllers shall be capable of implementing Flashing Yellow Arrow operation by remapping pedestrian channel yellow drivers to operate the yellow arrows. 

2.      Volume density functions

3.      Secondary coordination plans

4.      Time of day/day of week scheduler

5.      Time based coordination, minimum 3 dials, 3 offsets, 3 splits

6.      Internal preemption for railroad and emergency vehicles.  Railroad preemption shall conform to ODOT specifications. 

7.      Operator selectable single or dual entry in dual ring use

8.      Security access codes

9.      Detector features including delay timing, carryover (extension) timing and detector switching

10.    Simultaneous gap out feature

11.    If operated in a system, communication capabilities to interface with hardwired masters, dial up modems, and/or IP communication devices. 

12.    Data upload and download capability to a personal computer.  At least one IP port and one serial port shall be included. 

13.    Storage of detector counts utilizing phase detectors for a minimum 24 hour period in 15 minute increments

14.    Detector failure monitoring and logging features for constant calls and absence of calls

Furnish 60-month warranties or for the manufacturers’ standard warranty, whichever is greater for the following equipment: 

1.      NEMA Controller Equipment

          a.      TS-2 Controller Units

          b.      Bus Interface Units

          c.      Malfunction Management Units        

          d.      TS 1 Conflict Monitors

2.      CalTrans Controller Equipment

          a.      Model 2010 Conflict Monitor Units

          b.      2070L and 2070E Controller Units including the following subassembly units:

                   (1)     2070-1E, 2070-1B CPU Board

                   (2)     2070-2A Field I/O Module

                   (3)     2070-3B Front Panel.

                   (4)     2070-6A,B.

Ensure that the warranty period begins on the date of shipment to the project.  Ensure that each unit has a permanent label or stamp indicating the date of shipment.  Label shall indicate the equipment vendor name and or logo. 

C.      Type TS 2/A1.  Furnish a controller unit that meets NEMA TS-2 specifications and is shelf or rack mounted.  Ensure that controller settings are programmable through a keyboard on the front panel.  Ensure that the front panel contains an 8-line by 40-character display. Ensure the controller is equipped with a datakey to support controller database upload/download. Securely attach the datakey to the top of the controller with fiber-reinforced tape at the time of delivery to the project.

Furnish materials according to the Department’s Qualified Products List (QPL).

D.      Type TS-2/A2.  Furnish a controller unit that meets NEMA TS-2 specifications and is suitable for shelf mounting.  Furnish a controller unit that includes all ports and input/output connectors for complete interchangeability between NEMA TS-1 and TS-2 cabinets.  Ensure that  controller settings  are programmable through a keyboard on the front panel.  Ensure that the front panel contains an eight-line by 40-character display.  Ensure the controller is equipped with a datakey to support controller database upload/download. Securely attach the datakey to the top of the controller with fiber-reinforced tape at the time of delivery to the project.

Furnish materials according to the Department’s Qualified Products List (QPL).

E. Type 2070L. Furnish controller units that meet the specifications for “Transportation Electrical Equipment Specifications”, California Department of Transportation, including all addenda.  Furnish a controller unit that is listed on the ODOT Approved List.

The Type 2070E version controller unit consists of the following assembled modules:

Unit Chassis

Model 2070-1B:    CPU module, single board

Model 2070-2A:    Field I/O module

Model 2070-3B:    Front panel, Display B (8 lines of 40 char.)

Model 2070-4B:    Power supply module, 3.5 amp.

                                           [Power supply Model 2070-4A

                                  (10 amp) may be supplied in lieu of

                                           Model 2070-4B]

Model 2070-7A:    Async. Serial Communication Module

F.      Type 2070E.  Furnish controller units that meet the specifications for “Transportation Electrical Equipment Specifications”, California Department of Transportation, including all addenda.  Furnish a controller unit that is listed on the ODOT Approved List.

The Type 2070E version controller unit consists of the following assembled modules:

Unit Chassis

Model 2070-1E                                                CPU Module, Single Board

Model 2070-2A                                                Field I/O for 170 Cabinet

Model 2070-3B                                                Front Panel, Display B (8

                                                                     lines of 40 characters)

Model 2070-4A or Model 2070-4B    Power Supply

Model 2070-7A                                                Async Serial Communication

Also, equip all versions of the Type 2070 controller unit with the following:

1.      The appropriate communication port, cables, and connectors for communicating with a laptop computer.

2.      Modems, ports, and cables for system communication, if the controller is to operate as part of an interconnected signal system or has a telephone drop shown on the plans.

3.  Furnish a serial communication cable to be used to establish periodic automatic time sync between the 2070 controller software and the conflict monitor.  The cable shall consist of six feet (2 m) of unshielded 4- conductor cable, minimum 24 gauge stranded conductors with protective jacket.  End connectors shall be 9-pin D-subminiature with backshell, male and female, with pin assignments shown in the table below.

9-pin Male

9-pin Female

3

3

5

5

2

2

1

4

8

4

4. 8Mb data key (SFK 8Mb).

Furnish materials according to the Department’s Qualified Products List (QPL)

733.03  Cabinet.  Ensure that all cabinets comply with the requirements of this Section. Equip all NEMA specified cabinets as follows:

          Supply two through four phase controller operation with a minimum twelve position backpanel, configured for four pedestrian movements and four overlaps, with a twelve channel NEMA TS-1 conflict monitor or NEMA TS-2 malfunction management unit.

          Supply five through eight phase controller operation with a minimum 12 position backpanel, configured for four pedestrian movements and no overlaps, with a NEMA TS-2 malfunction management unit.

          For signal phasing configurations that require a larger capacity backpanel or conflict monitor, supply a 16 position backpanel with a 16 channel NEMA TS-1 conflict monitor or NEMA TS-2 malfunction management unit.

          Furnish each cabinet main door with a sturdy, permanently lubricated lock that is covered with a weatherproof tab.  Key the project locks to the master key used by the agency that will maintain the equipment.  Supply two keys with each lock.  Also, equip the small door-in-door with a lock that is keyed to the maintaining agency’s master key, covered with a weatherproof tab. The door handle shall swing out away from the door edge, not toward the center of the door.

          Any fasteners (rivets, bolts, etc.) that penetrate the cabinet exterior shall be tack-welded or brazed on the inside surface to prevent punch-thru if the fastener head is ground off from the outside. The preferred method of cabinet construction uses no such fasteners, but internal welds only.

Furnish cabinet with drawings that show the following:

1.      Intersection map.  The map shall include street names, all lanes, crosswalks and stop bars, all vehicle and pedestrian phases, all loops and detection zones, vehicular and pedestrian signal heads, and pedestrian pushbuttons.  All of these features shall be labeled.  Include a legend that shows the type of vehicular and pedestrian heads and north.

2.      Field wiring hook-up chart for all signal heads.  The chart shall include signal head name, signal head display indication, and field terminal on back panel.   

See example below.

Signal Head

G

Y

R

G

Y

G

Y

W

DW

1a

2G

2Y

2R

1G

1Y

2a

2G

2Y

2R

2b

2G

2Y

2R

4a

4G

4Y

4R

4b

4G

4Y

4R

4c

4G

4Y

4R

1G

1Y

6a

6G

6Y

6R

6b

6G

6Y

6R

8a

8G

8Y

8R

8b

8G

8Y

8R

A

9G

9Y

B

10G

10Y

C

11G

11Y

D

12G

12Y

3.      Conflict Monitor/MMU channel assignments and functions, switch positions, and settings.  Also show program card jumper locations diagrammatically (if applicable).  If the Conflict Monitor/MMU is programmed via methods other than a program card detail this diagrammatically.

4.      Legend with all wire gauges and insulator colors used in the cabinet.  Apply this legend to all wiring shown in the drawings.  Also include components such as MOVs and diodes.

5.      Detector panel wiring.  Detail all detector landings.

6.      All cable and wiring harness pin assignments.

7.      Detector rack layout.  Label detector number and associated phase.

8.      SDLC cable assignments.

9.      Pedestrian pushbutton wiring.

10.    Load switch assignments.

11.    Flash programming buss and field terminals wiring.

12.    I/O board, load switch, and flash transfer relay wiring.

13.    Any video, radar, preemption, or other device wiring, interface, and cabling details.

14.    UPS as-built schematic (if applicable).  Detail all connections to cabinet and controller.

15.    Netlist detailing all connectivity of the cabinet.  It shall include all instances in the cabinet.  Provide a description of all instances.

A. Type TS-1.

1.      Cabinets.  Furnish a cabinet size that provides ample space for housing the controller unit and all associated electrical devices furnished with it, together with any other auxiliary devices that are specified.  Furnish a cabinet with sufficient shelf space to accommodate all existing, proposed, and designated future equipment.   Ensure that the space provided accommodates the appropriate controller unit frame as designated in NEMA TS-1, Section 14.

Construct the cabinets of cast aluminum or sheet aluminum, drawn or formed, with aluminum support and stiffening of members provided as necessary.  Ensure that the exterior is smooth with no sharp edges.  Weld all joints.  Ensure that the cabinet is rigid and is designed to support all components.  Ensure that the application of the following loads do not result in breakage, deformation, or loss of weatherproof qualities:  a 100-pound (445 N) load applied to any 1-inch (25 mm) square surface of the cabinet or door (open or closed), in any direction; or a 300-pound (1.3 kN) load applied vertically downward to any 4-inch (100 mm) square of the top surface or to the top edge of the closed and latched door.

Provide cabinet exterior surfaces of bare aluminum.  When the plans specify a cabinet color, prime and finish all cabinet exteriors with two coats of high-grade enamel paint of the specified color.  Ensure that the cabinet interior surfaces are the same as the exterior, or may be painted flat white.

Ensure that the cabinet contains at least one rain-tight louvered vent equipped with a replaceable filter.  Install vents to allow for the release of excessive heat and any explosive gases that might enter the cabinet.

Ensure that the cabinets are functional in design and have a door in the front providing access to substantially the full interior area.  Attach a gasket of elastomeric material to the cabinet or door to form a weatherproof seal.  Furnish door hinge pins of stainless steel or equivalent corrosion resistant material.  Furnish a door stop to retain the door in at least a 90 degree open position.

Include a small, hinged, and gasketed door-in-door (police door) on the outside of the main controller door.  Ensure that the door-in-door does not allow entrance to the controller mechanism nor to exposed electrical terminals, but provides access to a small switch panel and compartment (police panel).

Fit the cabinet with the necessary provisions for mounting, with a bottom conduit connection provided for pole-mounted cabinets.  Furnish suitable hardware and equipment for each cabinet mounting method, including bolts for drilled and tapped holes on metal supports, pole attachment clamps, pedestal slipfitter, and anchor bolts and conduit ells for installation in concrete foundations.  Furnish steel anchor bolts that are galvanized at least 1 inch (25 mm) beyond the threads.  Certified cabinet anchor bolts are not required.

Directly place all equipment designed for shelf mounting on a shelf except for loop detector units (amplifiers) and similar devices designed for stacking on each other.  Arrange components on shelves and devices on the door so that a 1-inch (25 mm) minimum space separates them when the door is shut.  Ensure that plugs, wires, controls, or similar items do not compromise this space.

Reserve a minimum 4-inch (100 mm) clear area on the bottom of the cabinet for the routing of cables.  Do not locate panel mounted equipment in the bottom 6 inches (150 mm) of the cabinet.  Do not locate shelves or components within 6 inches (150 mm) of the bottom of foundation mounted cabinets.

Arrange all equipment for easy withdrawal and replacement, without the necessity of disturbing adjacent equipment.  Permanently locate devices within the cabinet to allow free circulation of air and that do not restrict air flow from fan ducts or vents. 

Ensure that the auxiliary equipment operates within a weatherproof cabinet at ambient temperatures between -30 and 165 °F (-34 and 74 °C).

When  terminals and panel mounted devices with exposed electrical contact points are located next to shelf mounted equipment, provide spacers, shelf lips, or other means to assure that component units cannot be accidentally moved into contact with any exposed electrical terminal points.

Ensure that load switches, relays, flashers, fuses, switches, terminal blocks, and other equipment mounted or plugged into the back or side panels are readily accessible.  Ensure that switches, controls, and indicator lights are visible and easily operable without moving the components from their normal shelf positions.

Furnish materials according to the Department’s Qualified Products List (QPL).

2. Accessory Equipment  

a.      Ventilating Fan.  Equip all cabinets with a forced air ventilating fan.  Furnish a fan that provides a capacity of at least 100 cubic feet (2.8 m³) per minute.  Furnish a fan that is thermostatically controlled and adjusted to start at cabinet temperatures above 120 °F (49 °C) and to stop when the temperature has dropped below 100 °F (38 °C).

b.      Load Switches.  Furnish all cabinets with solid state, triple-signal load switches complying with NEMA TS-1, Section 5.  Additionally, ensure that all load switches have both input and output indicators.

c.      Conflict Monitor.  Furnish all cabinets with a separate solid-state conflict monitor device.  Ensure that the cabinet wiring, in the event of monitor disconnection, transfers the signals to a flashing condition.  Furnish conflict monitors that comply with NEMA TS-1, Section 6.  Additionally, ensure that all conflict monitors are capable of causing the signals to flash as a result of the following events:

(1)     All red lamps associated with a load switch are burned out;

(2)     Within one second when red and green, or yellow and green color pairings are displayed on the same phase;

(3)     The absence of a minimum yellow interval.

Ensure that the monitor indicates the exact load switch output channel upon which the failure event occurred.  Furnish conflict monitors that are capable of storing a minimum of nine  fault events (event logging feature).  Furnish a monitor that utilizes a LCD display and has a RS-232 port for connection to a laptop computer.  Furnish software and connector cables to diagnose the conflict monitor.

d.      Flashers.  Furnish solid-state flashers that comply with NEMA TS-1, Section 8.  When signals have a normal stop-and-go sequence that includes flashing, either ensure that the controller unit generates that flashing display or provide flashers.  For this purpose, provide separate flashers from those provided for emergency back-up.  Furnish flashers that are designed with two circuits of at least 10 amperes each.

Equip each controller cabinet with terminals that are wired so that, by an interchange of jumpers, the flashing operation is arranged to display either flashing yellow or flashing red on the vehicular signals.

e.      Relays.  Ensure that the relays required for proper operation of the specified equipment are furnished and completely wired.  Furnish relays that are enclosed, readily replaceable, and designed for one-million operations without failure or need for adjustment.

f.       Surge Protection Devices.  Furnish surge protection on incoming power lines, interconnect lines, and detector leads.

The primary surge protection device (SPD) shall be an EDCO SHA-1250 or approved equal.  A plug-in base shall be used to hold the device.  All wiring connections shall be made to the base, and appropriate cabinet clearances maintained, to allow the SPD module to be relaced by hand without the use of tools.

Furnish loop detector lead-in cable protection that consists of devices installed in each detector circuit where the lead-in connects to the terminal block.  House each device in a case that consists of two stages; a 3-electrode gas tube arrestor and a semiconductor circuit.  Ensure that the arrestor shunts to ground a common mode transient with a 1,000 ampere peak and an 8/20 microsecond wave-shape, ionizing at 400 volts within 100 nanoseconds when subjected to a 1,000 volt per microsecond transient.  Furnish a semiconductor circuit that clamps a differential transient to 30 volts within 40 nanoseconds of the appearance of the transient, and a common mode transient to 30 volts within 500 nanoseconds of the ionization of the gas tube arrestor.  Ensure that the second stage is able to withstand a peak current of 13 amperes.  Furnish a device that has impedance characteristics compatible with the detector unit so as not to cause false calls or increase the loop impedance above the sensitivity of the detector unit.

Furnish pedestrian pushbutton inputs with the same protection as specified for the loop detector lead-in cables.

Protect interconnect cable against transients by devices across each conductor of the cable and ground.  The devices may be either 2 or 3-terminal devices.  If 3-terminal devices are used, connect two conductors and ground to the same device.  Furnish a protection device that consists of a gas tube arrestor with a maximum ionization voltage of 1000 volts on a 10,000 volt per microsecond transient or a maximum ionization voltage of 950 volts on a 3000 volt per microsecond transient.  Ensure that the maximum time from beginning of the transient to ionization is 1.1 microseconds on a 10,000 volt per microsecond transient.  Ensure that the device is not ionized by normal voltage variations on a 120-volt AC line.  Furnish a device that is able to withstand a 10,000 ampere peak with an 8/20 microsecond waveshape.

g.      Main Power Breaker.  Furnish an incoming AC+ power line that is controlled by a main circuit breaker rated at 240 volts and an auxiliary breaker, with capacity and wiring as specified in NEMA TS-1, Section 10.3.2.2 and Figure 10-4.

If a power service disconnect switch is located before the controller cabinet, the neutral (AC-) and the grounding bar in the controller cabinet shall not be connected together as shown in NEMA TS-1, Figure 10-4.

h.      Radio Interference Filter.  Furnish an incoming AC+ power line that contains a radio frequency interference (RFI) filter installed between the main circuit breaker and the solid state equipment.  Also, provide RFI filtering for the load switches and flasher, unless the equipment furnished provides signal and flasher circuits switching at the zero voltage point of the power line sinusoid wave form.

i.       Convenience Outlet and Light.   Wire a convenience outlet into the cabinet for use by electrical maintenance equipment.  Ensure that the outlet contains at least one standard duplex three-wire NEMA 5-15 receptacle of the ground-fault circuit-interrupting (GFCI) type.  Wire a second non-GFCI convenience outlet, not fed thru the UPS system (if used).  Furnish a door switch to control the convenience light.

j.       Manual Control and Pushbutton.  When required by the plans, provide intersection controller units with means for substituting manual operation of interval timing for automatic interval timing.  Ensure that manual operation provides the same interval sequence as when the controller unit is operating automatically.

Obtain manual interval timing by a momentary pushbutton contact switch mounted on a 5-foot (1.5 m) minimum flexible weatherproof extension cord.  Store that switch and cord behind the small door-in-door.

k.      Switches.  Furnish completely wired switches that are required for proper operation of specified equipment.  Clearly and permanently label switches as to function and setting position, and ensure that they are accessible without the necessity of moving components.

(1)     Signal Shutdown Switch.  Furnish a cabinet with a signal shutdown switch for turning off the power to the signals at the intersection.  Ensure that this switch only affects the power to the signals, and allows the controller to continue in operation.  Locate the switch in the panel behind the small door-in-door (police door).

(2)     Auto/Flash Switch.  Furnish a cabinet with a flash control switch for activating the flashing of vehicular signals in a preselected emergency flash display.  Ensure that the operation of the flash control switch causes a flashing display even under conditions of controller unit malfunction or of its removal from the cabinet.  Ensure that the operation of the switch overrides any operation commands from a local or remote time switch.  Locate the switch in the panel behind the small door-in-door (police door).

Program the transfer to and from flashing operation, when called remotely or by a local time switch, to occur only at points in the cycle allowed by the OMUTCD.

(3)     Automatic/Manual Transfer Switch.  Furnish a cabinet with an automatic/manual transfer switch.  In the automatic position, ensure that the controller unit automatically sequences the signal head displays.  In the manual position, ensure that the signal phase or interval sequencing occurs only upon manual activation of the manual control pushbutton.  Locate the switch in the door-in-door (police door).  Ensure that it is unnecessary, when switching from manual to automatic operation, or vice versa, to do so at any certain time or to make any time adjustments.

(4)     Run/Stop-Time Switch.  Furnish a cabinet with a run/stop-time switch that activates the controller stop-time feature when in the “stop-time” position.  Locate the run/stop-time switch on a switch panel in the cabinet.

(5)     Controller Shutdown Switch.  Furnish a cabinet with a controller shutdown switch that cuts off power to the controller unit, conflict monitor, and detector units.  Ensure that power is not cut off to those components required to maintain flashing operation.  Locate the controller shutdown switch on a switch panel in the cabinet.

(6)     Coordinated/Free Switch.  Furnish controllers operated in a coordinated system with a coordinated/free switch.  Ensure that this switch allows the choice of operating the controller under the supervision of a coordination device or operating the controller independently of coordination control.  Locate the coordinated/free switch on a switch panel in the cabinet.

(7)     Detector Test Switches.  Furnish momentary contact switches that will enter a vehicular or pedestrian call for any actuated phase.  Furnish a switch for each actuated phase vehicular and pedestrian detection input.  Conveniently group and label the switches.

l.       Terminal Blocks.  Furnish cabinets that include terminal blocks mounted on panels on the walls of the cabinet.  Ensure that the blocks are not obstructed by shelf-mounted devices.  Furnish sufficient terminal sets for each individual harness wire as well as for contacts of signal load switches, flasher transfer relays, flasher, and other components.  Also, provide separate terminal sets for field wiring connections, including power, signal, interconnection, and detector lead-in cables.  Group terminal sets to separate higher voltage (120 VAC) from lower voltage, and arrange them into logical groups.  Protect terminal blocks from accidental contact during the installation and removal of shelf-mounted equipment.  Locate the blocks no closer than 4 inches (100 mm) from the bottom of pole and pedestal mounted cabinets, and no closer than 6 inches (150 mm) from the bottom of foundation mounted cabinets.

Ensure that the terminal points are UL listed as suitable to carry the rated loading.  Ensure that the capacity and size of the terminals are as specified in NEMA TS-1, Section 10.2.5.  Ensure that the terminal points for signal field wiring for each circuit accommodates at least four 12 AWG conductors with spade type terminals.

Furnish terminal points for incoming power wiring that accepts either spade terminals or bare stranded wire and are suitable for either aluminum or copper conductors.

Space terminal sets for easy wiring.  Furnish at least six reserve terminal sets for controllers.  Harnesses may terminate on the back of terminal blocks using through-panel terminals.  Clearly mark terminal sets for ready identification including through-panel terminals that are identified on both sides.  Ensure that the contact between adjacent terminal points are made by bus bar, or by wire jumpers having spade type terminals securely attached to each end.

m.     Terminal Buses.  Furnish a cabinet with supply terminal buses fed from the line side of the incoming 120 VAC power line, after the phase wire has passed through the main power switch.  Ensure that the requirements for use of radio interference filters are according to Item 8 of this Section, with the buses supplying load switches and with flashers being filtered when required.  Ensure that a signal bus relay controls power to the bus supplying power for the signal load switches. .  The following overrides NEMA requirements for signal bus relays.  A solid-state relay shall be used for the signal bus relay.  The signal bus relay shall maintain output equal to or above the rating of the cabinet main overcurrent protection device over the NEMA TS-2 Environmental Operating Range of -50 to +185 degrees F (-45 to +85 degrees C).

Furnish a common terminal bus for the connection of the neutral wire of the incoming 120 VAC power line.  Ensure that the common bus has sufficient terminal points to accommodate all potential cabinet wiring as well as field wiring.  Use a separate common terminal, insulated from the panel, for the interconnect common.

Furnish bus terminal points that comply with Item 12 of this Section for conductor accommodation, attachment and identification.

n.      Grounding System/Bus Bars.  Furnish a cabinet that includes a grounding system as specified in NEMA TS-1, Section 10.3.2.1 with an adequate number (minimum of three) of ground terminal points. 

o.      Wiring.  Neatly organize and route the harnesses and wiring bundles to individual terminals.  Ensure that the harness provides a wire for each pin or contact of the device.  Connect each wire to a marked terminal position.  Use labeled spade type terminals or plug connections on all harness wiring.  Group and lash or restrain wire bundles in such a manner that they will not interfere with the access to components, terminal blocks or buses, or the legibility of terminal identification.  Ensure that the harnesses are of sufficient length to reach any point within the cabinet.  Ensure that the cables and harness bundles are easily traced through the cabinet to their terminations. Route all wiring terminated on printed circuit boards (as commonly done for BIU backpanel connectors) at right angles to the pin array; no wires shall pass over the connector pins.

Wire the cabinet so that controller pin connections associated with a given phase number matches the phase number assigned to the specified traffic movement as shown on the plans.

Furnish all wiring with stranded conductors.  Ensure that the wiring is adequate for the voltage and load that represents the ultimate load of the devices connected.  Ensure that the ampacity rating of the wires are as specified in NEMA TS-1, Section 10.3.3.1.  Ensure that the wiring is color coded as follows:

(1)     Solid white, AC common.

(2)     Solid green or green with yellow stripes, equipment ground.

(3)     Solid black, AC line side power (AC+).

p.      Loop Detector Units.  Furnish loop detector units that comply with the requirements of NEMA TS-1, Section 15, with the following modifications:

(1)     Furnish loop detector units that are shelf mounted and powered from 120 volts.

(2)     Ensure that the unit uses solid-state isolated output devices.

(3)     Furnish conductors in the cable harness for loop input pins that are twisted three to five times per foot (300 mm).

(4)     Furnish detector unit electrical connection plugs or wiring harness that are designed such that any multi-channel shelf mounted detector unit is readily replaced with single channel detector units.  Furnish only units with the connector type required for single channel shelf mounted detector units, or by wiring the controller back panel to single channel wiring harnesses which are, in turn, plug connected to an adapter harness that is mated to the multi-channel connector of the detector unit.

(5)     When shown on the plans, supply delay and extension timing capability on the detector unit; otherwise, the controller unit software requirements of 733.02 will provide these features.

(6)     Ensure that the harness provides a wire for each pin or contact of the device.

(7)     Furnish loop detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent).  This display shall be a bar graph or numerical display with at least eight (8) discrete levels indicated.

If vehicle detector types other than “loop” detectors are required by the plans, provide these detectors by separate bid item.

Furnish  TS-1 cabinets according to the Department’s Qualified Products List (QPL).

B.      Type TS-2.

1.      Furnish TS-2 cabinets that utilize a high speed data channel to connect the controller unit, malfunction management unit, rear panel (terminals and facilities), detectors and bus interface units and also comply with the general requirements of 733.03.  Furnish a prewired cabinet with malfunction management unit, loop detector units, and all accessory equipment as specified in NEMA TS-2, except as follows:

a.      Section 5.3.4, use detector racks for both Type 1 (A1) and Type 2 (A2) controller units.

b.      Section 5.4.2.1, if a power service disconnect switch is located before the controller cabinet, the neutral (AC-) and the grounding bar in the controller cabinet shall be connected together.

c.      Section 5.4.2.7, provide an LED type light.

d.      Section 5.4.2.7.2, provide the LED lamp.

e.      Section 5.4.2.7.3, provide the door actuated light switch.

f.       Section 6.5.2.2.1, provide 2-channel detector units, without delay/extension features (Type A). Furnish momentary pushbuttons on the cabinet door or a detector rack panel for actuation of Detector BIU #9, channels 1-16, and the four opto-isolated pedestrian detector inputs on BIU #1 and BIU #2. Permanently label these pushbuttons as “VEH DET 1” through “VEH DET 16” and “PED DET 1” through “PED DET 8.”

g.      Section 7.2, construct cabinets of sheet aluminum.

h.     

Section 7.3, unless otherwise specified in the plans, provide a Size 5 cabinet for four phase or less pole mounted cabinets, Size 5 for four phase or less ground mounted cabinets, and Size 6 for 5 phase or more ground mounted cabinets.  Supply larger cabinets if required to house the equipment to meet the plan requirements; such as master controllers, preemption devices, 16 position backpanels or special detection units. 

         Furnish all wire passages through and over metal edges with edge protection polymer trim.

i.       Section 7.5.7, ensure that the police panel contains switches for AUTO/FLASH, SIGNALS ON/OFF and AUTO/MANUAL in the police panel.  Furnish a pushbutton with a 5-foot (1.5 m) cord, and panel connector, not hard wired, unless a strain-relieving panel feed-thru bushing is provided.

j.       Section 7.7.3, supply unpainted cabinets.

k.      The following overrides the NEMA requirements for signal bus relays. A solid-state relay shall be used for the signal bus relay. This relay shall maintain output equal to or exceeding the requirements of the cabinet main overcurrent protective device over the NEMA TS-2 Environmental Operating Range of -30 to +165 degrees Fahrenheit.

2.      Furnish loop detector and pedestrian inputs that have lightning/surge protection as specified in 733.03.A.2.f.

3.      Include loop detector racks with the necessary number of two-channel loop detector units with the cabinet.  When shown on the plans, supply delay and extension timing capability on the detector unit; otherwise, provide the controller unit software with these features.  If vehicle detector types other than “loop” detectors are required by the plans, provide these detector units by separate bid item.  If the special bid detector units use standard TS-2 detector racks, furnish the racks as part of the pre-wired cabinet.

          Furnish loop detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent).  This display shall be a bar graph or numerical display with at least eight (8) discrete levels indicated.

4.      Furnish switches to control the controller unit and cabinet functions as specified in the plans. 

5.      Furnish load switches that have both input and output indicators.

         6.       The primary surge protection device (SPD) shall be an EDCO SHA-1250 or approved equal.  A plug-in base shall be used to hold the device.  All wiring connections shall be made to the base, and appropriate cabinet clearances maintained, to allow the SPD module to be replaced by hand without the use of tools. Cabinet power distribution shall conform to Figure 5-4, NEMA TS-2 2003 v02.06. In addition, locates a non GFCI NEMA 5-15 utility outlet on the right side power panel. This outlet shall be powered independently of the UPS by direct connection to incoming utility power through a 15-amp circuit breaker labeled “UTILITY OUTLET.”

     7.      Include serial and/or Ethernet cables, 4-feet minimum length, to interface with laptop computer.  Include all interface software. 

     8.      Include datakey module.  Provide a datakey with each controller, taped securely to the top of the controller chassis.. 

          9.      Include an SDLC expansion board with three available ports, mounted on a cabinet side wall.

          10.    Include an SDLC in-line surge suppressor, EDCO SRS-BIU-15 or equivalent, located at the controller SDLC port.

          11.   Furnish an aluminum shelf with integral storage compartment in the space immediately below the controller. Ensure the storage compartment has telescoping drawer guides for full extension. Ensure the compartment top has a non-slip plastic laminate attached.

. 

Furnish  TS-2 cabinet according to the Department’s Qualified Products List (QPL).

C.      Type 332. 

1.      General.  Furnish Model 332L cabinets that meet the specifications “Traffic Signal Control Equipment Specifications” and “Transportation Electrical Equipment Specifications”, California Department of Transportation.  Ensure that the manufacturer of the cabinets is listed on the CalTrans and/or ODOT QPL at the time of delivery to the project.

2.      Cabinets.

a.      Ensure that the cabinets are constructed of aluminum and are supplied unpainted.  An anodic coating is not required.  Supply galvanized anchor bolts with nuts and washers with each cabinet.  Furnish 3/4-inch (19 mm) diameter by 16 inches (0.4 m) minimum length anchor bolts with an “L” bend on the unthreaded end.

b.      Fit the cabinets with a PDA-2 power distribution assembly.

c.      When shown on the plans, provide the cabinet with door hinges that are “right” or “left” mounted when facing the front of the cabinet.

3.      Terminals and Wiring.

a.      “Hardwire” output files.  Do not use printed circuit wiring in the output file except for the red monitor board.

b.      Ensure that the vehicle and pedestrian detector field wiring inputs connect to side mounted terminal blocks.  Install terminal blocks and associated wiring to the input file.  Label the field wiring terminals of the side mounted terminal block by a permanent screening process to identify the input panel (I or J), the input file slot number (1 through 14) and the channel terminal (D, E, J, or K).  An example is “I4-E”.  Ensure that all terminals on these detector blocks are accessible without removing equipment from the EIA mounting rack.

c.      Install red monitor cabling in the cabinets.  Install a program board to enable/disable red monitoring.  Ship the cabinets with the red monitor jumpers set in the “enable” position.

d.      Do not connect the pedestrian yellow load switch outputs to the conflict monitor card-edge connector.

e.      Supply each cabinet with a cable at least 5 feet (1.5 m) long to connect a laptop computer with the controller.  Ensure that the cable has a DB-9 connector on one end, and a connector on the other end to mate with the C2 on the back of the controller.  The cable will allow a laptop computer to upload/download data to the controller.

f.       Supply each cabinet with a Category 5e cable with 8P8C (RJ45) plug on each end, minimum 5 feet in length.  The cable will allow a laptop computer to upload/download data to the controller. 

g.      On the output file, wire pin No. 11 of each switchpack connector to AC- so that the output indicators on dual indicator switchpacks will display properly.

4.      Accessories.

a.      Fully equip the cabinets with two channel loop detector sensors, flashers, flash transfer relays, power supply, AC and DC isolators, conflict monitor, switchpacks (with both input and output indicators), and a DC isolator in slot 14 for flash sense/stop time.  Do not switch the input file channels from the standard layout in order to minimize the number of two-channel detector units utilized.  If vehicle detector types other than “loop” detectors are required by the plans, provide these detectors under a separate bid item.

Flash Transfer Relays shall use AC coils only; the use of a series rectifier in combination with a DC coil is prohibited.

In addition to the requirements of Caltrans TEES, furnish detector unit with an LED or LCD display indication of call strength (∆L/L or equivalent). This display shall be a bar graph or numerical display with at least eight (8) discrete levels indicated.

Furnish loop detector sensors according to the Department’s Qualified Products List (QPL).

b.      Furnish a rack mounted detector test panel with test switches. Test switches shall call vehicle phases 1-8, pedestrian phases 2,4,6,8 and EVPE channels A,B,C,D as defined in the published ODOT Plan Insert Sheet for default 332/336 cabinet input file assignments. Furnish switches with three position “on/off/momentary on” switches.

c.      Furnish a police panel in each cabinet that includes a removable pushbutton with 5 feet (1.5 m) cord and three switches labeled AUTO/FLASH, SIGNALS ON/OFF and AUTO/MANUAL.  Wire the pushbutton cord to the controller harness wiring by a molex plug connection and not through an AC isolator.  When placed in the manual position, apply “manual control enable” to the controller and apply “recall” to all phases.  Ensure that activation of the push button “advances” the controller, except prohibit the manual advancement during the minimum green, yellow, and red timing intervals.

d.      Furnish an aluminum shelf with integral storage compartment in the rack below the controller.  Ensure that the storage compartment has telescoping drawer guides for full extension.  Ensure that the compartment top has a non-slip plastic laminate attached.  Top of shelf shall be at least 30 inches and no more than 48 inches above the workpad surface.  For cabinets with risers, this may require relocating the drawer to a position below Input File #2. 

e.      Ensure that each cabinet has two white LED lights installed at the top of the cabinet, one near each door.  Wire the lights to the door switches such that opening either door will turn on both lights.

5.      Surge Protection.

a.      Furnish surge protection on pedestrian and detector inputs.  Furnish three terminal surrestors equivalent to EDCO models SRA-6LCA, SRA-6LCB, or SRA-6LC.

b.      Protect the cabinet’s incoming power lines with an EDCO SHA1250 or approved equal surge protector in lieu of the CalTrans specified surge protection.  A plug-in base shall be used to hold the device.  All wiring connections shall be made to the base, and appropriate cabinet clearances maintained, to allow the SPD module to be relaced by hand without the use of tools. 

6.      Conflict Monitor.  Ensure that the conflict monitor unit was tested and accepted according to Supplement 1076.

a.      Materials and Warranties.    Furnish electrical parts, switches, and other elements of the installation that are of ample capacity to carry the required current without excessive heating or drop of potential.

Use standard industrial quality components (integrated circuit chips, transistors, diodes, resistors, capacitors, etc.) wherever possible.  Clearly identify these components with the original identification.  Designate the other vital information such as voltage polarity, emitter or collector terminals, pin locations, etc., by an approved industrial procedure.  Ensure that the major items or assemblies of equipment bear a nameplate, indelible marking, or brand that identifies it as to type, model, catalog number, and manufacturer.

Transfer that manufacturers’ guarantees or warranties to the Department upon delivery and acceptance of the equipment.  Ensure that all conflict monitors are warranted for a period of 60 months or for the manufacturer’s standard warranty period, whichever is greater, for parts and labor from date of shipment to the project or the ODOT Signal Shop.  Ensure that each unit has a permanent label or stamp indicating the date of shipment and name of vendor supplying the unit and/or logo..

b.      General Requirements.

(1)     Minimum Standards.  This specification establishes minimum standards for Conflict Monitoring Devices designed for use in Model 332 and 336 Traffic Signal Controller Cabinets supplied to the Department. 

(2)     Indicator Lights.  Furnish indicator lights that are water-clear (not colored or diffused lenses), ultra- bright light emitting diodes (LED), whose states are clearly readable in direct sunlight.  Ensure that each conflict monitor channel provides separate red, yellow, and green LEDs.

(a)     Furnish a GREEN AC POWER indicator light.

(b)     Arrange indicator lights in a vertical pattern with FAULT status lights as the upper indications and the output channel lights as the lower indications [See 733.03.C.6.c.(1) and 733.03.C.6.c.(9)].  An acceptable alternative is to provide a single fault indication and a supplemental display that clearly indicates the fault type.

(c)     Ensure that a failure causes its respective indicator light to display.

(3)     Monitor Power.  Ensure that the Monitor does not use the 24VDC power supply being sensed to run any of its internal circuitry.  Ensure that the watchdog, stop time, external reset, and 24VDC monitor input circuits are optically isolated from the Monitor internal power supply and are conditioned to provide proper sense circuit operation throughout the operating range.

(4)     Power Fail.  Consider a line voltage less than 85 V ac ± 2 V ac as a power failure.  Ensure that a power failure does not result in resetting the Monitor.  Ensure that once the Monitor is triggered by detection of a fault that it remains in that state until a Reset Command is issued.  Reset is issued only by the Front Panel Control Switch or by the External Test Reset input.

(5)     Power Up.  Furnish a Monitor that is compatible with the Model 170E controller as well as the Model 2070 controller unit that requires several seconds to power-up.  When power is established, > 103 ± 2 Vac, the 2010 will power up in the FAULT RELAY RECOVERY mode:

When power is established, initiate FAULT RELAY RECOVERY.  For an interval of 6.0 ± 0.5 seconds, the following will take place:

(a)     The Output Relay contacts remain closed, and the Stop Time output remains active.

(b)     All fault monitoring functions remain suspended.

(c)     The AC POWER indicator light flashes at a 2 hertz rate.

At the end of this time interval, the Monitor begins counting Watchdog transitions from the controller and prepares to resume normal fault monitoring.

Ensure that the resumption of normal Fault monitoring occurs when either:

(a)     The Monitor has counted 5 transitions between the True and False state from the controller Watchdog; or

(b)     10 ± 0.5 seconds has elapsed from the time of LINE RECOVERY.

If the controller Watchdog output does not become active, ensure that the Monitor goes into a Latched Fault condition.

(6)     Cabinet Signals Monitored.  Furnish a Monitor designed to monitor Green, Yellow, and Red AC circuits at the field output terminals of traffic signal cabinets.  Monitor shall be capable of monitoring Flashing Yellow Arrow channels.  In addition, monitor the cabinet 24VDC supply, and the Model 170E/2070 controller Watchdog Timer output.  These signals are processed by the Monitor circuitry, and if a failure is determined to have occurred, ensure that a relay output contact closure (FAILED state) places the cabinet and intersection into flashing operation.

(7)     Failed State Output Circuits.

(a)     Use an electro-mechanical relay to provide the FAILED STATE output circuit.  Ensure that the relay contacts are normally closed (FAILED STATE).  In a NON-FAILED state (relay coil energized), ensure that the contacts are open.  The function of this output circuit is to initiate flash operation within the cabinet and transfer field circuits from the switch pack outputs to the flash bus during a FAILED STATE.

(b)     Furnish relay contacts that are rated for a minimum of 3 amperes at 120 V ac and 100,000 operations.  Ensure that the contact opening/closing time is 30 ms or less.  Furnish contacts that present a minimum impedance of 50,000 ohms in the open state.

(c)     Ensure that the Stop Time output is active whenever the output relay contacts are in the FAILED STATE (closed).  Ensure that it is inactive whenever the output relay contacts are in the NON-FAILED (open) STATE.

(8)     Monitor Unit Reset.  Furnish a front panel momentary SPST pushbutton switch labeled “RESET” to reset the Monitor to a Non-FAILED state and restores normal monitoring operation.  Position the switch on the front panel so that the switch can be operated while gripping the front panel handle.

Ensure that the External Test Reset input line resets the Monitor circuitry to a Non-FAILED state and restores normal monitoring operation.  Optically isolate it from the internal circuitry.  Ensure that a reset issuance by either source (Unit Reset) is triggered by only the leading edge of the input signal (this will prevent a constant reset due to either a switch failure or a constant external input).  Ensure that a constant reset input is ignored within 5 seconds of issuance.

(9)     Input Impedance.  Ensure that the input impedance for all monitored AC inputs are 200 kilohms ± 100 kilohms.

(10)  Connectors.  Furnish PCB 28/56P Type Monitor and Conflict Program Card Connectors.  Ensure that all edge connectors use the “bifurcated bellow” type contact or equivalent.

(11)  Door Ajar Circuit.  Connect pin 24 to pin 25 on the Monitor PCB at the edge connector and ensure that it is capable of carrying one ampere according to CalTrans specifications.

(12)  Handle.  Ensure that the handle placement and design is such that no interference between the handle and a closed cabinet door exists.

(13)  Fuse Holder.  Furnish low profile fuse holders on the front panel.

c.      Functional Requirements.

(1)     General.  The Monitor monitors the cabinet for conflicts and unsafe operation.  If an unsafe condition exists, the Monitor will enter into a FAILED state.  This places the cabinet into flash operation and applies STOP TIME to the controller unit.  Ensure that the Monitor is designed to monitor red circuits, yellow timing, multiple outputs, and lack of outputs on a switch selectable, per channel basis.  Specific conditions for failure follow:

(a)     24VDC FAIL.  The cabinet +24 volts DC does not meet the specified thresholds.

(b)     CONFLICT.  When the green or yellow input to one or more channels is ON and they are not programmed as permissive on the Conflict Program Card.

(c)     WATCHDOG TIMER (WDT) ERROR.  When the 170E/2070 controller unit watchdog output has ceased.

(d)     CONFLICT PROGRAM CARD AJAR.  Illuminates, if the Conflict Program Card is removed or if it is not properly seated in the connector.  When it is not inserted into the monitor, ensure that the warning indicator light is displayed.

(e)     MONITOR FAILURE.  A fault is detected within the operation of the 2010 Monitor itself.

(f)     MULTIPLE OUTPUTS.  Simultaneous indications of Green, Yellow, or Red field outputs on a single channel.

(g)     RED FAIL.  No active field outputs on a single channel (green/yellow/red).

(h)     YELLOW ERROR.  The absence of a minimum yellow field output during a green to red sequence.  Minimum yellow shall be 2.7 seconds ± 100 ms.

(2)     Operating Range.  Furnish a Monitor Unit that is fully operational using an 85 to 135 V ac power source.  Ensure that the Monitor suspends Fault monitoring below 85 V ac ± 2 V ac, closes the output relay, and de-energizes the AC POWER indicator light.

(3)     Watchdog Timing.  Furnish WATCHDOG Timing Circuitry to monitor the controller unit WATCHDOG output.  Ensure that the WDT Circuitry senses state changes and the time between the last change.  Ensure that an absence of change for 1.5±0.1 seconds places the Monitor in a FAILED state.

(4)     Channels Monitored.  Furnish a Monitor that senses and responds to conflicts and 24 VDC failures whenever the AC line voltage is within the 85 to 135 V ac operating range of the Monitor, except during FAULT RELAY OPERATION.

(5)     Yellow Inhibit.  Furnish means to selectively inhibit the monitoring of a Yellow channel input.

(6)     Power Fail after Fault.  In the event that the Monitor senses a fault, followed by a loss of operating voltage, ensure that the initial Failure Status is retained in memory and is redisplayed after restoration of power.

(a)     Once the Monitor is LATCHED in a fault condition for any reason, including the removal of the Conflict Program Card, ensure that it REMAINS LATCHED, even through a power fail/recovery, until a RESET is issued by the front panel reset switch, or by the external test reset line.

(b)     Display the status of the Green, Yellow, and Red inputs of all channels, at the time the fault was latched.  Ensure that a power loss does not affect the retention of this data.  An acceptable alternative is to save status of all channels in memory and only display the latched fault.

(7)     Insertion/Removal of Unit.  Ensure that it is possible to insert and remove the Monitor while the cabinet is energized without placing the cabinet into Flash operation provided that:  The cabinet door remains open and the reset switch is held depressed while the unit is being inserted or removed.  Any momentary disruption of field signal indications is less than 500 ms.

(8)     Microprocessor Use.  If a microprocessor is used in the Monitor design, ensure that its program is written so that:

(a)     Integrity tests are performed periodically on each memory cell of each memory device, relevant to each device type.

(b)     Hardware external to the microprocessor circuits is employed to constantly sense proper microprocessor operation.

(c)     The Monitor reverts to a FAILED state if a fault is detected with the microprocessor or during integrity tests.

(9)     Front Panel Indicators.  Ensure that the Monitor has red/yellow/green indicators for channel inputs and indicators to provide status and failure detection information.  Furnish a GREEN AC POWER indicator.  Ensure that all indicators are clearly readable in direct sunlight.  Arrange and label the indicators as shown below:

(a)     AC POWER.  Illuminates when the incoming AC Line Voltage exceeds 103 ± 2V ac, and FLASHES during FAULT RELAY OPERATION.

(b)     VDC FAIL.  Illuminates when the Monitor has detected a 24VDC failure.

(c)     CONFLICT.  Illuminates when a conflicting signal condition is detected.

(d)     WDT ERROR.  Illuminates when a Watchdog error is detected.  Do not provide a switch or similar device to disable WDT monitoring.

(e)     PC AJAR.  Illuminates when the Conflict Program Card is removed or is not properly seated in its connector.

(f)     MON FAIL.  Illuminates to indicate an internal Monitor failure.

(g)     RED FAIL.  Illuminates when the Monitor detects that there is no active output on any of the field outputs that comprise a monitored channel.  Ensure that the failed channels are displayed on the corresponding channel indicators.  If for any reason red fail is not enabled, ensure that the red fail indicator light flashes at approximately 2hertz.

(h)     MULT IND.  Illuminates when the Monitor detects simultaneous outputs on more than one of the field outputs that comprise a monitored channel (green/yellow/red).  Ensure that the failed channels are displayed on the corresponding channel indicators.

(i)      YELLOW.  Illuminates when the Monitor detects the absence of a minimum period of active yellow field output during a green to red sequence.  Ensure that the failed channel is displayed on the corresponding channel indicator.

(j)      1, 2, 3, 48.  Furnish channel indicators that illuminate a FAILED state in conformance with 733.03.C.6.c.(6).

(10)  Monitor Board Edge Connector.  Furnish monitor board edge connectors that conform to CalTrans specifications.

(11)  Monitoring of Conflicting Voltages.  Ensure that inputs to any channel that exceed the specified conflict threshold (see Section 6) are sensed as “ON” and illuminate their respective channel indicators.  Ensure that the number of active channels in no way affects the conflict threshold.

Ensure that the following voltage levels and times apply:  A conflict has occurred and will cause a FAILED state only when voltages appear at the field output terminals.

> 20 ± 5.0 V rms for a duration > 350 ± 150 ms.

(12)  Conflict Program Card.  Furnish conflict program cards that comply with CalTrans specifications.

d.      Fault Relay Operation.

(1)     Line Drop Out.  Furnish a Monitor that determines that a LINE DROP OUT has occurred when:

The AC Line Voltage is:

< 98 ± 2 VAC for > 400 ± 100 ms.

Within this time frame, ensure that the Monitor suspends all fault monitoring functions, closes the output relay contacts, enables Stop Time output, and the AC POWER indicator on the front panel flashes at a rate of 2 hertz ±20 percent to indicate LINE DROP OUT status.  Ensure that the Monitor remains in the FAULT RELAY mode until a LINE RECOVERY has occurred.

(2)     Line Recovery.  Ensure that the Monitor that determines that a LINE RECOVERY has occurred when:

The AC Line Voltage is:

> 103 ± 2 VAC for > 400 ± 100 ms.

(3)     Fault Relay Recovery.  When LINE RECOVERY is established, initiate the FAULT RELAY RECOVERY.  For an interval of 6.0 ± 0.5 seconds, the following will take place:

(a)     The Output Relay contacts remain closed, and the Stop Time output remains active.

(b)     All fault monitoring functions remain suspended.

(c)     The AC POWER indicator light flashes at a rate of 2 hertz ± 20 percent.

At the end of this time interval the Monitor begins counting Watchdog transitions from the controller and prepares to resume normal fault monitoring.

(4)     Resumption of Normal Monitoring.  Ensure that the resumption of normal Fault Monitoring occurs when either:

(a)     the Monitor has counted five transitions between the True and False state from the controller Watchdog; or

(b)     10 ± 0.5 seconds has elapsed from the time of LINE RECOVERY.

If the controller Watchdog output does not become active, the Monitor shall go into a Latched Fault condition.

e.      Red Monitoring Connector.

(1)     Connector.  Mount a connector, 3M-3428-5302, with two 3518 polarizing keys, or equivalent, on the Monitor front panel.  The pin assignments of the P20 connector and terminal assembly are defined in this specification.

Ensure that it is possible to plug and unplug the Red Monitoring Connector P20 without placing the cabinet into Flash operation.

P20 Connector Pin Assignments

Pin

Function

Pin

Function

1

CHANNEL 15 RED

2

CHANNEL 16 RED

3

CHANNEL 14 RED

4

UNDEFINED

5

CHANNEL 13 RED

6

SPECIAL FUNCTION 2

7

CHANNEL 12 RED

8

SPECIAL FUNCTION 1

9

CHANNEL 10 RED

10

CHANNEL 11 RED

11

CHANNEL 9 RED

12

CHANNEL 8 RED

13

CHANNEL 7 RED

14

CHANNEL 6 RED

15

CHANNEL 5 RED

16

CHANNEL 4 RED

17

CHANNEL 3 RED

18

CHANNEL 2 RED

19

CHANNEL 1 RED

20

RED ENABLE

Ensure that keying is between pins 3/5, and 17/19.  The odd numbered pins are on one side, and the even pins are on the other.  Key the P20 connector and the CMU connector physically alike (to prevent the Red Monitoring cable from being inserted into the P20 180 degrees out of alignment).

(2)     Red Enable Input.  Ensure that pin 20 of the Red Monitoring Connector provides the Red Enable input to the Monitor.  When the Red Monitoring Connector is disconnected, or Red Enable is not present, ensure that the Monitor checks for conflicting combinations of Greens and Yellows, Watchdog Timer, 24VDC, Conflict Program Card Ajar, and Monitor Fail.  When enabled, ensure that the extended Monitor functions become active including:  Red Fail, Multiple Output, and Yellow Fail.

(3)     Special Function 1 and 2 Inputs.

(a)     PIN 8, Special Function 1:  Furnish an AC input to the Monitor, which will DISABLE only the RED FAIL monitoring functions while it is active (e.g. during Railroad Preempt).

(b)     PIN 6, Special Function 2:  Reserved for future use.

Furnish a means to select either a PRESENCE of, or LACK of AC+ to enable these inputs.

f.       Electrical Requirements.

(1)     Operation Range.  Furnish a Monitor that is fully operational from an 85 to 135 V ac power source.

(2)     Isolation.  Isolate the Chassis Ground and AC - from one another.

(3)     Monitored AC Inputs.  The following voltage and time thresholds apply to all monitored AC inputs.

(a)     Green and Yellow Inputs.

Any inputs < 15.0 V rms are considered OFF.

Any inputs > 25.0 V rms are considered ON.

Both sinusoidal and half-wave inputs of the specified RMS values  are to meet these thresholds.

(b)     Red, Red Enable, and Special Function Inputs.

Any inputs < 50.0 V rms are considered OFF.

Any inputs > 70.0 V rms are considered ON.

Red inputs, both sinusoidal, and half-wave, of the specified RMS values, are to meet these thresholds.

Red enable and special function inputs are to meet these thresholds for sinusoidal waveforms only.

(c)     Timing of Conflicting Inputs or Multiple Inputs.

Inputs ON < 200 ms are NOT considered a FAULT.

Inputs ON > 500 ms are considered a FAULT.

(d)     Timing of Red Fail.

Lack of output < 1200 ms is NOT considered a FAULT.

Lack of output > 1500 ms is considered a FAULT.

(4)     Monitored DC Inputs.

(a)     24VDC Input.

Input < 18.0 VDC is considered Low VDC input.

Input > 22.0 VDC is NOT considered Low VDC input.

(b)     24VDC Timing.

Low VDC input < 200 ms is NOT considered a FAULT.

Low VDC input > 500 ms is considered a FAULT.

(c)     Watchdog Monitor Input.

Input < 4.0 VDC is considered a LOW STATE.

Input > 12.0 VDC (or OPEN) is considered a HIGH STATE.

(d)     Watchdog Error Timing.

Lack of valid input state changes for < 1400 ms is NOT a FAULT.

Lack of valid input state changes for > 1600 ms is a FAULT.

g.      Communications and Software.

(1)     Install an RS232 port for laptop communications on the front panel of the Monitor.  If specified in the plans, an IP port shall be used in place of RS232. 

(2)     Furnish a Monitor with compatible communications software for installation on a laptop computer, capable of interfacing with the communication port on the front panel.  Furnish the software on a 3 1/2-inch (85 mm) floppy disk with each Monitor.  Label each disk with revision number and date.

(3)     Unless specified otherwise in the plans, furnish a Monitor that is capable of being programmed and set-up for intersection operation without the use of a laptop computer and communication software.

(4)     Furnish a Monitor communications software that is capable of showing and/or programming the status of all programmable set-up parameters of the unit.  Furnish a communications software that is capable of displaying the following data:

(a)     Fault type

(b)     Field status (must update status continuously)

(c)     AC line voltage (must update status continuously)

(d)     Status of Red Enable

(e)     Previous fault data

(f)     Program card matrix

(g)     Yellow disable jumpers (if applicable)

(h)     Switch settings per channel (as applicable)

(i)      Option switches

(j)      Current time

(k)     Temperature (must update status continuously)

(l)      Event logs

(5)     Furnish a Monitor that is capable of storing events into memory.  Typical events are fault events, AC line events, reset events, etc.  When a fault event is stored into memory, the Monitor will store the fault condition (type), channel status, date, time, temperature, and line voltage.  Ensure that the log history stores a minimum of 100 total events.

h.      Diode Matrix, Programming Key, and Software.  Furnish a Monitor that loads the diode matrix or Programming Key programming into a non-volatile memory device.  When the diode matrix or Programming Key is loaded into memory, the memory will regularly compare with diode card or Programming Key and fault condition will occur if memory does not match the diode card matrix.

Furnish  332 cabinet according to the Department’s Qualified Products List (QPL).

D.  Type 334.

1.  General.  Furnish Model 334C cabinets that meet the specifications “Traffic Signal Control Equipment Specifications” and “Transportation Electrical Equipment Specifications”, California Department of Transportation.  Ensure that the manufacturer of the cabinets is listed on the CalTrans QPL at the time of the project award.

2.  Cabinets.  Furnish cabinets that are constructed of aluminum and are supplied unpainted.  An anodic coating is not required.  Supply galvanized anchor bolts with nuts and washers with each cabinet.  Furnish 3/4-inch (19 mm) diameter by 16 inches (0.4 m) minimum length anchor bolts with an “L” bend on the unthreaded end.

3.  Terminals and Wiring.  Ensure that the vehicle detector field wiring inputs connect to side mounted terminal blocks.  Install terminal blocks and associated wiring to the input file.  Label the field wiring terminals of the side mounted terminal block by a permanent screening process to identify the input panel (I), the input file slot number (1 through 14) and the channel terminal (D, E, J, or K).  An example is “I4-E”.  Ensure that all terminals on these detector blocks are accessible without removing equipment from the EIA mounting rack.

4.  Accessories.

a.      Fully equip the cabinets with two channel loop detector sensors, transfer relay, power supply, conflict monitor and switchpacks.  When ramp meter warning signs with flashers are used, include a NEMA or Caltrans type flasher wired for control from the controller.

b.      Furnish a police panel in each cabinet with the Caltrans required switches.  No pushbutton with cord is provided.

c.      Furnish an aluminum shelf with integral storage compartment in the rack below the controller.  Ensure that the storage compartment has telescoping drawer guides for full extension.  Ensure that the compartment top has a non-slip plastic laminate attached.

d.      Ensure that each cabinet has two fluorescent lights installed at the top of the cabinet, one near each door.  Wire the lights to the door switches such that opening either door will turn on both lights.

5.  Lightning/Surge Protection.  Comply with the requirements of 733.03.C.5.

6.  Conflict Monitor.  Furnish a Model 208 conflict monitor unit.

Furnish 334 cabinet according to the Department’s Qualified Products List (QPL).

E.      Type 336.

1.      General.  Furnish Model 336 cabinets that meet the basic cabinet specifications “Traffic Signal Control Equipment Specifications”, California Department of Transportation, latest edition.  Ensure that the manufacturer of these Model 336 cabinets is listed on the ODOT QPL.

2.      Cabinets.

a.      Furnish cabinets that are constructed of aluminum and are supplied unpainted.  An anodic coating is not required.

b.      The CalTrans Model 336 cabinet specification is only modified so that the cabinet supplied is the “stretch” type that provides approximately 10 inches of (250 mm) additional cabinet height.

c.      Supply galvanized anchor bolts with nuts and washers with each base mounted cabinet.  Furnish 3/4-inch (19 mm) diameter by 16 inches (0.4 m) minimum length anchor bolts with an “L” bend on the unthreaded end.

d.      Furnish pole mounted cabinets with two pole mounting brackets attached and bottom plates installed.  Ensure that both of the cabinet sidewalls are reinforced for pole brackets; however, also ensure that the cabinet is shipped with the brackets installed on the door hinge side of the cabinet.  When a pole mounted cabinet is ordered, ensure that the door hinges are specified as “right” or “left” mounted as looking into the front of the cabinet.  Ensure that the brackets are designed for banding to a pole.

e.      Fit cabinets with a PDA-2 power distribution assembly.

3.      Terminals and Wiring.  Comply with the requirements of 733.03.C.3.

4.      Accessories.  Comply with the requirements of 733.03.C.4.

5.      Lightning/Surge Protection.  Comply with the requirements of 733.03.C.5.

6.      Conflict Monitor.  Comply with the requirements of 733.03.C.6.

Furnish  336 cabinet materials according to the Department’s Qualified Products List (QPL).

733.04  Cabinet Risers.  Furnish the type (size and shape) of cabinet riser that is compatible with the type of controller cabinets specified for the project.

A. Cabinet Riser for NEMA Cabinet.  Furnish an aluminum riser that will raise the NEMA cabinet approximately 12 inches (0.3 m) above the concrete foundation.  Ensure that the bottom of the riser bolts to the standard cabinet foundation anchor bolts (not included with the riser) and the top of the riser bolts to the bottom of the cabinet.  Furnish attachment hardware for connecting the riser to the cabinet.

Construct the riser in a minimum of two pieces such that an existing cabinet can be raised off the foundation without disconnecting the field wiring and the riser can be inserted below the cabinet.  Furnish hardware for rigidly connecting the riser sections together.

Fabricate the riser from 0.125-inch (3 mm) sheet aluminum with flanges on the top and bottom to provide rigidity.  Furnish mounting flanges as necessary to connect with the controller cabinet and foundation anchor bolts.  Ensure that the outside surface of the riser has a smooth, uniform, natural finish unless controller cabinet painting is shown on the plans.  If painting is required, prepare and paint the riser to match the cabinet.

B. Cabinet Riser for Type 332, 334 or Type 336 Cabinet.  Furnish an aluminum riser that will raise the Model 332, 334 or 336 cabinet approximately 8 inches (0.2 m) above the concrete foundation.  Ensure that the bottom of the riser bolts to the standard cabinet foundation anchor bolts (not included with the riser) and the top of the riser bolts to the bottom of the cabinet.  Furnish attachment hardware for connecting the riser to the cabinet.  Manufacture the unit to CalTrans specifications.  Ensure that the outside surface of the riser has a smooth, uniform, natural finish unless controller cabinet painting is shown on the plans.  If painting is required, prepare and paint the riser to match the cabinet.

Furnish materials according to the Department’s Qualified Products List (QPL).

733.05  Flasher Controller.  Furnish solid-state flasher that complies with NEMA TS-1, Section 8, and have two circuits, each rated at 10 amperes.  Furnish a cabinet that conforms to applicable requirements of 733.03.A, except that the following items are not required:  a small door-in-door (police door), shelves, and a fan.  Ensure that the cabinet size is not less than 12 inches (300 mm) high by 10 inches (250 mm) wide by 6 inches (150 mm) deep.  Furnish cabinets that are designed for pole mounting with a 1-1/2 inch (38 mm) or larger conduit opening in the bottom.  Ensure that the auxiliary equipment includes:  on-off power switch with integral 20-ampere circuit breaker, lightning protection devices on incoming power lines, interference filters, terminal blocks, and a ground bus bar.

Furnish materials according to the Department’s Qualified Products List (QPL).

733.06  Controller, Master, Traffic Responsive.

A.      Description.  The traffic responsive master controller is one component of a distributive processing, traffic responsive, control, and monitoring “closed loop” system.  The master controller’s principal operational task is to select and implement traffic signal timing plans in response to both actual traffic conditions or time based events.  The master controller monitors, in real time, local intersection activity, and overall system performance, reporting failures and status conditions to the Remote Monitoring Station.

The master controller is typically located in a local intersection cabinet; however, in special circumstances it may be located at a Remote Monitoring Station site.  The master controller is capable of uploading/downloading information to local intersection controllers and the Remote Monitoring Station.

B.      Functional Requirements.

1.      Design.  Furnish a solid state, digital microprocessor master controller design.  Furnish a controller that uses menu driven prompts, unless of Type 170 design.  If the master controller is used with Type 170E or Type 2070 controllers, provide software unless otherwise shown on the plans.

Furnish a master controller that has a RS-232 port for connection to a laptop computer or printer.  Furnish software and connector cables for communication with a laptop.

2.      Local Controllers.  Ensure that each master controller is able to supervise and communicate with at least 24 local intersection controllers.

3.      System Detectors.  Ensure that each master controller is able to analyze traffic sensor data from at least 32 system detectors.  Distribute system detectors up to eight per intersection, but do not exceed the total system sensor capacity.

Ensure that the detectors are assignable to each of the computational channels in each group, with the channels representing cycle selection, directionality (offset), non-arterial flow (split), and special congestion indicators of queue or occupancy.

Furnish a master controller that is capable of monitoring and detecting system detector failure and removing failed detectors from volume and occupancy calculations.  Upon resumption of satisfactory sensor operation, sensors shall automatically resume input to volume and occupancy calculations.

4.      Timing Patterns.  Ensure that each master controller provides a minimum of 16 selectable patterns.  Ensure that each pattern shall consist of a combination of cycle, offset, and split numbers for each intersection in the system.

Furnish a master controller that is capable of implementing a “free” mode whereby all intersection controllers will operate without system coordination and a “flash” mode whereby all intersection controllers will operate in a flashing operation.

5.      Operational Modes.  Ensure that each master controller is able to operate in the following modes of operational control:

a.      Traffic responsive mode whereby pattern selection is based on dynamic traffic conditions as measured by system sensors located in the control area.  As a minimum, base the pattern selection on the quantitative traffic flow parameters of volume, occupancy, and directionality of the arterial traffic.

Base transfer of patterns on programmable threshold values.  Furnish system sensors that are capable of selective weighting.

b.      Time of day/day of week (time base) mode whereby pattern selection is based on a preprogrammed event scheduler with automatic adjustments for seasonal daylight savings time changes.  Ensure that this mode of operation is able to call or override traffic responsive mode.

c.      Manual override mode whereby pattern selection is made by operator control at the Remote Monitoring Station or master controller site.

Ensure that the system coordination control for each master controller is selected on a priority basis.  The priority from highest to lowest is as follows:

a.      Manual control entry or remote command

b.      Time base control

c.      Traffic responsive control

6.      Reports.  Ensure that each master controller monitors and formats intersection and system information for immediate output to the Remote Monitoring Station or for storage for a minimum period of 48 hours.  As a minimum, ensure that the following types of reports are generated:

a.      A local intersection activity log showing the time, date and activity of all monitored local intersection failure conditions.

b.      A system sensor failure log that includes time, sensor location, and type of failure.

c.      A system log with pattern changes.

d.      A system sensor data log that includes volume and occupancy for all system sensors.

7.      Alarms.  Ensure that each master controller continuously monitors intersection and system information for various systems and user defined critical conditions.  Upon detection of an alarm condition, ensure that the master controller attempts to transmit alarm information to the Remote Monitoring Station or a preprogrammed telephone number.  In case of failure to connect to the central software, the master will continue to periodically retry reporting to the Remote Monitoring Station.

8.      Communications.  Furnish a master controller that supports two-way dial-up communications to a Remote Monitoring Station computer for control, monitoring, data collection, and for timing pattern updating purposes.  Through continuous, 7 days/week, 24 hours/day system monitoring, ensure that the master controller is able to automatically dial-up the Remote Monitoring Station computer upon detection of user defined critical alarm conditions.

Furnish a master controller that includes any communication devices or modems necessary to interface with the local intersection controllers within its control area.

9.      Security.  Furnish a master controller that provides for a user specified security code before any data is altered.  In order to view any parameter, ensure that a security code entry is not required.  Furnish a master controller that has the ability to disable security code requirements, allowing for perpetual access without requiring hardware changes.

733.07  Remote Monitoring Station.

A.      Description.  The Remote Monitoring Station describes a distributive processing, traffic responsive, control and monitoring “closed loop” system.  The system monitors, in real time, local intersection activities, and overall system performance, reporting failures and status conditions both automatically and by operator request.  In order to meet current and future traffic control needs, the system also provides extensive control monitoring, data collection, reporting, and analysis functions.

For complete user flexibility, the system provides full access of each local system intersection controller from the Remote Monitoring Station site.  Full access includes the capability to upload all time settings, operation parameters, and status information, as well as the capability to download all time settings and operation parameters.

B.      System Architecture.  The system consists of four principal elements:

1.      Local intersection controller (see 733.02)

2.      Communication links

3.      Traffic responsive master controller (see 733.06)

4.      A Remote Monitoring Station consisting of computer equipment and software

C.      Local Intersection Controllers.  Furnish controller units conforming to 733.02 for the type of controller shown on the plans.  Furnish a controller that has internal communication capability compatible with the type of interconnect cable shown on the plans.  Furnish a local system controller that is capable of processing controller and detector data and provide all necessary intersection control functions.

D.      Communications.  Ensure that communication between the Remote Monitoring Station and the master controller is through an auto-answer/auto-dial external modem on standard dial-up telephone service.  Furnish telephone service at the Remote Monitoring Station site by the maintaining agency, unless otherwise shown on the plans.  Furnish telephone service at the master controller or the isolated local intersection location by separate bid item as specified for “Telephone Service”.

Include error checking in the software to assure transmission and reception of valid data between the local controller, master controller, and the Remote Monitoring Station.

E.      Equipment.  Ensure that the Equipment provided at each Remote Monitoring Station location is as shown on the plans and, as a minimum, consists of the following items:

1.      Microcomputer with monitor

2.      Software

3.      Modem

4.      Printer

5.      Accessory Items

F.      System Functional Requirements.  The system software provides a simplified user friendly, color menu format at the Remote Monitoring Station.  Ensure that no special computer programming skills are required for the user to fully access and operate this control and monitoring system.

1.      Graphical Representation.  Furnish system software that enables the operator to display in color, the vehicular signals, pedestrian signals, and detector actuations in a real time mode.  Ensure that the user is able to construct an intersection layout graphically by using predetermined intersection shapes.

2.      System Capacity.  Furnish a Remote Monitoring Station software that has the capacity to monitor and control at least 24 traffic responsive masters.  Ensure that the central software is also capable of monitoring and controlling isolated system controllers.

Furnish a system software that has the capability to manually select any timing plan, free mode or flash mode.

Ensure that the system software has the capability of accepting, formatting, and processing data from at least 32 system detectors from each master controller.

3.      Data Transfer.  Ensure that it is possible to upload/download the signal timing database, including coordination, and preemption settings, between the Remote Monitoring Station and the master controller or local intersection.

Furnish a Remote Monitoring Station that provides a means to compare a currently uploaded timing database with a previously developed database stored in the Remote Monitoring Station memory.  Ensure that it reports differences in the databases.

During either uploading or downloading operations, ensure that the normal traffic control operations are not suspended.

4.      Security.  Furnish a Remote Monitoring Station that provides for a user specified security code before any data is altered.  Maintain controller access procedures from the Remote Monitoring Station allowing the user full security control of all system components from a remote location.

5.      Isolated Intersection Management.  Furnish a Remote Monitoring Station software that includes the capability of accessing system controllers at remote intersection locations.  Ensure that this capability includes total access to controller timing parameters, alarm conditions, detector data, and intersection status conditions in real time without the use of a master controller.  Ensure that this feature utilizes the local intersection controller with a dial-up modem and telephone service.

733.08  Telephone Service.  Ensure that the telephone service is a standard dial-up service capable of supporting 2400 baud data transmission.  Ensure that the external modem provided is a Hayes compatible, auto-answer/auto-dial unit with all connections, cables, and lightning protection on the incoming wires provided.

733.09  Uninterruptible Power Supply(UPS). 

A.      Operation.  In addition to the material requirements below, furnish a UPS system with a minimum two and one half (2.5) hours of full run-time operation for an “LED-only” intersection with 1000 watts of active output power.

          Ensure the UPS cabinet has a mastic tape, neoprene foam, or silicone weather-resistant seal between the cabinet bottom flange and the concrete foundation. Minimum tape thickness shall be 1/8-inch (3 mm) and the tape shall be continuous with no gaps between tape pieces or between cabinet and foundation. Sealing tape shall completely cover the bottom cabinet flange and shall be rated for a temperature range of at least -30 °F to +140° F.

          The maximum transfer time allowed, from disruption of normal utility line voltage to stabilized inverter line voltage from batteries, shall be 65 milliseconds or less.  The same maximum allowable transfer time shall also apply when switching from inverter line voltage to utility line voltage.

          Include a means to switch the intersection from full-operation to flashing operation after 2-hours of run-time. This is to conserve battery operation during an extended utility power outage.

          Include standard form C relay contacts to trigger an alarm within the controller assembly, informing a technician the system is operating on battery backup.

          Operating temperature for both the inverter/charger, power transfer relay and manual bypass switch shall be -35 °F to +165 °F         (-37 °C to +74 °C).

          Both the power transfer relay and manual bypass switch shall be rated at 240VAC/30 amps, minimum.

          The UPS shall bypass the utility line power whenever the utility line voltage is outside the following voltage range: 100VAC to 130 VAC, + 2 VAC.

          When utilizing battery power, the UPS output voltage shall be between 110 VAC and 125 VAC, pure sine wave output, 60Hz ± 3Hz.

          When the utility line power has been restored between 100 VAC and 130 VAC for more than 30 seconds, the UPS shall dropout of battery backup mode and return to utility line mode.

          In the event of inverter/charger failure, battery failure or complete battery discharge, the power transfer relay shall revert to the NC (and energized) state, where utility line power is connected to the cabinet.

          Recharge time for the battery, from “protective low-cutoff” to 80% or more of full battery charge capacity, shall not exceed 10 hours.

          Include all necessary wiring and hardware for mounting (shelf angles, rack, etc).

Furnish a UPS with available buck/boost mode operation,  with a minimum input voltage range of 85 to 150 vrms. The unit display shall indicate when buck/boost mode is engaged. Default buck/boost setpoints shall be 108 vrms and 132 vrms unless specified otherwise in the Plans.

Furnish a UPS with an Ethernet port for remote monitoring and control. Provide interface software unless the Ethernet port has built-in web browser compatibility. Remote communication shall have the ability to make setting changes, review status, retrieve alarm and event logging that is time and date stamped for up to 50 events.  The logs shall be printable.

Ensure the UPS cabinet has a mastic tape seal between the cabinet bottom flange and the concrete foundation. Minimum tape thickness shall be 1/8-inch (3 mm) and the tape shall be continuous with no gaps between tape pieces or between cabinet and foundation.

The UPS output notifications for on battery, battery 2 hour timer and low battery shall be wired into the traffic signal back panel to provide special status alarms for each output into the signal controller.

This item shall include a red LED status indicator lamp to allow maintenance personnel and law enforcement to quickly assess whether a traffic signal cabinet is being powered by a UPS.  The LED housing shall be NEMA 4X, IP65 or IR66, rated for outdoor use and be tamper/shatter resistant.  It shall be a domed enclosure contained a red lens with LED that is visible from 100 foot minimum.  The enclosure and LED lamp unit should be placed and centered on the top surface of the UPS cabinet and sealed from water intrusion.  It should be wired using minimum 20 GA stranded, insulated hookup wire to the status relay outputs of the UPS.

The wires shall be terminated by lugs at the display end and permanently labeled "Backup Power Status Display," with wire polarity indicated.  The red LED shall only illuminate to indicate the cabinet is operating under UPS backup power (the "backup" operating condition).  This item also includes programming the UPS status relay outputs to produce the lamp status displays.  These status displays will be solid 100% duty cycle (not flashing) displays.  The operating voltage of the LED lamp shall be 120V AC unless otherwise indicated.

B. Maintenance, Displays, Controls and Diagnostics.  Furnish a UPS with a backlit LCD display that includes an event counter, hour meter, line and battery voltages/percentages and fault status.  The LCD display shall have touch keys for changing display statuses and to reset counters, hour meter date and time.

          Furnish a UPS with lightning surge protection compliant with IEEE/ANSI C.62.41.

          Furnish two (2) sets of equipment lists, operation and maintenance manuals, and board-level schematic and wiring diagrams of the UPS, and the battery data sheets. Manual shall conform to TEES 1999, Chapter 1 Section 1.2.4.2.

C. Battery System.  Supply a minimum of four (4) batteries with the UPS system. Each battery shall be 12VDC and be rated at a minimum of 95 Ahrs, 20-hour discharge rate to 1.8 volts/cell at 77 degrees Fahrenheit (25 degrees Celsius), to achieve the 2.5 hour run time requirement. Furnish batteries easily replaced and commercially available off the shelf.

          Furnish deep cycle, sealed prismatic lead-calcium based AGM/VRLA (Absorbed Glass Mat/ Valve Regulated Lead Acid) batteries.

          Furnish batteries certified in writing by the manufacturer to operate over a temperature range of -13 °F to +165 °F (– 25 °C to +74 °C).

          Place all batteries on battery heater mats in the enclosure. The battery heater mats are designed to extend the life of the batteries.

          An integral system shall prevent the battery from destructive discharge and overcharge. Batteries shall not be recharged when battery temperature exceeds 122°F+5°F(50°C±3°C).

D.  Enclosure.  Furnish an enclosure mountable to a standard Model 332, NEMA TS-1 or TS-2 traffic signal cabinet and be constructed of natural unpainted aluminum.  Furnish cabinet size adequate to house “all” the UPS equipment including the controller unit, manual bypass switch and the (4) batteries.  Key the enclosure to the State master #2 lock and include 2 keys.

Furnish a base seal for use between the enclosure to the concrete foundation or riser of continuous tape gasket material, minimum 1/8-inch (3 mm) thickness.  Completely seal the interface to the adjacent controller cabinet with silicone caulk.

Furnish an enclosure with a vent, fan and thermostat as per TEES Chapter 7, Section 2-Housings.

E. Warranty.  Provide a two (2) year factory-repair warranty for parts and labor on the UPS from date of acceptance by the State. Warrant batteries for full replacement for two (2) years from date of purchase.

Furnish materials according to the Department's Qualified Products List (QPL).

740  PAVEMENT MARKING MATERIAL

740.01  General.  Permanent pavement marking materials that meet the requirements of this specification and that have passed the service test required by Supplement 1047 are included on the    Approved List maintained by the Office of Materials Management (OMM).  OMM may retest pavement marking materials pre-qualified by a service test to determine formulation compliance to pre-qualified material and compliance with physical properties specified herein.  Certified test data and samples will be furnished by the manufacturer to OMM.  Failure of testing or certified test data to show formulation conforming to pre-qualified material or compliance with specified physical properties may be cause for removal of the material from the Approved List.

Ensure that the marking material is delivered in containers that are clearly marked to indicate the number of gallons (liters), weight or size of material, material density (weight per unit volume), material color, batch number or other similar manufacturer’s identification, date of production, and the company name and address.

740.02  Traffic Paint.  Furnish white and yellow ready-mixed traffic paint suitable for marking various types of pavement.   Furnish paint that is a suitable binder for glass beads, 740.09 Type A, on pavement exposed to traffic.  Furnish paint that will not deteriorate in storage, within one year after date of receipt, to the extent that it cannot be readily broken up with a paddle to a smooth uniform paint capable of easy application by spray.

Furnish paint that does not bleed or discolor when sprayed on asphalt concrete surfaces.

Type 1 paint is the fast dry, water-based, 100 percent acrylic type.

Type 1A paint is fast dry, water-based, 100 percent acrylic type, used for cold weather applications.

Ensure that Type 1A paint conforms to the following requirements:

Property

Test Method

Requirements
(Applies to both White and Yellow, unless noted)

Total Solids

ASTM D2369

70% minimum by weight

58% minimum by volume

Titanium Dioxide, rutile type II

ASTM D1394

1 lb/gal (120 g/l) minimum, White

0.2 lb/gal (24 g/l) minimum, Yellow

Pigment % by Weight

ASTM D3723

+/- 2% of qualifying sample

Weight per Gallon

ASTM D1475

+/- 0.3 lb/gal (36 g/L) of qualifying sample

Color

SS 1047

Appendix A

Viscosity (krebs units)

ASTM D562

70 minimum and 95 maximum @ 77 °F (25 °C)

Lab Drying Time

ASTM D711

10 minutes max. @ 77 °F (25 °C), 50% RH

12 minutes max. @ 50 °F (10 °C), 50% RH

14 minutes max. @ 35 °F (1.7 °C), 50% RH

Prequalify materials according to Supplement 1047.  Use materials certified according to Supplement 1089. Furnish materials according to the Department’s Approved List.

740.03  Polyester Pavement Marking.  Ensure that the polyester pavement marking material supplied is a two part polyester system capable of being applied at ambient temperature down to 50 °F (10 °C).  Ensure that the material is capable of retaining reflective glass beads, 740.09 Type B, after application.

Ensure that the catalytic component of the system is the commercially available type recommended by the manufacturer of the polyester.

Ensure that the ratio of the catalyst to resin is specified by the manufacturer.

Ensure that the polyester conforms to the following requirements:

Minimum

Maximum

1.

Consistency, Krebs units ASTM D562, Procedure A

70

90

2.

Field Dry Time (No Track), minutes

--

45

Furnish pavement marking material that will be in “no tracking condition” in 45 minutes.  The “no tracking condition” will be determined by applying the markings and beads at the specification requirements to dry pavements at a low temperature of 50 °F (10 °C) and high temperature of 120 °F (49 °C).  Run tests at the manufacturer’s highest and lowest recommended application humidity.  The marking materials will be applied at the manufacturer’s recommended application temperature.  The “no tracking” time will be determined by passing over the line with a passenger car at a speed of 25 to 35 mph (44 to 55 kmph) in a simulated passing maneuver.  A line showing no visual deposition of the material to the pavement surface when viewed at a distance of 50 ft (15 m) will be considered as showing “no tracking” and conforming to this requirement for time to “no track”.

3.

Prime Pigment Content, percent by weight of paint

   White ASTM D1394

13.9

--

   Yellow ASTM D126 or Department approved lab method

13.8

--

4.

Pigment Content, percent by weight of paint ASTM D2698

   White

--

40

   Yellow

--

41

5.

Nonvolatile Vehicle Solids Content, percent by weight of paint FED STD 141C, Method 4053.1

   White

31

--

   Yellow

29

--

6.

Fineness of Dispersion,  ASTM D1210 micrometers

50

--

7.

Bleeding Ratio, Fed. Std.  TT-P-115F, Section 4.3.2

   White

0.93

--

   Yellow

0.92

--

8.

Color:

a.  White, Daylight Directional Reflectance, ASTM E1347

85

--

b.  Yellow

1.  Refer to Highway Yellow Color Tolerance Chart PR Color No. 1, June, 1965 U.S. Dept. of Transportation, FHWA:  Yellow, Color Difference 595-33538, ASTM D 2244

50

--

i.  Measure E, L, a, b as Cielab, Source “C”

   L

+0.75

+1.0

   a

+0.9

+1.7

   b

+4.4

+5.1

9.

Dry Opacity, ASTM D 2805 at 0.005 wet
Fed Std 141 No 4121 Process B, Method A, white and yellow

0.97

--

10.

Condition in container, Fed Std 141 No 3011.2,
hand stirring by spatula, minutes

5

Prequalify materials according to Supplement 1047.  Use materials certified according to Supplement 1089.  Furnish materials according to the Department’s Approved List.

740.04  Thermoplastic Pavement Marking.   Furnish thermoplastic pavement marking material formulated expressly for use as retroreflective pavement markings on asphalt concrete or Portland cement concrete pavement.  Furnish material that includes a mixture of Alkyd resins-19% minimum by weight at least one of which is solid at room temperature, and contains premixed glass beads 740.09 Type C, 30% minimum by weight, with a 1.50 minimum index of refraction.  Ensure that the ingredients are well mixed so that all parts are evenly dispersed throughout.  Ensure that there are no foreign objects, skins, dirt, or such ingredients that would cause staining, discoloration, or bleeding.  Furnish suitable materials for application in molten form by extrusion method.  Ensure that the material is capable of retaining reflective glass beads, 740.09 Type C, after application.

A.      Specific Gravity.  Ensure that the thermoplastic compound has a specific gravity of 1.6 to 2.3 at 77 °F (25 °C) ASTM D 792.

B.      Flowability.  Meet percent residue requirements according to

1.  AASHTO M 249, Section 4.3.6 and

2.  AASHTO M 249, Section 4.3.8

C.      Drying Time. AASHTO M249, section 4.3.2.

D.      Field Placement Stability.  After proper application and drying time, ensure that the material is not tacky and does not have an appreciable deformation or discoloration when subjected to typical vehicular traffic, and in air or road temperatures between -30 and 140 °F (-34 and 60 °C).  Ensure that when the material is properly applied that it forms markings of a constant cross-section with a uniform density and character.  Ensure that the markings maintain their original shape and pavement position.

E.      Ring and ball Softening Point.  Furnish a material that has a softening point of not less than 190 °F (88 °C) when tested according to ASTM E 28.

F.      Impact Resistance.  AASHTO M 249, section 4.3.4

G.     Pigment Content.  Furnish yellow material containing a minimum of 5 percent by weight of primary yellow (lead chromate) pigment (or a lead free pigment) (measured according to ASTM D 126 or Department approved lab method). Furnish white material containing a minimum of 10 percent Titanium Dioxide-Rutile Type -2 by weight of white pigment.

H.     Color. 

Minimum

Maximum

a. White, Daylight Directional Reflectance, ASTM E 1347

75

--

b. Yellow

1. Refer to Highway Yellow Color Tolerance Chart PR Color No. 1, June, 1965 U.S. Dept. of Transportation, FHWA:  Yellow, Color Difference 595-13538, ASTM D 2244

50

--

Measure E, L, a, b as Cielab, Source “C”

   L

+0.75

+1.0

   a

+0.9

+1.7

   b

+4.4

+5.1

I.       Yellowness Index, AASHTO M 249, section 4.3.7

Prequalify materials according to Supplement 1047.  Use materials certified according to Supplement 1089.  Furnish materials according to the Department’s Approved List.

740.05  Preformed Pavement Marking.  Furnish the preformed material suitable for retroreflective pavement markings on asphalt concrete or portland cement concrete pavement.  Furnish material that is free of cracks and that has edges that are straight, true, and unbroken.  Ensure that the material is flexible, formable, and suitable for application with an adhesive without heating.  Furnish material containing glass beads uniformly distributed throughout with a 1.50 minimum index of refraction.  Ensure that the material has a uniform surface layer of firmly bonded glass beads to provide the initial minimum specific luminance values specified for the various types of material.

Furnish material that resists deterioration by contact with highway deicing chemicals or because of the oil content of asphalt concrete pavement, or from oil droppings and other effects of traffic.

A.      Type A1 Material.  Furnish Type A1 material conforming to ASTM D 4505, Level 1, Classes 2 or 3,  and that have a thickness of not less than 0.090 inch (2.28 mm), including any pre-coated adhesive layer.

B.      Type A2 Material.  Furnish Type A2 material conforming to ASTM D 4505, Level 1, Classes 2 or 3, , and that have a thickness of not less than 0.060 inch (1.52 mm), including any pre-coated adhesive layer.

C.      Type A3 Material.  Furnish Type A3 material conforming to ASTM D 4505, Level 1, Classes 2 or 3, skid resistance level A, and that have a minimum thickness at the thinnest portion of the cross-section of not less than 0.020 inch (0.50 mm), including any pre-coated adhesive layer.

Prequalify materials according to Supplement 1047.  Use materials certified according to Supplement 1089.  Furnish materials according to the Department’s Approved List.

740.06  Work Zone Pavement Marking.  Furnish work zone pavement marking material conforming to ASTM D 4592, Type I (removable) or Type II (non-removable) with the following modifications:

A.      Type I (removable):  0.030-inch (0.76 mm) minimum thickness.

B.      Type II (non-removable):  0.015-inch (0.38 mm) minimum thickness.

Furnish materials according to the Department’s Approved List.

740.07  Epoxy Pavement Marking Material.    Ensure that the material supplied is a 100 percent solids two-part epoxy system capable of being applied at ambient temperature down to 50 °F (10 °C).  Furnish a slow cure material  capable of retaining reflective glass beads 740.09 type D, after application.

Furnish epoxy conforming to the following requirements:

A.      Formulation.  Furnish epoxy formulated as a Long Life Pavement Marking System, capable of providing a minimum of 4 years of performance, free of any peroxides and any Tri-methyolpropane Tri-acrylate) TMPTA and other multi-functional monomers.  Ensure that the epoxy is designed to provide simple volumetric mixing ratio of its components (such as 2:1).

B.      Epoxide Number.  Ensure that the epoxide number of the epoxy resin is the manufacturer’s target value ±0.05 as determined by ASTM D 1652 for both white and yellow Part A on a pigment free basis.

C.      Amine Number.  Ensure that the amine number of the curing agent (Part B) is the manufacturer’s target value ±50 according to ASTM D 2074 on a pigment free basis.

D.      Laboratory Drying Time.  Ensure that the pavement marking material, when mixed in the proper ratio and applied at the properly prescribed wet film thickness at 75 ± 2 °F (24 ± 0.5 °C) and with the proper saturation of glass beads, exhibit a no tracking time of no greater than 40 to 45 minutes when tested according to ASTM D 711.

E.      Field Time to No-Track.  Furnish pavement marking material that will be in “no tracking condition” between 15 to 45 minutes.  The “no tracking condition” will be determined by  applying the markings and beads at the specification requirements to dry pavements at a low temperature of 45 °F(7 °C) and high temperature of 120 °F (49 °C).  Run tests at the manufacturer’s highest and lowest recommended application humidity.  The marking materials will be applied at the manufacturer’s recommended application temperature.  The “no tracking” time  will be determined by passing over the line with a passenger car at a speed of 25 to 35 mph (44 to 55 kmph) in a simulated passing maneuver.  A line showing no visual deposition of the material to the pavement surface when viewed at a distance of 50 ft (15 m)  will be considered as showing “no tracking” and conforming to this requirement for time to “no track”.     Protect the line from tracking during the setting period by coning off or as shown on the plans.

F.      Field Curing.  Furnish epoxy pavement marking material capable of fully curing at a constant surface temperature of 45 °F (7 °C) or above.

G.     Hardness.  Furnish epoxy pavement marking materials, when tested according to ASTM D 2240, that have a Shore D Hardness of between 70 and 90.  Allow samples to cure at room temperature 75 ± 2 °F (24 ± 0.5 °C) for a minimum of 24 hours and a maximum of 72 hours before performing the indicated test.

H.     Certified test data.  Provide a material manufacturer’s certified test data showing the material complies with the provisions of this specification.  The provisions of a certification of compliance do not waive a state inspection, sampling, or testing.

I.       Infrared Spectra.  Supply a copy of the infrared spectra of each component on each lot number

J.      Material Performance Qualifications.  Ensure that the manufacturer has expertise and performance history including:  completed and passed service tests according to Supplement 1047. ; verifiable installations; ample production capacity; proper facility; compliance with EPA regulations; verifiable quality control program; and has passed a minimum of 4 years of performance (durability and retroreflectivity) on concrete or asphalt surface in the State.

K.     Condition in Container.    Fed Std 141 No. 3011.2 Hand stirring by spatula.  5 minutes maximum

Prequalify materials according to Supplement 1047.  Use materials certified according to Supplement 1089.  Furnish materials according to the Department’s Approved List.

740.08  Heat-Fused Preformed Plastic Pavement Marking Material.  Furnish heat-fused preformed plastic pavement marking materials conforming to the following Type A, Pre-heated  tape and Type B, Post-heated tape:

Type A90 and B90 - 90 mil thickness (2.29 mm)

Type A125 - 125 mil thickness (3.18 mm)

Type B125 - 125 mil thickness (3.18 mm)

Glass beads............................................................. .740.09

Use materials certified according to Supplement 1089. Furnish materials according to the Department’s Approved List.

740.09  Glass Beads. 

Furnish certified test data for the arsenic and lead content of all glass bead samples sent to the Department for testing to ensure that all glass beads furnished to the Department contain no more than 200 parts per million of arsenic or lead as determined in accordance with Environmental Protection Agency testing methods 3052, 6010B, or 6010C, according to SEC 1504 STANDARDS. Section 109 of title 23, United States Code, (r) Pavement Markings.

  A.         Type A.  Furnish Type A glass beads for traffic paint conforming to Supplement 1008 and to AASHTO M 247, Type 1 without flotation properties but dual coated (for moisture resistance and adhesion), with the following exception:  4.6 Flotation Test. 

Ensure that the glass beads for traffic paint are packaged in bags designated “740.02”.  Use materials certified according to Supplement 1089.

B. Type B.  Furnish Type B glass beads for polyester marking material conforming to Supplement 1008 and AASHTO M 247, Type 1 with 50 ± 5 percent flotation coating and ensure that a 50 ± 5 percent moisture resistant coating is retained on each sieve, with the following exception:  4.6 Flotation Test.  Ensure that the minimum percent floating equals 90 of flotation coated beads or 40.5 percent of total mixture. 

Ensure that the glass beads for polyester marking material are packaged in bags designated “POLY”.

Use materials certified according to Supplement 1089.

C. Type C.  Furnish Type C glass beads for thermoplastic material conforming to Supplement 1008 and meeting the following specification.

Sieve Size

Percent Retained

No. 16 (1.18 mm)

3 maximum

Refractive Index

1.50 to 1.60

No. 20 (850 µm)

5 to 20

Roundness

80 minimum

No. 40 (425 µm)

65 to 95

Coating

Moisture resistant

(for drop-on beads only)

No. 50 (300 µm)

0 to 5

Ensure the glass bead packaging is clearly marked “THERMO” 

Use materials certified according to Supplement 1089.

D. Type D.  Furnish Type D glass beads for Epoxy Pavement Marking conforming to Supplement 1008. 

Ensure that the glass bead packaging clearly indicates EPOXY - SIZE I or EPOXY SIZE II.

Ensure that the glass beads have the following gradation when tested according to Supplement 1089.

SIZE I

SIZE II

Sieve Size

Percent Retained

Sieve Size

Percent Retained

No. 10 (2.00 mm)

0

No. 20 (850 µm)

0 to 5

No. 12 (1.70 mm)

0 to 5

No. 30 (600 µm)

5 to 20

No. 14 (1.40 mm)

5 to 20

No. 50 (300 µm)

30 to 75

No. 16 (1.18 mm)

40 to 80

No. 80 (180 µm)

9 to 32

No. 18 (1.00 mm)

10 to 40

No. 100 (150 µm)

0 to 5

No. 20 (850 µm)

0 to 5

Pan

0 to 2

Pan

0 to 2

Reflective Media:  Ensure that the glass beads are smooth, clear, free from any air inclusions, and scratches that might affect their functions as a retro-reflective media, and that have the characteristics listed below.

Roundness (Percent by Weight):  Ensure that not more than 20 percent of the glass beads are irregular or fused spheroids and that at least 80 percent of the beads are true beads.

Index of Refraction:  Ensure that the refractive index of the beads is a minimum of 1.50 as determined by the liquid immersion method at 77 °F (25 °C).  Ensure that the silica content of glass beads is not less than 60 percent.

Coating:  Furnish Size I glass beads that are coated with a silane-type adherence coating to enhance its embedment in, and adherence to the applied binder film.  Ensure that the coated beads emit a yellow-green fluorescence when tested by the Dansyl Chloride test procedure.  Furnish Size II glass beads that are treated with a moisture-proof coating.  Ensure that both types of glass beads show no tendency to absorb moisture in storage and remain free of clusters and lumps.  Ensure that they flow freely from the dispensing equipment at any time when surface and atmosphere conditions are satisfactory for marking operations.

Determine the moisture-resistance of the glass beads on the basis of the following test:

Place 2.2 pounds (1 kg) of beads in a washed cotton bag, having a thread count of 50 per square inch (8/cm²) (warp and woof) and immerse the bag in a container of water for 30 seconds.  Remove the bag and force the excess water from the sample by squeezing the bag.  Suspend and allow them to drain for two hours at room temperature 70 to 72 °F (21 to 22 °C).  After draining, mix the sample in the bag by shaking thoroughly.  Transfer a sample slowly to a clean, dry glass funnel having a stem 4 inches (100 mm) in length, with a 3/8-inch (10 mm) inside diameter stem entrance opening, and a minimum exit opening of 1/4 inches (6 mm).  Ensure that the entire sample flows freely through the funnel without stoppage.  When first introduced to the funnel, if the beads clog, it is permissible to tap the funnel to initiate flow.

Use materials certified according to Supplement 1089.

748  WATER MAIN AND SERVICE BRANCH MATERIAL

748.00  Acceptance.  Follow the requirements listed in each 748 section.

748.01  Ductile Iron Pipe, Joints, and Fittings.  Furnish ductile iron pipe  conforming to ANSI/AWWA C151/A21.51 and to ANSI/AWWA C150/A21.50 for thickness design.  Furnish pipe with a cement mortar lining conforming to ANSI/AWWA C104/A21.4.  Furnish gaskets conforming to ANSI/AWWA for each length of pipe and suitable for the type of joint of the pipe.  Ship gaskets in a separate container.

Furnish push-on joints, mechanical joints, and boltless restrained joints conforming to ANSI/AWWA C111/A21.11. For restrained joints, ensure that the restraint is a design approved by the owner of the utility and provides a positive lock designed to prevent joint separation. Steel locking segments molded into a gasket to grip the pipe do not meet the requirements for this joint.

Ball and socket joints are suited for underwater installations.  The Contractor may use ball and socket joints for other types of installations where an appreciable amount of joint deflection and a positive lock against joint separation are required.

Manufacture fittings for ductile iron pipe according to ANSI/AWWA C110/A21.10 or ANSI/AWWA C153/A21.53, and ANSI/AWWA C111/A21.11.  For fittings 16 inches (406 mm) or larger, use ductile iron only.  Ensure that fittings are cement mortar lined according to ANSI/AWWA C104/A21.4.

Furnish materials according to the Department’s Qualified Products List (QPL).

748.02  Polyvinyl Chloride (PVC) Pipe, Joints, and Fittings.  Furnish PVC pipe  conforming to AWWA C 900, AWWA C 905, AWWA C909, or ASTM D 2241.  Furnish push-on type pipe joints conforming to ASTM D 3139 with a thickened bell and with a rubber gasket conforming to ASTM F 477.

Use PVC, PE, or PB pipe and couplings, and solvent cements made from compounds that are tested and certified as suitable for potable water distribution products by the National Sanitation Foundation (NSF) Testing Laboratory or the Canadian Standards Association Testing Laboratory, or any other similarly accredited testing agency acceptable to the Laboratory.  Do not use PVC, PE, or PB pipe and couplings, or solvent cements containing any ingredient in an amount that has been demonstrated to migrate into water in quantities considered to be toxic, as tested according to Sections 3 and 4 of NSF Standard Number 14.

Furnish materials according to the Department’s Qualified Products List (QPL).

748.03  Polyethylene (PE) Service Branches and Fittings.  Furnish PE service branches and fittings conforming to AWWA C901.Furnish material with plain ends conforming to the potable waterline requirements specified in 748.02.

Furnish materials according to the Department’s Qualified Products List (QPL).

748.05  Copper Service Branches and Fittings.  Furnish copper service branches conforming to ASTM B 88 (ASTM B 88M), Type K.  Assemble branches using flare-type compression fittings conforming to AWWA C800.  Ensure a minimum working pressure for the branches of 150 pounds per square inch (1.0 MPa).  Use either coil type (temper 060 annealed) or drawn type (temper H) material.

Furnish high-quality copper brass fittings with AWWA C800 dimensions.

Furnish materials according to the Department’s Qualified Products List (QPL).

748.06  Steel Pipe Encasement.  Furnish steel casing pipe conforming to ASTM A 139/A 139M, Grade B or ASTM A 53, Grade B, that is galvanized on exterior and interior surfaces as specified in Section 711.02.  Furnish the manufacturer’s certification.  Steel casing pipe shall have a minimum wall thickness as shown below:

Pipe Diameter

Wall Thickness

Wall Thickness

(in)

(mm)

Designation

(in)

(mm)

4 to 10

100 to 260

Standard

0.237 to 0.365

6.02 to 9.27

12 to 22

300 to 560

Standard

0.375

9.53

24 and larger

600 and larger

Extra-strong

0.500

12.7

For steel casing pipe specified to be bored or jacked, provide ungalvanized pipe with the largest wall thickness.

748.07  Polyethylene Encasement.  Furnish 8-mil (200 mm) thick polyethylene encasement material conforming to ANSI/AWWA C105/A21.5.

748.08  Gate Valve and Valve Box.  Furnish ductile iron gate valves conforming to AWWA C509 resilient seated.

Gate valves shall open counter-clockwise.  Use valves suitable for push-on and mechanical joints for ductile iron pipe and for push-on joints for PVC pipe.

Furnish cast iron valve boxes consisting of adjustable two or three-piece with cover and with a base corresponding to the size of the valve.  Use heavy-duty type valve boxes for locations within existing or proposed pavement, driveway, or other traveled areas.  Ensure that valve boxes are coated with an asphaltic coating by the manufacturer.  The cover shall have the word “WATER” cast in it. 

Furnish materials according to the Department’s Qualified Products List (QPL).

748.09  Inserting Valve and Valve Box.  Furnish inserting valves that operated like ordinary gate valves, with the same gate and seating assembly as AWWA C509 gate valves.  Furnish material that consist of a two-piece sleeve for assembly around the main the valve, and a valve box conforming to 748.08.  Furnish the equipment necessary to drill the main wall and insert the valve according to the manufacturer’s recommendations.

Furnish materials according to the Department’s Qualified Products List (QPL).

748.10  Cutting-in Sleeve, Valve, and Valve Box.  Furnish cutting-in valves with the same gate and seating assembly as AWWA C509 gate valves.  Furnish material that consists of a cutting-in sleeve and valve suitable for assembling over the ends of a cutout length of existing pipe, according to the manufacturer’s recommendations, and a valve box conforming to 748.08.  Furnish sleeves and valve joints of the mechanical joint type.

Furnish materials according to the Department’s Qualified Products List (QPL).

748.11  Tapping Sleeve, Valve, and Valve Box.  Furnish tapping valves with the same gate and seating assembly as AWWA C509 gate valves.  Furnish material that consists of a two-piece sleeve for assembly around the main, the valve, and a valve box conforming to 748.08.  Furnish cast iron, epoxy-coated steel, or stainless steel tapping sleeves.  Furnish the equipment necessary to drill the main wall through the valve according to the manufacturer’s recommendations.

Furnish materials according to the Department’s Qualified Products List (QPL)

748.12  Tapping Saddle and Corporation Stop.  Furnish iron, bronze, brass, or, AWWA C223, stainless steel tapping saddles.  Furnish band type or double-strap type tapping saddles, with International Pipe Standard (IPS) tapping or AWWA tapered thread inlet.

For use with saddles, provide bronze alloy corporation stops with IPS inlet thread of AWWA tapered thread and with outlet thread compatible with connecting pipe, without special adapters.  For direct tapping, provide bronze alloy corporation stops with AWWA tapered inlet thread and with outlet thread compatible with connecting pipe, without special adapters.

Furnish materials according to the Department’s Qualified Products List (QPL).

748.13  Service Stop and Service Box.  Furnish bronze service stops with coupling threads conforming to AWWA C800.  Use service stops designed so that water pressure from the inlet side of the body provides additional sealing action.  Furnish service stops that open counter-clockwise.

Use Buffalo type service boxes.  Furnish covers that have the word “WATER” cast in raised letters.  Securely fasten covers with a bronze or brass bolt.

Furnish materials according to the Department’s Qualified Products List (QPL).

748.14  Meter, Setting, Stop, and Chamber.  Furnish meter setting yokes that allow the meter to be readily installed without disturbing piping.  Furnish angle pattern meter stops with lock wings for the street side of the meter piping.  Furnish check valves for the customer side of the meter piping.  Furnish chambers composed of concrete, vitrified clay, PVC, or PE.  Furnish double walled, tightly fitting lids.

748.15  Fire Hydrant.  Furnish cast iron, dry-barrel post type fire hydrants conforming to AWWA C502, with the following modifications:

Furnish hydrants incorporating an approved groundline breakable flange and valve stem coupling.

Furnish compression type hydrants with the valve opening against the pressure.  Ensure that the valve end of the valve stem is designed to eliminate contact of dissimilar metals.  Ensure that the valve stem is at least 1-inch (25 mm) diameter or 1-inch (25mm) square steel between the hydrant operating nut and the valve, except for the valve stem coupling located at the point corresponding to the breakable flange.

Furnish a main valve port that is at least 4 1/4-inch (108 mm) diameter.  Furnish a rubber faced valve.

Ensure that the hydrant is designed so the nozzles may be oriented to point in any direction.  Ensure that the hydrant connection to the pipe has at least a 6 inches (150 mm) inside diameter.  Furnish push-on or mechanical type joints conforming to ANSI/AWWA C111/A21.11.

Ensure that the hydrant has one center-front pumper nozzle of 4-inch (100 mm) internal diameter with male threads to match the fire apparatus of the maintaining agency.  Furnish two hose or streamer nozzles of 2 1/2-inch (63 mm) internal diameter with male threads to match apparatus of the maintaining agency.  Ensure that nozzle sections are designed to lock into the hydrant body using locking lugs or threads.  Furnish nozzles with threaded cast iron caps having an integral nut of the same design as the hydrant operating nut.

Contact the maintaining agency to determine the desired color and number of coats of enamel for the hydrants.

Furnish materials according to the Department’s Qualified Products List (QPL).

Subject Index

ABS drain waste and vent pipe, 783

ABS sewer pipe, 783

ABS sewer, drain waste and vent pipe, 472, 473, 474

Acceptance, 5, 29, 30, 38, 43, 82, 169, 192, 205, 211, 218, 234, 241, 260, 292, 299, 383, 399, 402, 411, 432, 654, 684, 695, 768, 902

Water mains & service branches, 902

Aeration for trees not welled, 637

Aeration with tree wells, 637

Aggregate, 2, 5, 39, 142, 152, 204, 224, 235, 280, 404, 461, 474, 495, 518, 665, 706, 722, 725

Base, 672

Coarse, 289, 461, 463, 474, 529

Drains, 454

Fine, 2, 495, 670, 710, 712, 713, 714

Mineral filler, 168, 670

Portland cement concrete, 149, 198, 200, 266, 283, 516, 895, 900, 902

Prime coat, 784

Screenings, 715

Slag, 3, 97, 183, 285, 669, 671, 706, 707, 712, 715, 718, 719

Underdrains, 451

Aggregate Base

Compaction, 95, 103, 107, 111, 159, 160, 167, 179, 238, 241, 245, 447, 477, 707

Finished Surface, 159, 160

Spreading, 95, 100, 107, 110, 112, 113, 115, 158, 159, 167, 175, 177, 181, 202, 209

Aggregate for

Aggregate base, 672

Tree root aeration, 637

Agriculture liming materials, 640

Air-entraining, 404

Admixtures, 144, 290, 673, 728

Admixtures, 728

Portland cement, 112, 114, 149, 198, 200, 207, 222, 266, 283, 404, 423, 450, 516, 670, 763, 895, 900, 902

Alteration of plans or work, 18

Altered quantities, compensation for, 65

Aluminum, 417, 472, 494, 525, 554, 677, 682, 776, 802, 806, 838, 857

Alloy structural plate conduit, 779

Castings for signs, 838

Extrusions for signs, 554, 555, 838

Fence, 89, 92, 95, 458, 459, 460, 681, 682, 791, 792, 796, 798

Fence, 796

Hardware for signs, 839

Paint, 787

Pipe, 768

Railing, 417, 418

Railing, 802

Railing, structure, 418

Sheet and plate for signs, 554, 838

Tube and pipe for signs, 838

Anchor assembly, guardrail, 457

Anchor bolts, 538, 553

Light poles, 538

Sign supports, 557

Sign supports, 553

Structures, 9, 89, 272, 274, 298, 423, 476, 666, 667, 676, 772, 787

Structures, 416

Approval by director, cellular retaining walls, 468

Approval of structure

Fabricator, 4, 7, 292, 293, 299, 359, 360, 362, 402, 403, 404, 681, 682, 683

Fabricator, 292

Foundation, 430, 547, 550, 564, 593, 903

Reinforcing bar placement, 320

Shop drawings, 293, 373

Shop drawings, 292

Temporary bridge, 299

Arc welding electrodes and fluxes, 800

Arm caps, sign supports, 553, 838, 854

Asphalt

Antistrip additive, 225, 231, 232

Emulsified, 345, 669, 703

Waterproofing, 344, 345, 355, 356, 357, 358, 359, 471, 484, 669, 682, 683, 696, 803, 805, 806

Waterproofing, 345

Asphalt Binder Compatibility, 167, 181

Asphalt Binder Price Adjustment, 167, 182

Asphalt concrete

For maintaining traffic, 512

Authority of, 22

Engineer, 22

Inspector, 2, 7, 25, 27, 41, 61, 67, 83, 84, 381, 382, 387, 388, 389, 390, 392, 393, 394, 395, 400, 615, 625, 658

Inspector, 25

Project Engineer, 22

Auxiliary equipment and wiring, controller, 864

Award, 5, 16, 17

Cancellation of, 17

Cancellation of, 17

Of contract, 16

Axle steel deformed bars, 789

Backfill, 89, 134, 301, 303, 313, 419, 429, 441, 444, 451, 480, 497, 542, 547, 561, 603, 654, 671, 715, 716, 717

Low strength mortar, 494

Porous, 420

Retaining walls, 469

Structures, 9, 89, 90, 272, 274, 298, 423, 476, 666, 667, 676, 772, 787

Watermain and service branches, 598

Ballast wiring enclosure

Mounting bracket, 568, 849

Ballasts, 567

Barbed wire fence, 460

Barricades, 498

Barrier, 457, 514, 529, 530, 531, 551, 552, 687, 835

concrete, 514, 529, 531

Concrete, 529

Barrier reflectors, 551

Installation, 551

Layout, 551

Materials, 551

Base, 2, 62, 91, 94, 96, 126, 161, 170, 171, 281, 452, 454, 455, 553, 562, 564, 665, 688, 712, 756, 811, 837, 887

Aggregate, 672

Base and arm plates, sign supports, 837

Beam supports, for signs, 558

Bearing bolts, 366, 414

Bearing devices, structural, 413, 415

Bearing pads, 803

Elastomeric, 415, 803

Preformed, 414, 803

Bedding, pipe, 596

Bending reinforcing steel, 318

Bidder, 1, 5, 8, 11, 12, 13, 14, 15, 17

Disqualification, 15

Disqualification, 15

Prequalification, 11, 584, 585, 788

Prequalification, 11

Bidding, 12, 13, 30

Requirements and conditions, 11

Billet steel bars, 789

Bituminous

Weather Limitations, 167, 173, 197, 205, 208, 212, 214

Bituminous coated corrugated steel pipe and pipe arches with paved inverts, 772

Bituminous lined corrugated steel pipe, 472, 774

Bituminous material

Asphalt for waterproofing, 345

Polymer modified, 696

Bituminous pipe joint filler, 475, 675, 766

Blast cleaning, 363

Blast furnace slag cement, 4, 96, 141, 144, 149, 151, 203, 204, 520, 623, 627, 706, 710, 727

Blocking and wedging, water mains, 597

Blocks, 445, 681, 727, 798, 868

Bolts, 360, 366, 367, 368, 369, 372, 550, 682, 687, 688, 801, 803, 837, 839

Bearing, 360, 366, 375, 413, 414, 415, 417, 667, 682, 803

Bearing, 366

High-strength steel, 801

Bond, requirement of Contract, 17

Bonded Patching of Portland Cement Concrete Pavement, 267

Borrow and waste areas

Approval and restoration, 27

Box culverts, 774

Braces and fasteners, 796

Brick, 441, 446, 450, 485, 672, 727

Clay or shale, 727

Concrete, 727

Masonry, 446

Bridge, 5, 7, 294, 300, 323, 326, 329, 337, 344, 411, 413, 448, 457, 476, 489, 524, 531, 564, 667, 680, 752, 753, 757, 758, 761, 762, 791, 800

Over navigable waters, 35

Temporary, 299

Bridge terminal assembly, 457

Bronze, 414, 682, 802

Cast, 802

Leaded, 802

Phosphor, plate, 802

Burlap blankets, plastic coated, 335

Burlap cloth, 332, 728

Cabinet, controller, 862, 863

Cable, 3, 524, 537, 538, 546, 550, 566, 685, 691, 843, 855, 856, 857

And wire for traffic signal, 856

Lighting, 386, 513, 514, 537, 547, 550, 668

Support assembly, 853

Calcium chloride

Dust control, 518

Camber, 364, 411

Falsework, 10, 276, 296, 297, 314, 315, 316, 317, 323, 332, 333, 334, 337, 376, 418

Camber, falsework, 315

Camber, structural steel, 364

Cancellation of award, 17

Care of reinforcing steel, 318

Castings, 526, 554, 681, 682, 685, 689, 799, 801, 802, 816, 838

Aluminum, 417, 418, 472, 473, 494, 525, 554, 677, 682, 683, 689, 776, 777, 778, 779, 780, 802, 806, 838, 839, 857

Aluminum, 802

Iron, 1, 32, 417, 418, 603, 604, 682, 694, 801, 802, 902

Iron, 801

Iron, 801

Raised pavement marker, 60

Raised pavement marker, 838

Steel, 1, 2, 32, 258, 309, 320, 377, 378, 384, 400, 524, 529, 532, 553, 599, 603, 667, 671, 707, 712, 718, 768, 771, 783, 784, 787, 795, 806, 836, 903

Steel, 799

Catch basin, 767

Inlet tops, 767

Cellular polyvinyl chloride sponge, 806

Cellular retaining walls, 468

Approval by the Director, 468

Backfill, 469

Concrete, 468

Concrete cellular walls, 468, 469, 470

Construction methods, 470

Excavation, 469

Galvanized metal cellular walls, 468, 469

Manufacture of units, 469

Materials, 468

Cement, 1, 2, 4, 113, 114, 115, 116, 118, 148, 284, 289, 290, 322, 441, 446, 494, 495, 623, 627, 667, 669, 673, 674, 675, 676, 727, 733

Center lines, 528, 608

Certified drawings, traffic signal controller, 585

Changeable-message sign, 566, 840

Channel protection, 441

Dumped rock, 444

Channelizing devices, 499

Channelizing lines, 528

Character of workers, methods, and equipment, 55

Chemical admixture for concrete, 309, 729

Cited specifications, 30

Civil rights, 45

Clay drain tile, 452, 766

Clay or shale brick, 727

Cleaning, 22, 336, 352, 360, 377, 383, 388, 621, 623, 634

Structural steel, 414, 418, 553

Structural steel, 377

Cleanup

Roadside, 9, 635

Cleanup, definition, 22

Roadside, 634

Clear coating, traffic signs, 840

Clearances, reinforcing steel, 318

Clearing and grading, fence, 458

Coarse aggregate, 289, 461, 463, 474, 529

Coated dowel bars, 790

Cold rolled steel, 799

Cold weather curing, concrete, 331

Combination of conditional proposals, 14

Commercial fertilizer, 640

Compaction, 95, 96, 103, 107, 108, 111, 159, 160, 167, 179, 238, 241, 245, 447, 477, 707

Embankment, 95, 100, 104, 107, 108, 111, 470, 474, 637, 638, 665, 666, 671, 720, 721

Pipe, 3, 89, 94, 313, 418, 451, 476, 494, 532, 635, 738, 739, 740, 741, 793, 7803, 836, 838, 902

Subgrade, 10, 107, 108, 109, 111, 118, 133, 134, 135, 141, 143, 202, 252, 255, 811

Compensation, 39, 59, 65, 68, 73

Altered quantities, 65

Extra work and force account, 65

Failure to meet, 49

Completion date, 56, 658

Failure to meet, 59

Liquidated damages, 17

No-passing zone markings, 501

Compressive strength, structural concrete, 426

Concrete, 61, 96, 141, 201, 238, 241, 243, 249, 251, 255, 267, 280, 309, 311, 314, 323, 623, 706, 814, 815, 825

Admixtures, 144, 290, 673, 728

Asphalt, 61, 62, 96, 141, 167, 190, 201, 224, 226, 228, 242, 250, 251, 345, 355, 497, 512, 514, 520, 623, 627, 662, 665, 666, 669, 670, 673, 675, 696, 700, 701, 706, 712, 713, 714

Barrier, 457, 514, 529, 530, 531, 551, 552, 687, 835

Barrier, 529

Barrier, 767

Beams, 359, 366, 407, 688, 837

Brick, 441, 446, 450, 485, 672, 727

Brick, 727

Bridges, cast-in-place, 327

Cellular retaining walls, 468, 469, 470

Compressive strength, 280

Construction joints, 335

Curb, 94, 95, 609, 613, 615, 626

Curing, 117, 118, 142, 152, 252, 264, 321, 322, 323, 324, 331, 333, 335, 421, 422, 439, 440, 441, 474, 529, 530, 673, 728, 785, 786, 897

Drain tile, 452, 765

Entrained air, 495

Headwalls and cradles, 446

Masonry, 450, 485, 669, 672, 727

Masonry, 446

Pavement, 4, 89, 91, 94, 99, 136, 141, 151, 166, 201, 204, 211, 220, 225, 231, 243, 252, 258, 497, 503, 520, 526, 604, 613, 615, 619, 621, 626, 628, 631, 665, 666, 671, 685, 693, 706, 707, 718, 816, 893, 895, 896, 897, 898, 899, 900

Prestressed, 402, 411, 413, 667, 683

Prestressed for bridge members, 292

Slope protection, 443

Slump, 274, 277, 278, 280, 281, 285, 323, 326

Steps, 6, 52, 89, 91, 94, 462, 474, 492, 683, 806

Walks, 89, 91

Concrete barrier, 529, 767

Contraction joints, 530

Curing, 530

Expansion joints, 530

Finish, 530

Joints, 530

Materials, 529

Portable concrete barrier, 529

Concrete for structures, 323

Admixtures, 729

Cold weather curing, 331

Construction joints, 331

Curing and loading, 322, 333

Depositing and curing during cold weather, 331

Depositing under water, 331

Finishing, 422

Grout cleaning, 336

Materials, 323

Method A water cure, 330

Method B membrane cure, 335

Mixing, 325, 425

Patching, 421

Placing, 326, 422, 426

Prestressed, 402

Proportions, 324, 425

Removal of concrete, 424

Removal of forms, 333

Roadway finish, 337

Rubbed finish, 333

Sidewalk finish, 338

Slump, 326

Surface finish, 336

Work stoppage, 331

Concrete incidentals

Air entraining admixture, 728

Burlap cloth, 728

Chemical admixtures, 404

Chemical admixtures, 729

Hot applied crack and joint sealer, 728

Liquid compounds for curing concrete, 728

Nonshrink mortar, 446, 474, 475

Nonshrink mortar, 733

Preformed elastomeric compression seals, 729

Preformed fillers, 414, 418

Preformed fillers, 728

Quick setting concrete mortar, 731, 733, 734

Sheet materials for concrete curing, 728

Type 3 membrane primer, 345

Type 3 membrane primer, 728

Concrete Pavement Incidentals, 727

Concrete, General

Admixtures, 144, 290, 673, 728

Admixtures, 326

Admixtures, 728

Curing and curing agents, 331, 333, 530, 728

Cylinders, 324

Equipment, 7, 38, 55, 70, 123, 140, 149, 151, 153, 167, 175, 182, 197, 205, 208, 259, 286, 345, 351, 378, 384, 402, 405, 429, 430, 489, 494, 496, 537, 545, 547, 565, 584, 594, 599, 604, 606, 610, 615, 621, 622, 623, 626, 628, 631, 667, 738, 844, 858, 865, 889

Equipment, 405

Finish, 530

Fly ash, 96, 289, 290, 495, 696

Ground granulated blast furnace slag, 283, 289

Joints, 530

Proportioning, 205, 207, 494, 495

Slump, 274, 277, 278, 280, 281, 285, 323, 326

Conduit, 471, 491, 493, 494, 497, 537, 549, 550, 566, 585, 685, 687, 690, 691, 842, 855

Flexible for lighting, 842

Riser, for traffic signal, 855

Sign lighting, and electrical signs, 565

Steel, aluminum and plastic, 768

Conflict monitor, 580, 862, 865

Conformity, 8, 23

With plans and specifications, 23

Consideration of proposals, 16

Construction

Maintenance during, 27

Construction joints, concrete, 339

Contents of bidding documents, 11

Contract

Award, 16

Award of, 16

Bond, requirement, 17

Cancellation of, 17

Cancellation of, 17

Execution of, 17

Execution of, 17

Failure to execute, 17

Intent of, 17

Liquidated damages, 17

Subletting of, 46

Subletting of, 46

Termination of, 60, 65, 84

Termination of, 60

Contraction joints, 530

Contractor

Control Charts, 225

Cooperation of, 24

Coordination between, 25

Definition, 6, 10, 108

Responsibilities for damage claims and liability insurance, 38

Responsibilities for utilities, 42

Responsibilities for work, 41

Termination of responsibility, 83

Contractor personnel requirements

Sign lighting, 565

Signal controller, 584

Control of material, 30

Control of work, 22

Controller (see Traffic controller), 586, 866, 867, 868

Convenience outlet and light, 867

Cooperation, 24, 25

Between contractors, 25

By contractor, 24

With utilities, 24

Coordination of plans, specifications, and special provisions, 23

Copper, 417, 595, 603, 604, 682, 694, 802, 857, 903

Copper service branches, and fittings, 903

Corrugated

aluminum box culverts, 472

aluminum spiral rib, 472

polyethylene drainage pipe, 473

polyethylene drainage tubing, 451

polyethylene smooth lined pipe, 472, 473

steel box culverts, 472

steel underdrains, 452

Corrugated aluminum alloy conduits and underdrains, 452, 777, 778

Corrugated aluminum box culverts, 780

Corrugated aluminum spiral rib, 779

Corrugated metal structures, 428

Corrugated polyethylene drainage pipe, 781

Corrugated polyethylene drainage tubing, 452, 780

Corrugated polyethylene smooth lined pipe, 452, 781

Corrugated steel box culverts, 774

Corrugated steel pipe, 773

Corrugated steel pipe and pipe arches, 772, 774

Bituminous coated, 772, 774

Corrugated steel rib conduit, 773

Corrugated steel underdrains, 452, 768

Covering of signs, 502, 560

Crosswalk lines, 608

Crushed aggregate slope protection, 443

Culvert, 7, 449, 493, 494, 675, 749

Curb, 667

Curing and loading, dowel holes, 322

Curing and loading, structural concrete, 333

Curing compounds, 415, 728

Curing concrete barrier, 530

Curing, patched concrete structure, 422

Curing, sheet materials for, 728

Cutting, in sleeve, valve and valve box, 904

Dead trees, 659

Deduction for deficiency, markings, 609

Deep beam rail, 418, 455

Deep pipe underdrains, 451, 452, 454

Deflection of falsework, 315

Delineators, 524

Flexible posts, 525

Installation, 525

Layout, 525

Materials, 524

Removal, storage and disposal, 525

Delivery of proposals, 14

Depositing and curing structural concrete during cold weather, 331

Depositing structural concrete under water, 331

Dewatering, water main trench, 597

Dial, 890

Differing site conditions, 18

Dimensions, verification of, structures, 292

Disadvantaged business enterprise, 45

Disconnect switch

For traffic signals, 856

Discrimination, 33

Disinfection of completed water main, 599

Disposal of refuse, roadside cleanup, 635

Disputes and Claims, 6, 47, 48, 49, 50, 51, 52, 53

Disqualification of bidders, 15

Dotted lines, 605, 609

Dowel bars, 142, 152, 252, 529, 790

Dowel holes, 322, 323

Curing and loading, 322

Materials, 322

Placement, 322

Down guy, 854

Drain tile

Clay, 766

Concrete, 765

Drainage of structures, 419

Excavation, 420

Fabrication, 419

Materials, 419

Pipe, 420

Porous backfill, 420

Scuppers, 420

Drains, 451, 454, 455, 635, 636, 811

Aggregate, 454

Drift pins, structural steel, 369, 376, 428

Drilled shafts

Friction type, 433

Drive posts, for signs, 558

Drums, 513

Ductile iron castings, 801

Ductile iron pipe, joints, and fittings, 595, 902

Dump rock fill, 444

Dust control, 517

Duties, 25, 381

Inspector, 25

Project Engineer, 22

Earth embankment, tree root aeration, 638

Earthwork, 95, 104, 635, 636

Limitations of operations, 55

Edge drain prefabricated, 453

Edge lines, 608

Elastomeric bearing pads, 415, 803

Elastomeric joint sealer, 729

Electrical signs, 565, 567

Inspection, 568

removal and storage or reerection, 568

Testing, 568

Electrodes, welding, 800

Eliminated items, 21

Embankment, 95, 96, 97, 100, 101, 104, 107, 108, 111, 112, 114, 470, 474, 637, 638, 665, 666, 671, 720, 721

Compaction, 95, 96, 103, 107, 108, 111, 159, 160, 167, 179, 238, 241, 245, 447, 477, 707

Emergency, structural concrete placement, 331

Emulsions, 62, 669, 696

Engineer

Authority of, 22

Environmental protection, responsibility for, 43

Epoxy coated reinforced concrete pipe, 749

Epoxy coated steel wire and fabric, 790

Epoxy coated, reinforcing steel, 317, 320, 788

Equipment, 7, 38, 55, 70, 71, 72, 73, 74, 78, 123, 140, 149, 151, 153, 167, 175, 182, 197, 205, 208, 209, 212, 213, 252, 253, 259, 286, 345, 351, 378, 384, 402, 405, 429, 430, 489, 494, 496, 537, 545, 547, 565, 566, 584, 594, 599, 604, 606, 610, 611, 613, 614, 615,616, 619, 621, 622, 623, 626, 628, 629, 631, 667, 738, 844, 858, 859, 860, 861, 865, 889

Erecting rail elements, 456

Pavement markings, 607

Erection procedures

Plate girders, 364, 373

Erosion control blanket, 661

Erosion control mats, 661

Erosion protection

Seeding and erosion control blanket, 661

Seeding and paper blanket, 661

Examination of plans, specifications, special provisions and site work, 12

Excavation, 28, 37, 96, 99, 104, 107, 111, 132, 295, 300, 301, 302, 304, 305, 419, 420, 429, 430, 431, 432, 435, 452, 453, 454, 467, 469, 470, 471, 480, 594, 596, 601, 666

Retaining walls, 469

Execution of contract, 17

Expansion and Contraction Joints, Joint Sealers, and Bearing Devices

Description, 413

Fabrication, 413

Materials, 414

Expansion joints, concrete barrier, 530

Expansion joints, structure

Preformed, 414

Sliding plates, 415

Structural, 414

Expansion rockers, 416

Expansion shield anchors, 142, 458

Explosives, 35, 119

Fabric for waterproofing, 805

Fabric, for fence, 459

Fabrication, structural steel, 371

Fabricator, 4, 7, 292, 293, 299, 359, 360, 362, 402, 403, 404, 681, 682, 683

Approval of, 292

Failure to execute contract, 17

Failure to maintain roadway or structures, 27

Falsework and forms, structures, 314

Camber, 315

Deflection, 315

Forms, 316

Oiling forms, 317

Removal, 316

Federal-Aid provisions, 35

Fence, 89, 92, 95, 458, 459, 460, 681, 682, 791, 792, 796, 798

Barbed wire, 458

Barbed wire, 460

Barbed wire, 791

Chain link, 792

Clearing and grading, 458

Fabric, 111, 112, 356, 420, 421, 458, 459, 475, 680, 789, 790, 795, 805

Fabric, 459

Hardware, 792

Horizontal deflections, 459

Post assemblies, 458

Posts, line, 459, 796, 797

Steel posts, gates, frames, braces, 793

Woven steel wire, 458

Woven steel wire, 460

Woven steel wire, 791

Fertilizer, 634, 638, 640, 649, 650, 662, 668

Fertilizing, 653, 664

Fiber bounded bituminous coated corrugated steel pipe and pipe arches, 772

Field splices, structural steel, 376

Fillers, preformed, 414

Fillers, structural steel, 365

Filter fabric, 419, 441, 444, 451, 452

Final, 84

Fine aggregate, 289, 423, 474

Finish, structural steel, 365

Finishing machine, 337

Finishing, patched concrete structure, 422

Fire hydrant, 595, 601, 905

Fire hydrant adjusted, 601

Flagger, 502

Flasher controller, 585, 587, 885

Flasher, for traffic signal controller, 866

Forms, 252, 255, 265, 314, 316, 317, 323, 333, 406, 478, 529

Oiling, 317

Proposal, 11

Removed, 333

Foundation, 430, 547, 550, 564, 593, 903

Traffic sign support, 557

Traffic signal controller, 587

Friction type drilled shafts, 433

Furnishing right-of-way, 43

Galvanized metal cellular retaining walls, 468, 469

Galvanized steel, 310, 791, 799

Railing, 418

Galvanizing, 455, 680, 791

Gate valve and valve box, 595, 904

Glass beads, 605, 606, 614, 616, 621, 622, 623, 625, 627, 628, 893, 896, 897, 898, 899, 900

Granulated slag, 161, 204

Grass seeds, 641

Gravel, 183, 203, 725

Gray iron castings, 801

Grease, multipurpose, 767

Grid, 550

Ground bus bars, signal controllers, 869, 885

Ground rods, 538

Grounding, 537, 543, 545, 550, 869

Grout, 322, 336, 486, 673, 712, 730

Non-shrink, non-metallic, 730

Grout cleaning structural concrete, 336

Guaranty, material, 15

Guaranty, proposal, 13, 17

Guard posts, 798

Guardrail, 89, 92, 95, 133, 134, 135, 455, 456, 457, 552, 681, 682, 797, 798

Anchor assemblies, 457

Bridge terminal assembly, 457

Deep beam rail, 455

Deep beam rail, 455

Deep beam rail, 796

Erecting rail elements, 456

Galvanizing, 455

Material, 455, 792

post, 455

Posts, 456, 797

Pressure treated, 455

Rebuilt, 456

Setting posts, 456

Wire rope rail, 796

Guardrail post

Pressure treated, 798

Square sawed and round, 797

Steel, 798

Gutters, paved, 444

Hand laid stone, riprap for tree protection, 636

Handhole cover, sign supports, 553, 837

Handling materials, 32

Hardware, fence, 792

Hardware, signs, 838

High-strength steel, 367

High-strength steel bolts, nuts and washers, 367

Highway lighting

Cable splicing kit, 538

Duct-cable, 549

Ground grid, 548

Ground rods, 538

Junction box, 538, 548

Lamps, 538, 686, 690, 844

Light pole, 538, 548

Light towers, 538

Luminaire, 537, 539, 547, 550, 562, 564, 565, 567, 568, 569, 686, 687

Unit type duct-cable systems, 537

Holes, for dowels, 322

Horizontal deflection, fence, 459

Horizontally curve beams and girders, 366

Hot applied sealer, crack and joint, 728

Hydrostatic test, water main, 598

Identification, 128, 374, 539, 719

Incidentals, 537, 538

Inlets, 493, 494

Precast, 767

Inoculating bacteria, 642

Inoculating legumes, 642

Inserting valve box, 904

Inspection, 3, 25, 26, 41, 43, 83, 98, 371, 374, 375, 379, 382, 383, 386, 399, 401, 402, 406, 423, 427, 431, 435, 438, 471, 478, 487, 488, 489, 493, 494, 553, 561, 565, 568, 596, 665, 684, 686

Final, 82

Of work, 25

Inspection and testing, pneumatically placed mortar, 427

Inspector, 2, 7, 25, 27, 41, 61, 67, 83, 84, 381, 382, 387, 388, 389, 390, 392, 393, 394, 395, 400, 615, 625, 658

Authority and duties, 25

Installation of

Barrier reflectors, 551

Delineators, 525

Insulating concrete, 333

Intensity of roadside cleanup, 634

Intent of contract, 17

Internally illuminated signs, 568, 841

Interpretation of quantities in proposal, 12

Iron castings, 801

Ductile, 801

Gray, 801

Irregular proposals, 13

Island marking, 609

Issuance of proposals, 11

Joint, 13, 201, 252, 257, 261, 262, 267, 349, 413, 414, 415, 417, 439, 441, 475, 489, 672, 673, 728, 729, 766, 768

Concrete barrier joint, 530

Resilient and flexible, 767

Sealer, 252, 414, 439, 441

Joint filler, bituminous pipe, 766

Joint sealer

Elastomeric compression, 729

Joint and splices, structural steel, 366

Structural, 415

Junction boxes, 538, 548

Labor, extra work, 68

Lamps, 538, 686, 690, 844

Incandescent, 844, 850

Signal, 3, 578, 588, 667, 668, 690, 691, 842, 843, 844, 846, 849, 850, 853, 857, 858, 862, 867, 875

Signal, 844

Landscape watering, 658

Lane arrows, 609

Lane lines, 510, 608

Lateral bracing, 367

Law enforcement officer, 501

Laws to be observed, 41

Laying water mains, 596

Layout, 505, 524, 525, 526, 531, 534, 535, 551, 604, 607, 608, 616, 619, 620

Layout of barrier reflectors, 551

Layout of delineators, 525

Layout of raised pavement markers, 526

Lead, sheet, 802

Leaded bronze, 377, 802

Legal relations and responsibility to public, 33

Legal rights, no waiver of, 43

Licenses, permits, and taxes, 34

Lifting sod, 652

Light pole, 538, 548

Light tower, 538

Lighting, 386, 513, 514, 537, 547, 550, 668

Lightning protection device, traffic signal controller, 866

Limitation of operations, 55

Line marking descriptions, RPM, 500

Line placement tolerance, pavement marking, 608

Line post, fence, 459, 796, 797

Line types, pavement markings, 608

Liquid membrane-forming compounds, 728

Liquidated damages, 17

Load restrictions, 26

Load switch, 863

Loop detector unit, 852, 866

Delay and extension type, 852

NEMA TS-1, 842, 847, 852, 858, 860, 862, 864, 865, 866, 867, 869, 870, 885, 890, 892

NEMA TS-1, 852

NEMA TS-2, 847, 852, 858, 860, 862, 869, 871, 872

NEMA TS-2, 852

Low strength mortar backfill, 494

Equipment, placing, 496

Materials, proportioning, 494

Mix adjustment, alternates, 495

Lumber, 681, 683, 805

Luminaire, 537, 539, 547, 550, 562, 564, 565, 567, 568, 569, 686, 687

Luminaire for high intensity discharge lamp

Working drawings, 554

Machine bolts, structural, 801

Magnetic particle inspection, 375

Main power breakers, 867

Maintaining pavement markings, 499, 501

Maintaining traffic, 497

Asphalt concrete for maintaining traffic, 512

Flaggers, 497, 502

Flaggers, 502

Law enforcement officer, 502

Pavement marking operations, 512

Road closed, 501

Temporary signal, 502

Traffic maintained, 501

Work zone markings, 502

Maintenance during construction, 27

Failure to, 27

Maintenance of temporary structure, 300

Manholes, catchbasins, inlets, monuments

Riser section, precast, 767

Manual control and pushbutton, controller, 867

Manufacturers, cellular retaining walls, 468

Markers, raised pavement, 526

Masonry, 446, 450, 485, 669, 672, 727

Masonry cement, 446

Material

Control of, 30

Department furnished, 32

Guaranty, 15

Handling, 32

Patented, 34

Plant sampling, 31

Quality requirements, 30

Samples, 30

Small quantities, 31

Source of supply, 30

Storage of, 31

Structural expansion and contraction, 414

Testing plan, 31

Tests, 30

Unacceptable, 32

Materials for temporary applications, 31

Materials found on the work, 22

Measurement of quantities, 61

Measurement, acceptance, and payment, 61

Messenger wire, 553, 855

Meter and chamber removed, water main, 602

Microprocessor, traffic signal controller, 879

Mill test reports, 414, 418, 419

Mineral filler, 168, 670

Minority business enterprise, 45

Mobilization, 535, 536

Monuments, 531, 532, 533, 534

Mortar, 152, 243, 320, 427, 428, 472, 474, 475, 494, 496, 497, 595, 667, 674, 676, 712, 731, 733, 773

Lined corrugated steel pipe, 773

Quick setting, 731, 733, 734

Mulching, 458, 460, 638, 639, 647, 648, 649, 650, 651, 668

MUTCD, 498, 605

Navigable water, bridges over, 35

NEMA TS-2, 847, 852, 858, 860, 862, 869, 871, 872

NEMA, TS-1, TS-2, cabinet and controller, 852

Neoprene elastomer bearings, 804

No waiver or legal rights, 43

Nondestructive testing, 373

Non-reflective sheeting, sign, 840

Non-reinforced concrete pipe, 471, 472, 473, 738

Nuts, high-strength, 367

Ohio Manual of Uniform Traffic Control Devices, 3, 498

Oiling forms, 317

Opening project to traffic, 41

Operations, pavement markings, 512

Optically programmed signal lamps, 843

Outlets, precast reinforced concrete, 768

Outlets, underdrain, 454

Overpass structure mounted sign supports, 554

Paint, 86, 177, 393, 395, 399, 418, 610, 660, 679, 693, 736, 774, 784, 785, 786, 851, 892

Aluminum, 417, 418, 472, 473, 494, 525, 554, 677, 682, 683, 689, 776, 777, 778, 779, 780, 802, 806, 838, 839, 857

Aluminum, 787

Blue-green vinyl finish coat, 795

Inorganic zinc silicate primer, 784, 801

Material, 785

Structural steel prime, 784

Panels, flashing arrows, 513

Patching concrete structures, 421

Placing, finishing, and curing, 422

Preparation of surface, 422

Removal of disintegrated concrete, 421

Patented devices, materials, and processes, 34

Paved gutter, 444, 445

Pavement, 4, 5, 89, 99, 136, 166, 201, 211, 220, 225, 231, 243, 252, 258, 266, 269, 277, 497, 503, 512, 527, 604, 613, 615, 619, 621, 626, 628, 631, 665, 666, 671, 685, 693, 706, 707, 718, 816, 893, 895, 896, 897, 898, 899, 900

Marking, 503, 606

Preformed fillers, 414, 418

Preparation for marking, 606

Pavement deficiency

Pavement incidentals, 727

Pavement Markings, 497, 503, 505, 512, 605, 609, 892

Application, 606, 607, 614, 615, 617, 620, 622, 623, 624, 626, 627

Center lines, 608

Channelizing lines, 608

Curb and island marking, 609

Deduction for deficiency, 609

Dotted lines, 609

Edge types, 608

Equipment, 607, 610, 613, 614, 615, 616, 619, 621, 622, 623, 626

Glass Beads, 504, 610, 613, 693, 694, 898, 900

Lane arrows, 609

Lane lines, 510

Lane lines, 608

Layout and premarking, 607

Line placement tolerance, 608

Long lines, 609

Maintained, 503

Marking types, 608

Materials, 605, 892

Operations, 512

Parking lot stall marking, 609

Pavement preparation, 607

Polyester, 613, 666, 693, 893

Polyester, 893

Preformed, 896

Removal, 609

Stop and crosswalk lines, 608

Symbol marking, 609

Thermoplastic, 616, 617, 628, 693, 895, 900

Thermoplastic, 616

Thermoplastic, 619

Thermoplastic, 895

Traffic paint, 619

Transverse lines, 609

Two way radio communications, 609

Words on pavement, 609

Work zone, 503

Pavement repair, 136

Pavement, Portland Cement Concrete

Admixtures for, 728

Air-entraining admixture, 728

Burlap cloth, 728

Chemical admixtures, 729

Hot applied joint sealer, 728

Incidentals, 727

Liquid membrane-forming compounds for curing concrete, 728

Non-shrink grout, non-metalic, 730

Non-shrink mortar, 733

Preformed elastomeric compression seal, 729

Preformed fillers, 728

Quick setting mortar, 731, 733, 734

Sheet materials for concrete curing, 728

Silicone joint seals, 804

Payment

Acceptance and measurement, 61

Payroll records, 61

Scope of, 64

Pedestal traffic signal support, 855

Pedestrian pushbutton, 851, 863

Pedestrian signal head, 844

Pedestrian signal lamp, 844

Performed expansion joint filler, 417

Permit, restoration of surfaces opened by, 34

Permits, licenses, and taxes, 34

Phosphor bronze plate, structure, 802

Pile, 2, 4, 309, 310, 311, 312, 313, 314, 430, 596, 667

Temporary bridge, 300

Piling, timber, 805

Pin holes, structural steel, 366

Pins and rollers, 366

Pipe, 3, 89, 313, 418, 451, 476, 494, 532, 558, 564, 594, 603, 738, 739, 740, 766, 793, 803, 836, 838, 902, 903, 904

(see also water mains), 594, 595, 596, 598, 600

ABS drain, waste, and vent, 783

ABS sewer, 472, 473, 474

ABS sewer, 783

Aluminum alloy, 472, 473

Aluminum alloy, 777

Aluminum alloy, 778

Arches, 676, 772

Arches, 757

Arches, 772

Arches, 772

Bituminous coated, 472

Bituminous coated, 772

Bituminous lined, 472

Bituminous lined, 774

Concrete, non-reinforced, 738

Concrete, perforated, 765

Concrete, reinforced, 738

Concrete, reinforced elliptical, 738

Concrete, reinforced, epoxy coated, 749

Corrugated aluminum box, 472

Corrugated aluminum box, 780

Corrugated steel, bituminous lined, 772

Corrugated steel, box, 774

Corrugated steel, metallic coated, 768, 771

Corrugated steel, mortar lined, 773

Corrugated steel, spiral rib, 773

Corrugated steel, underdrains, 452

Corrugated, aluminum spiral rib, 779

Corrugated, aluminum underdrains, 777

Corrugated, polyethylene, 781

Drainage of structures, 420

Joint filler, bituminous, 766

Metallic coated, 768, 771

Precast reinforced concrete box sections, arches, & three sided, 751

Precoated, galvanized steel, 472

Precoated, galvanized steel, 772

Steel, aluminum, and plastic, 768

Structural plate, aluminum, 779

Structural plate, steel, 772

Tile, clay drain, 452, 766

Tile, concrete drain, 452, 765

Tubing, corrugated polyethylene, 780

Tubing, square and rectangular steel, 772

Underdrains, 451, 452, 453, 454, 455, 676, 677, 768, 777, 811

Underdrains, 451

Underdrains, 451

Underdrains, aluminum, 452

Underdrains, steel, 452, 768

Vitrified clay, 471, 472, 473, 475

Vitrified clay, 452

Vitrified clay, 766

Welded and seamless steel, 783

Pipe culverts, sewers and drains

Certification, 768

Pipe drains, for rip-rap tree protection, 636

Pipe drains, large trees reset, 636

Plans, 5, 6, 8, 11, 23, 24, 25, 44, 292, 537, 851, 890

Conformity with, 23

Coordination with specifications and special provisions, 23

Plans and working drawings, 23

Plans, approval of, 292

Plant sampling and testing plan, 31

Plastic manhole steps, 806

Plates, web and flange, 374

Pneumatically Placed Mortar, 427, 428

Description, 423

Materials, 423

Reinforcement, 424

Poles, 553, 687, 688, 691, 837, 854

Light, 3, 347, 548, 550, 687, 841, 844, 850, 867

Power service, 538, 548, 566

Steel sign supports, 557

Strain, 691, 854

Strain, 854

Tower, 550

Wood, 854

Polyethylene encasement, 595, 903

Polyethylene encasement, water main, 599

Polyethylene service branches, 903

Polyvinyl chloride (pipe, culverts, sewers, and drains), 451

ABS composite pipe, 782

Corrugated smooth interior pipe, 782

Profile wall pipe, 782

Solid wall pipe, 451

Porous backfill, 420

Portable concrete barrier, 514, 529

Portland cement, 112, 114, 149, 198, 200, 207, 222, 266, 283, 404, 423, 450, 516, 670, 763, 895, 900, 902

Posts, 455, 456, 458, 459, 524, 681, 685, 688, 793, 794, 796, 797, 798, 836, 837

Fence, 89, 92, 95, 458, 459, 460, 681, 682, 791, 792, 796, 798

Fence, 458

Fence, 796

Guardrail, 89, 92, 95, 133, 134, 135, 455, 456, 457, 552, 681, 682, 797, 798

Guardrail, 456

Guardrail, 797

U-Channel, 688, 836

U-Channel, 836

Wood, 2, 538, 638, 648, 656, 687, 691, 854

Wood, 796

Power breaker, 867

Power service, 538, 548, 566

Precast concrete, 529

Precast reinforced concrete box sections, 471, 472

Precast reinforced concrete manhole riser, 767

Precast reinforced concrete outlets, 768

Precoated galvanized culverts, 772

Preconstruction conference and progress schedule, 46

Preconstruction testing, pneumatically placed mortar, 425

Prefabricated edge drain, 453

Preformed Bearing Pads, 682, 803

Preformed elastomeric compression joint sealer, 414, 729

Preformed expansion joint filler, 474

Preparation of, 12, 197, 355, 400, 401, 421, 422, 423, 425, 651, 652

Preparation of repair are, pneumatically placed mortar, 425

Prequalification of bidders, 11

Preservative, 456, 684

Pressure treated guardrail, posts, braces, block, 455, 798

Pressure, pneumatically placed mortar, 425

Prestressed concrete bridge members, 402

Concrete, 407

Construction methods, 406

Equipment, 405

Materials, 404

Prestressing steel, 806

Prestressing strands, 409

Release of prestressing strands, 409

Transportation, storage and erection, 409

Prestressing steel, 404

Primer, 62, 355, 379, 383, 385, 392, 394, 669, 679, 696, 700, 784

Primer coat, 355

Processes, patented, 34

Progress, 48, 53, 60

Schedule and preconstruction conference, 46

Unsatisfactory, 60

Project Engineer, authority and duties, 22

Proportioning, 205, 207, 494, 495

Pneumatically placed mortar, 425

Structural concrete, 324

Proposal, 5, 6, 7, 8, 11, 12, 13, 14, 15, 16, 17, 24, 29, 32, 38, 46, 167, 270, 451

Combination or conditional, 14

Consideration of, 16

Consideration of, 16

Contents, 11

Delivery of, 14

Guaranty, 13, 17

Interpretation of quantities, 12

Irregular, 13

Issuance of, 11

Preparation of, 12

Public opening, 14

Return of guaranty, 17

Withdrawal of, 14

Withdrawl of, 14

Prosecution and progress, 46, 53

Protection and restoration of property, 35

Pruning for roadside cleanup, 635

Public convenience and safety, 35

Pull box, 538, 548, 550

Quantities

Small, 31

Quick setting concrete mortar, 731, 733, 734

Radio Interference Filter, 867

Radiographic inspection of weld, 373

Rail steel bars, 789

Railings, 417, 418, 682, 802

Construction Methods, General, 418

Materials, 418

Railings for structures, 417

Aluminum, 418

Steel, 418

Raised pavement markers, 60

Adhesive, 816

Layout, 526

Rebuilt guardrail, 456

Recycled portland cement, 96

Reflective sheeting, sign, 839

Reflectors, barrier, 551

Reinforced concrete elliptical culvert, pipe, 749

Reinforced concrete pipe, 471, 472, 738

Reinforced concrete pipe, epoxy coated, 471, 749

Reinforced polypropylene manhole steps, 806

Reinforcing steel, 142, 252, 309, 317, 326, 330, 404, 418, 421, 423, 441, 446, 451, 455, 458, 474, 529, 537, 553, 788

Bending, 318

Care of material, 318

Clearances, 318

Coated dowel bars, 790

Epoxy coated, 317, 431, 439, 474

Epoxy coated, 320

Epoxy coated, 406

Placing, 318, 320

Prestressing steel, 404

Sampling, 317

Splicing, 320

Supports, 320

Reinforcing steel, material, 788

Axle steel deformed and plain bars, 789

Billet steel bars, 789

Epoxy coated, 320, 788

Prestressing steel, 806

Rail steel bars, 789

Steel bar or rod mats, fabricated, 789

Steel wire fabric, deformed, welded, 790

Steel wire fabric, epoxy coated, 790

Steel wire fabric, welded, 790

Steel wire, cold drawn, 789

Steel wire, deformed, 790

Relays, for traffic signal controllers, 865

Release of prestressing strands, 409

Removal of disintegrated concrete, structures, 421

Removal of falsework, 315

Removal of pavement markings, 609

Removal of rubbish, tree pruned, 660

Removal of temporary structure, 300

Removal of unacceptable and unauthorized work, 26

Removal, storage or disposal of delineators, 525

Removal, storage or reerection, sign lighting, 568

Reporting, investigating, and resolving motorist damage claims, 40

Requirement for contract bond, 17

Resilient and flexible joints, 767

Responsibility for damage claims and liability insurance, 38

Responsibility to public, legal relations and, 33

Responsibility, Contractors’

For the work, 41

For utility property and services, 42

Restoration of surfaces opened by permit, 34

Restrained joints, water main, 598

Retaining walls, cellular, 468

Return of proposal guaranty, 17

Right-of-way

Furnished, 43

Use of materials found on the work, 22

Rigid overhead sign support, 567

Riprap, 441, 442, 443, 445, 635, 636, 637

Road

Haul, 27

Haul, 27

Road closed, 501

Roadside, 9, 635

Cleanup, 634

Roadside cleanup

Cleaning, 634

Disposal of refuse, 635

Intensity of cleanup, 634

Pruning, 635

Roadway, 5, 9, 23, 27, 41, 323, 337, 449, 457, 530, 537

Finish, concrete, 336

Rock channel protection, 444

Rolled beams

Camber, 364

Rubbed finish, concrete, 333

Rustication, 316

Safety, public convenience and, 35

Samples, tests, and cited specifications, 30

Sampling, reinforcing steel, 317

Sanitary Provisions, 35

Scalping, 86, 87

School speed limit sign assembly, 566, 568, 842

Scope of payment, 64

Scope of work, 17

Screenings, 715

Screw threads, structural steel, 372

Sealer, 345, 417, 673, 728

Hot applied, joint, 728

Preformed elastomeric compression, 414

Preformed elastomeric compression, 729

Silicone, joint, 804

Seeding, 458, 460, 638, 646, 647, 648, 649, 650, 651, 668

And mulching with erosion control netting, 661

And renovating existing sod, 663

Fertilizer, 634, 638, 640, 649, 650, 662, 668

Methods, 646

Watering, 638, 648, 651, 653, 657, 658, 659

Blanket, paper, 661

Seeding and mulching, 638

Fertilizer, 640

Innoculating bacteria, 642

Repair seeding and mulching, 648

Seed, 641

Watering, 648

Seeds, 641, 642, 643

Service branches, water mains, 602

Service stop and service box, 595, 904

Setting guardrail posts, 456

Shale, 96, 99, 101, 107, 109, 304, 305, 672, 711, 713, 714, 716, 722, 723, 725, 727

Sheet copper, 414, 802

Sheet lead, 414, 802

Sheet materials for concrete curing, 728

Sheeting, 414, 603, 604, 673, 689, 729, 839, 840

Traffic sign, 554

Shipping, storage & erection of structural steel, 376

Shop assembly, structural steel, 372

Shop drawings, structures, 292, 362

Shoulders, 99

Sidewalk finish, 338

Sign, 17, 51, 383, 512, 514, 553, 554, 557, 559, 560, 562, 563, 564, 565, 566, 568, 569, 690, 840, 841, 842

Erection, 560

Fabrication, 554

Flasher assembly, 566

Service, 566

Storage, 560

Sign flasher assembly, 566

Sign lighting and electrical signs, 565

Ballast, 567

Changeable-message sign, 566, 840

Conduit, 565, 842

Disconnect switch, 567

Electrical signs, 567

Flexible conduit, 842

Inspection, 568

Internally illuminated sign, 566, 841

Materials, 566

Photoelectric controls, 567

Removal, storage or reerection, 568

School speed limit sign assembly, 842

Sign flasher assembly, 566, 841

Sign service, 566

Signs wired, 566

Switch enclosure, 566

Testing, 568

Timer with enclosure, 567, 842

Sign service, 566

Sign supports, 557

Ground mounted, 558

Overpass structure mounted, 558, 559

Pole mounted, 558

Span wire, 559

Signal lamps, 843

Signal supports, 853

Significant changes in the scope of work, 18

Signs wired, 566

Signs, for work zone marking, 502

Signs, traffic, 553

Site conditions, differing, 18

Sliding plates, 415

Slip form, 330

Bridge railing, 329

Slope and channel protection, 441

Concrete, 443

Crushed aggregate, 443

Dumped rock, 444

Materials, 441

Paved gutter, 444

Riprap, 442

Rock channel protection, 444

Slump, 274, 277, 278, 280, 281, 285, 323, 326

Portland cement concrete, 330

Structural concrete, 326

Small quantities, 30

Sod, 651, 652, 653, 661, 668

Sodding, 651, 661

Erosion protection, 661

Placing, 652

Preparation, 652

Sod, 652

Watering, 653

Sodium chloride, 787

Soft subgrade, 515

Soil, 4, 96, 101, 595, 638, 639, 640, 641, 649, 650, 665, 666, 706, 811

Solid state digital type controller, 852

Soundness of aggregate, 707

Source of supply and quality requirements, 23

Span wire supports, 559

Special provisions

Coordination with plans and specifications, 23

Specifications, 2, 1, 2, 3, 5, 6, 9, 10, 11, 15, 24, 30, 32, 61, 70, 97, 119, 120, 186, 292, 293, 294, 295, 296, 300, 350, 366, 381, 448, 489, 503, 532, 533, 534, 738, 750, 753, 758, 762, 763, 803, 804, 807, 849, 854, 858, 860, 861

Conformity, 23

Coordination with plans and provisions, 23

Samples and tests, 30

Stainless, 418, 524, 532, 553, 688, 838

Stainless steel, for signs and supports, 838, 839, 850, 851, 853, 854, 855, 856, 864, 904

Steel

Epoxy coated, reinforcing, 788

Expansion and contraction, 413

Reinforcing, 317, 788

Structural, 360, 799

Steel woven wire fabric fence, 791

Steel, material, 798

Anchor bolts, 557, 837

Bars or mats, 789

Bearing bolts, 366

Bolts, 367, 801

Castings, 799, 801

Cold rolled, 799

Conduit, 768

Epoxy coated, reinforcing, 320

Epoxy coated, welded wire fabric, 790

Fence, 791

Galvanized, 799

Guardrail posts, 456, 798

Hardware, 838

Pipe, 772

Poles and arms, 553, 837

Prestressing, 806

Shear connectors, 372

Sheet piling, 799

Stainless, 838

Structural, 363, 799

Tube and pipe, 836

Wire fabric, welded, 789

Wire, cold drawn, 789

Wire, deformed, 790

Steps, 6, 52, 89, 91, 94, 462, 474, 492, 683, 806

Manhole, 806

Stiffeners, structural steel, 365

Stone, riprap for tree protection, 636

Stop and crosswalk lines, 608

Storage of materials, 31

Straightening, structural steel, 364

Structural, 89, 297, 306, 309, 311, 377, 378, 400, 414, 416, 429, 441, 442, 444, 445, 472, 480, 553, 558, 561, 562, 564, 565, 595, 671, 675, 676, 677, 679, 681, 682, 683, 684, 715, 716, 717, 768, 772, 779, 784, 799, 805

steel, 414, 418, 553

Tube and pipe, 553, 554

Structural bearing devices, 415

Structural expansion and contraction joints, 414

Structural joint sealers, 415

Structural plate corrugated metal structures on footings, 428

Structural plate, aluminum, 802

Structural plate, corrugated steel structure, 772

Structural steel, 799

Anchor bolts, 416

Arc welding electrodes and flux, 800

Bearing bolts, 366

Bearing devices, 415

Bolts, 801

Bolts, high-strength, 366

Camber, 364

Care of material, 364

Castings, 799, 801

Cellular polyvinyl chloride sponge, 806

Cleaning ASTM steel, 377

Cold rolled steel, 799

Ductile iron castings, 801

Elastomeric bearings, 803

Fabrication, 360

Fillers, 365

Finish, 365

Galvanized steel, 799

High-strength bolts, 367, 801

Holes for bolts, 366

Horizontally curved beams and girders, 366

Joints and splices, 366

Machine bolts, 801

Material control, 363

Nondestructive testing, 373

Pin holes, 366

Pins and rollers, 366

Plates, web and flange, 374

Preformed Bearing Pads, 803

Prestressed, 806

Screw threads, 372

Sheet piling, 799

Shipping and erection, 376

Shop assembly, 372

Shop drawings, 292, 362, 403

Stiffeners, 365

Straightening and workmanship, 364

Stud shear connectors, 372

Test reports, 299

Threads for bolts and pins, 372

Welding, 371

Structures

Concrete for, 323

Drainage of, 419

Falsework and forms, 314

Patching, 421

Pneumatically placed mortar, 423

Railings, 417

Shop drawings, 292

Steel, 360

Test reports, 299

Traffic, 299

Verification of dimensions, 292

Waterproofing, 344

Stud shear connectors, 372

Subgrade, 10, 107, 108, 109, 111, 118, 133, 134, 135, 141, 143, 202, 252, 255, 811

Suitable material, 97

Superpave asphalt concrete, 238

Supports, 317, 320, 421, 537, 539, 553, 557, 558, 559, 561, 680, 687, 691, 791, 853

Reinforcing steel, 320

Traffic sign, 553, 836

Traffic signal, 853

Surface finish, 336

Surface preparation

Patching structural concrete, 421

Waterproofing, 355

Switch enclosure, 566, 856

Switches, 865, 867, 868, 875

Switches for traffic signal controllers, 865, 867

Symbol markings, 609

Tanks Removed, 89

Tapping saddle, 595

Tapping saddle and corporation stop, 904

Tapping sleeve, valve, and valve box, 904

Taxes, licenses, permits, 34

Temporary concrete barrier, 767

Temporary concrete barrier (see Portable), 529

Temporary material applications, 31

Temporary preformed pavement markings, 503

Temporary structure, 299

Maintenance, 300

Removal of, 300

Temporary traffic signals, 502

Terminal blocks, controller, 868

Terminal buses, controller, 869

Termination of contract, 60

Termination of contractor’s responsibility, 83

Test reports

Railing, 418

Structural drainage, 419

Structural steel, 299

Testing plan, 31

Testing, prequalification, traffic signal controllers, 585

Testing, signs, 568

Tests, samples, other specifications, 30

Thermoplastic pavement marking, 616, 895

Threads for bolts and pins, 372

Through traffic, 501

Thrust block, water main, 598

Tie bars, 318

Tightening bolts, 369

Tile, tree root aeration, 637

Timber, 62, 309, 310, 312, 314, 418, 683, 684, 805

Structural, 805

Time based coordinator, 858

Time extension, 21, 56

Time switches, 868

Timer with enclosure, 566, 842

Topsoil, 638, 639, 641, 646, 650, 668

Tracer tape, water main, 597

Traffic, 41, 70, 75, 82, 91, 141, 170, 202, 228, 252, 266, 297, 300, 333, 497, 500, 512, 517, 527, 554, 584, 610, 667, 693, 844, 849, 858, 875, 886, 892

Activated controller, 858

Arm caps, 553

Control, 498

Controller work pad, 587

Load switch, 863

Maintaining, 497

Messenger wire, 553

NEMA TS-1, 842, 847, 852, 858, 860, 862, 864, 865, 866, 867, 869, 870, 885, 890, 892

NEMA TS-2, 847, 852, 858, 860, 862, 869, 871, 872

Nonreflective sheeting, 554

Paint, 619

Pavement marking, 503, 606, 607, 608, 609, 610, 619, 622, 624

Pedestrian pushbutton, 863

Power service, 538, 548, 566

Reflective sheeting, 525, 554, 856

Rigid overhead supports, 558

Silk screen inks, 554

Square posts, 553

Stainless steel hardware, 524, 553

Transformer base, 548

U-channel posts, 553, 836

Traffic signal controllers, 580, 584

Auxiliary equipment, 864

Cabinets, 586, 862, 863

Certified drawings, 585

Conflict monitor, 865

Contractor personnel requirements, 584

Controllers, 586, 858

Convenience outlet and light, 867

Coordination, 586

Dial coordinators, 887

Flasher, 841

Flasher controllers, 587, 885

Flashers, 866

Foundations, 587

Ground bus bar, 869

Lightning protection devices, 866, 875

Load switch, 865

Main power breaker, 867

Manual control and pushbutton, 867

Materials and equipment, 584

Microprocessor, type controller, 879

NEMA TS-1, 842, 852, 858, 860, 862, 864, 865, 866, 867, 869, 870, 885

NEMA TS-2, 871

Radio interference filter, 867

Relays, 866, 868, 874

Solid state-digital type controller, 886

Switches, 867

Terminal blocks, 868

Terminal buses, 869

Testing and prequalification, 585

Ventilating fan, 865

Wiring, 868, 873

Wiring harness, 869

Work pad, 587

Traffic signal equipment

Cable and wire, 856

Cable support assemblies, 855

Conduit riser, 855

Disconnect switch and enclosure, 856

Down guy assemblies, 854

Loop detector unit, 852

Messenger wire, 855

Pedestal, 855

Pedestrian pushbutton, 851

Pedestrian signal head, 849

Pedestrian signal lamps, 844

Power service, 856

Signal lamps, 844

Signal supports, 853

Strain poles, 854

Vehicular signal head, 842

Wood poles, 854

Traffic signs and sign supports, 553

Aluminum castings, 838

Aluminum extrusions, 554, 838

Aluminum forgings, 839

Aluminum sheet and plate, 554, 838

Aluminum tube and pipe, 838

Aluminum welding rods, 839

Arm caps, 838

Base and arm plates, 837

Beam supports, 558

Clear coating, 840

Covering of signs, 560

Drive posts, 558

Foundations, 557

Glare shields, 554

Handhole covers, 837

Hardware, 839

Inspection, 561

Materials, 553

Nonreflective sheeting, 840

Pole caps, 838

Reflective sheeting, 839

Removal, storage or erection, 561

Rigid overhead supports, 558

Sheeting, 554, 852

Sign erection, 560

Sign fabrication, 554

Sign identification, 556

Sign storage, 560

Silk screen inks, 840

Square posts, 837

Stainless steel, 838

Stainless steel hardware, 838

Steel anchor bolts and nuts, 557, 837

Steel hardware, 838

Steel poles and arms, 553, 837

Steel tube and pipe, 836

Supports, 557

U-channel posts, 836

Working drawings, 554

Transportation, prestressed concrete members, 409

Transverse lines, 608, 609

Tree, 88, 637, 657, 659, 660, 668

Tree root aeration, 637

Aggregate, 637

Earth embankment, 638

Tile, 637

Wells, 637

Trees

Protection, riprap for, 635

Root aeration, 637

Wells for, 635

Tubing, steel, square and rectangle, 772

Type 2 waterproofing, 357, 805

Type 3 waterproofing, 357, 806

Type A waterproofing, 356

Type B waterproofing, 331, 356

Type D waterproofing, 356

U-Channel post, signs, 836

Ultrasonic testing of welds, 376

Unacceptable and unauthorized work, 26

Unacceptable materials, 32

Underdrains, 451, 452, 453, 454, 455, 676, 677, 768, 777, 811

Aggregate, 454

Edge drain, prefabrication, 453

Materials, 451

Outlets, 454

Pipe, 452

Use of explosives, 35, 120

Utilities, 4, 24

Contractor’s responsibility, 42

Cooperation with, 24

Structures, general, 292

Valve box and service box, water main, 603

Valves and equipment, water main, 599

Vehicular signal head, conventional, 842

Vehicular signal head, optically programmed, 843

Ventilating fan, for traffic signal controller, 865

Verification of dimensions, structures, 292

Vertical extension of expansion joints, 413

Vibrators, 328

Vibratory roller, 245

Vines, 657, 668

Vitrified clay pipe, 471, 472, 473, 475, 766

Walks, 89, 91

Walls in cut, rip-rap tree protection, 636

Walls, retaining, cellular, 468

Washers, 360, 367, 416, 682, 801, 803, 839

High-strength, 367

Waste areas, borrow and, 27

Water for dust control, 517

Water main

Fire hydrant, 595

Water main and service branches, 904

Acceptance, 902

Backfilling, 598

Blocking and wedging, 597

Copper service, branches and fittings, 903

Dewatering, trench, 597

Disinfection, 599

Excavation, 596

Fire hydrant, 601

Materials, 595

Meter, setting, stop, chamber, 602, 905

Polyethylene, pipe, branches, fittings, 599, 903

Restrained joints, 598

Testing, hydrostatic, 598

Tracer tape, 597

Trench for dewatering, water main, 597

Watering, 638, 648, 651, 653, 657, 658, 659

Landscape, 658

Sod, 653

Trees, reset, 648

Waterproofing, 344, 345, 355, 356, 357, 358, 359, 471, 484, 669, 682, 683, 696, 803, 805, 806

Coal tar pitch, 749

Materials, 345

Preparation of surface, 355

Primer coat, 355

Type 2, 357, 805

Type 3, 357, 806

Type A, 356

Type B, 356

Type D, 356

Weep holes, 317, 449

Welded deformed steel fabric, 790

Welded steel fabric, 789

Welding, 2, 5, 318, 360, 364, 365, 371, 372, 373, 374, 375, 376, 403, 554, 675, 676, 677, 678, 679, 689, 800, 839

Magnetic particle inspection, 375

Radiographic inspection, 374

Structural steel, 414, 418, 553

Structural steel, 371

Ultrasonic testing, 376

Wire, 2, 458, 460, 559, 562, 564, 571, 577, 584, 679, 680, 681, 685, 691, 789, 790, 791, 793, 796, 855, 856, 857, 867, 870, 874

Barbed, 791

Cold-drawn steel, 789

Deformed steel, 789

Fabric, 789, 790

Fence, 791

Rope rail, 796

Wiring harness, 852

Wiring of traffic controllers, 868

Withdrawal of proposals, 14

Words on pavement, 609

Work zone markings, signs, 503

Work, The

Contractor’s Responsibility for, 41

Extra, 21, 65

Inspection of, 25

Scope of, 17, 18

Suspension of, 18, 22

Working drawings, plans and, 23

Working drawings, sign lighting, 565

Working drawings, sign supports, 554

Workmanship, straightening structural steel, 364

Wound dressing, tree, 659

Woven wire fence, 458, 460, 791

 [RT1]Office and project

 [RT2]Formatted submittal summary

 [RT3]Is required to…SEAN