106Control of Materials

Control of Materials

106.01Source of Supply and Quality Requirements. All materials used shall meet all quality

requirements of the Contract. The Contractor shall comply with the requirements of the special notice to contractors contained in the Department’s Field Materials Manual, including notifying the Engineer of the proposed sources of materials at least two weeks before delivery. When alternative materials are permitted for an item in the Contract, the Contractor shall state at the Pre-construction Conference the material that will be furnished for that item. Reference in the Contract to a particular product or to the product of a specific manufacturer, followed by the phrase “or approved equal”, is intended only to establish a standard of quality, durability, and design, and shall not be construed as limiting competition. Products of other manufacturers will be acceptable provided such products are equal to that specified. All rental equipment companies and all entities who meet the Supplier definition, as outlined in

101.02, in which the written agreement exceeds $10,000, shall have the following requirements

for the Contract:

system.

time that the $10,000 amount is known to be exceeded and/or before the following occurs on the Contract: • the Supplier’s upper tier begins work, or • rental equipment is being used, or • incorporating materials into the Contract

Failure to comply with the requirements of this subsection shall be grounds for withholding of progress payments.

106.02Material Sources. Where practicable, borrow pits, gravel pits, and quarry sites shall

be located so that they will not be visible from the highway.

as a source of sand, gravel, or borrow material, the location will be known as an available source. The Department will have an agreement with the property owner that allows removal of material under certain conditions and for a stated price. Conditions of this agreement that concern use of this material on the project and pit construction and reclamation requirements for the available source will be included in the Contract. The Contract will indicate whether the Department has or has not obtained the necessary County or City Zoning Clearance and the required permit from Colorado Department of Natural Resources needed to explore and remove materials from the available source. If the Department did not obtain the necessary clearances or permits, the Contractor shall obtain them. Any delays to the project or additional expenses that are incurred while these clearances or permits are being obtained shall be the responsibility of the Contractor. The Contractor shall ensure that the requirements of the permits do not conflict with the pit construction and reclamation requirements shown in the Contract for the available source.

106.02

The Department will investigate and obtain samples from the various available sources. These samples are not intended to indicate the full extent and composition of an entire deposit. These samples will be tested by the Department and may be combined with various materials such as mineral fillers and additives for further testing, especially for testing aggregate sources to obtain a satisfactory design mix. The Contract will show the location of the test holes where samples were obtained, test results, and amounts and kinds of any added materials utilized in the testing to obtain a satisfactory product. If the Contractor uses an available source, all material shall meet contract specifications. The Department will not be responsible for the material as produced by the Contractor. All costs of producing specification material shall be borne by the Contractor.

be known as contractor sources. The contractor source will be tested by the Department and approved by the Engineer before incorporation of the material into the project. If the submitted materials do not meet the contract specifications it will become the Contractor's responsibility to re-sample and test the material. The Contractor shall supply the Department with passing test results from an AASHTO accredited laboratory electronically sealed by a Professional Engineer. If requested by the Engineer, the Department will then re-sample and re-test the material for compliance to the contract specifications. The Contractor shall produce material that meets contract specifications throughout construction of the project. The cost of sampling, testing, and corrective action by the Contractor will not be paid for separately but shall be included in the work. The Contractor shall obtain all permits and agreements necessary to explore and remove material from a contractor source. The Contractor shall also be responsible for any costs or delays associated with obtaining these permits and agreements. For each source of imported embankment or topsoil the Contractor shall provide the following certification. The Contractor shall assure and certify that unacceptable levels of hazardous waste and substances; including but not limited to those defined in the Code of Federal Regulations (CFR), 40 CFR Part 261 Subparts C and D, and the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA), importing embankment or topsoil materials. For each contractor source outside of the project limits, the Contractor shall submit such certification to the Engineer, signed by either a Certified Industrial Hygienist (CIH), Certified Hazardous Materials Manager (CHMM), Certified Safety Professional (CSP), or Registered Environmental Manager

If contractor source material for embankment or topsoil, originating outside of the project limits, is placed on the project and is at any time found to be contaminated with unacceptable levels of hazardous waste or substances, the Contractor shall remove the contaminated material from the Department’s right of way, dispose of it per applicable laws and regulations, and make necessary restoration. The cost of complying with these requirements, including sampling, testing, and corrective action by the Contractor, shall be included in the work.

106.03

106.03Samples, Tests, Cited Specifications. All materials or the finished product where the

materials are used, will be inspected and tested by the Engineer, or by others if specified in the Contract. The Engineer will furnish copies of test results that indicate out of specification material, to the Contractor, promptly as the test results become available. Acceptance will be based on the applicable requirements of Section 105. Any work where untested and uninspected materials are used shall be performed at the Contractor’s risk and may be considered as unacceptable and unauthorized work.

Unless otherwise designated, when AASHTO, ASTM, or other specifications, standards, or policies are cited, the reference shall be to the latest edition as revised or updated by approved supplements or interim editions published and issued before the date of advertisement for bids.

Sampling and testing will be done per the Department’s minimum sampling, testing, and inspection schedule; the special notice to contractors; and the Colorado procedures; all contained in the Department’s Field Materials Manual.

Where the method of test is not cited, the applicable procedure shall be per the Standard AASHTO Method that was current on the date of advertisement for bids.

Samples will be taken by the Department except that the Contractor shall take samples of Portland Cement Concrete per CP 61; asphalt cement, per AASHTO T 40; hot mix asphalt per CP 41; and a composite of aggregates for hot asphalt mixtures per CP 30. The Engineer will determine the sampling locations, and the samples shall be taken in the presence of the Engineer. The Contractor may retain a split of each sample.

All materials being used are subject to inspection and testing at any time before or during incorporation into the work. Tests will be made by and at the expense of the Department.

106.04Qualification of Testing Personnel and Laboratories. Personnel performing tests used

in mix design or the acceptance, rejection, or price adjustment decision, and the laboratories where those tests are performed, shall be qualified per Colorado Procedure 10.

106.05Sampling and Testing of Hot Mix Asphalt. All HMA, Item 403, except HMA (Patching)

and temporary pavement shall be tested per the following program of process control testing and acceptance testing:

all elements listed in Table 106-1. Process control testing shall be performed at the expense of the Contractor. The Contractor shall develop a process control plan (PCP) per the following:

adequate details to ensure that the Contractor will perform process control. The Contractor shall submit the PCP to the Engineer at the Pre-construction Conference. The Contractor shall not start any work on the project until the Engineer has approved the PCP in writing.

frequency, which shall not be less than that shown in Table 106-1. The process control tests shall be independent of acceptance tests.

test result forms, and test results charts per CP 12 as part of the PCP.

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the tolerance limits shall be plotted. For in place density tests, only results after final compaction shall be shown. The chart shall be posted daily at a location convenient for viewing by the Engineer.

incentive or disincentive in Table 106-1 and each required sieve size shall be plotted. The QL will be calculated per the procedure in CP 71 for Determining Quality Level (QL). The QL will be calculated on tests 1 through 3, then tests 1 through 4, then tests 1 through 5, then thereafter the last five consecutive test results. The tonnage of material represented by the last test result shall correspond to the QL. For in place density tests, only results after final compaction shall be shown. The chart shall be posted daily at a location convenient for viewing by the Engineer.

test results, beginning with the first group of five test results, shall be a standard for evaluating material not conforming to process control. When the group QL is below 65, the process shall be considered as not conforming to the PCP. In this case, the Contractor shall take immediate action to bring the process back into control. Except where the cause of the problem is readily apparent and corrected without delay, production shall be suspended until the source of the problem is determined and corrected. A written explanation of actions taken to correct control problems shall accompany the test data and be submitted to the Engineer on the day the actions are taken.

Contractor using approved procedures. Acceptable procedures are Colorado Procedures, AASHTO and ASTM. The order of precedence is Colorado Procedures, AASHTO procedures and then ASTM procedures. The location where material samples will be taken shall be indicated in the PCP.

Acceptable standards are Colorado Procedures, AASHTO and ASTM. The order of precedence is Colorado Procedures, AASHTO procedures and then ASTM procedures.

sampling and testing shall be identified in the PCP and be qualified according to the requirements of CP 10

qualified according to the requirements of CP 10.

testing shall conform to the standards specified in the test procedures and be in good working order. Nuclear testing devices used for process control testing of in-place density do not have to be calibrated on the Department’s calibration blocks.

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control tests to the Engineer in writing at least once per day. The Contractor shall assemble a process control (PC) notebook and update it daily. This notebook shall contain all worksheets, test results forms, test results charts and quality level charts for each of the elements listed in Table 106-1. The Contractor shall submit the PC notebook to the Engineer for review once a month on the date agreed to at the Pre-Paving Conference. The PC notebook will be returned to the Contractor within one working day after submittal. The Engineer will notify the Contractor in writing of any deficiencies in the PC notebook, including the failure to submit the notebook on time or an absence of the required reports. Upon the second failure to submit the complete PC notebook on time or with an absence of the required reports, the Engineer will notify the Contractor, and the pay estimate will be withheld until the Contractor submits, in writing, a report detailing the cause for the failure to submit the complete PC notebook on time or the cause for the absence of required reports. The report shall include how the Contractor plans to resolve the failures. Additional failures to submit the PC notebook on time or absent the required reports will result in a delay of the pay estimate until the Contractor has identified and resolved the failure along with revising and resubmitting his PCP to address these issues. Once the Engineer has reviewed and approved the revised PCP the estimate may be paid. Upon submittal of the PC notebook for the semi-final estimate, the PC notebook shall become the property of the Department. The Contractor shall make provisions such that the Engineer can inspect process control work in progress, including PC notebook, sampling, testing, plants, and the Contractor’s testing facilities at any time.

not be addressed in the PCP. The Department will determine the locations where samples or measurements are to be taken. The maximum quantity of material represented by each test result and the minimum number of test results will be per Table 106-1. The location or time of sampling will be based on a stratified random procedure as described in CP 75. Acceptance sampling and testing procedures will be per the Schedule for Minimum Materials Sampling, Testing and Inspection in the Department’s Field Materials Manual. Samples for project acceptance testing shall be taken by the Contractor per the designated method. The samples shall be taken in the presence of the Engineer. Where appropriate, the Contractor shall reduce each sample to the size designated by the Engineer. The Contractor may retain a split of each sample which cannot be included as part of the PCP. If the Contractor elects to question the Hot Mix Asphalt (HMA) acceptance test results, the steps outlined in CP 17 shall be followed. The results from the CP 17 resolution process shall be binding on both the Department and the Contractor. Requests for CP 17 process for all elements except density shall be submitted in writing to the Engineer within 5 workdays from the date the Contractor receives acceptance test data from the Engineer. The specific element questioned shall be identified in writing. All requests for the CP 17 process for the density element shall be submitted in writing to the Engineer within 24 hours of receiving test data from the Engineer. The Contractor shall choose either the CDOT Materials and Geotechnical Branch or a consultant laboratory not associated with the project to perform the third-party testing. The Contractor shall document his choice in writing at the Pre-Paving Conference. If a consultant laboratory is chosen, the CDOT Materials and Geotechnical Branch will determine the consultant that will be used from a pre-established list and ensure there is no conflict of interest.

106.05

If third party testing is required, the responsibility for the testing expenses shall be assigned per CP 17. The costs for testing are shown in CP 17, Table 17-2. All materials being used are subject to inspection and testing at any time prior to, during, or after incorporation into work. Acceptance tests will be made by and at the expense of the Department, except when otherwise provided.

of asphalt pavement, under the direction of the Engineer, a CTP will be conducted between acceptance testing and process control testing programs. The CTP will consist of testing for asphalt content, theoretical maximum specific gravity, HMA 4.75 mm (#4) sieve, HMA 2.36 mm (#8) sieve, HMA 0.075 mm (#200) sieve, in-place density, and joint density per CP 13. If the Contractor intends to test to determine air voids and VMA, check testing for these tests is recommended. The CTP will be continued until the acceptance and process control tests are within the acceptable limits shown in Table 13- 1 of CP 13. An additional set of split samples from this CTP shall be retained and used in the event of third party testing per CP-17. For joint density, the initial check test will be a comparison of the seven cores tested by CDOT and the seven cores tested by the Contractor. These are the cores from the compaction test section used for nuclear gauge calibration and test section payment. During production, a split sample check will be conducted at the frequency shown in Table 106-1. Except for joint density, the split samples will be from an acceptance sample obtained per subsection 106.05(b). The acceptance test result will be compared to the process control test result obtained by the Contractor using the acceptable limits shown in Table 13-1 of CP 13. For joint density, the comparison sample for testing by the Contractor will be obtained by taking a second core adjacent to the joint density acceptance core. The acceptance test result will be compared to the process control test result obtained by the Contractor using the acceptable limits as shown in Table 13-1 of CP 13 and following the check testing procedure given in CP 13. If production has been suspended and then resumed, the Engineer may order a CTP between process control and acceptance testing persons to assure the test results are within the acceptable limits shown in Table 13-1 of CP 13. Check test results shall not be included in process control testing. The Region Materials Engineer shall be called upon to resolve differences if a CTP shows unresolved differences beyond the values shown in Table 13-1 of CP 13.

commences, the Department will perform a minimum of three stability verification tests to verify that the field produced HMA conforms to the approved mix design: The test frequency shall be one per day unless otherwise directed by the Engineer. The test results will be evaluated, and the Contractor shall make adjustments if required per the following:

specifications. There will be no tolerance limit.

106.05

If the QL for stability is less than 65, then production shall be halted, and the Contractor shall submit a written proposal for a mix design revision to the Engineer. The Engineer shall give written approval to the proposed mix design revision before production continues. After a new or revised mix design is approved, three additional stability tests will be performed on asphalt produced with the new or revised mix design. The test frequency shall be one per day unless altered by the Engineer. If the stability QL is less than 65, then production shall be halted until a new mix design has been completed and approved using plant produced material or the Contractor shall submit a written proposal for a mix design revision to the Engineer. The Engineer shall give written approval to the proposed mix design revision before production continues.

resumes, three additional stability field verification tests shall be performed, and the test results evaluated per the above requirements. The test frequency shall be one per day unless altered by the Engineer.

is complete and production continues, the sample frequency will revert back to 1 per 10,000 tons.

commences, the Department will perform a minimum of three volumetric verification tests for each of the following elements to verify that the field produced Hot Mix Asphalt (HMA) conforms to the approved mix design:

The test frequency shall be one per day unless altered by the Engineer. The test results will be evaluated, and the Contractor shall make adjustments if required per the following:

field test results on project produced hot mix asphalt or the target value specified in Table 403-1 and Table 403-2 of the specifications, whichever is higher. The target value for VMA will be set no lower than 0.5 percent below the VMA target on Form 43 prior to production. The target values for the test element of air voids and AC shall be the mix design air voids and mix design AC as shown on Form 43.

AC ± 0.3 percent Air Voids ± 1.2 percent VMA ± 1.2 percent

field verification test results. If the QL for VMA or AC is less than 65 or if the QL for air voids is less than 70, the production shall be halted, and the Contractor shall submit a written proposal for a mix design revision to the Engineer. Production shall only commence upon receipt of written approval from the Engineer of the proposed mix design revision.

106.05

After a new or revised mix design is approved, three additional volumetric field verification tests will be performed on asphalt produced with the new or revised mix design. The test frequency shall be one per day unless altered by the Engineer. If the QL for VMA or AC is less than 65 or the QL for the test element of air voids is less than 70, then production shall be halted until a new mix design has been completed per CP 52 or CP 54, a new Form 43 issued, and the Contractor demonstrates that he is capable of producing a mixture meeting the verification requirements per A or B below:

The Contractor shall notify the Engineer a minimum of 48 hours’ notice prior to the requested test. The location and time of the test are subject to the approval of the Engineer, prior to placement. Three samples will be tested for volumetric properties. If the QL for VMA or AC is equal or greater than 65 and the QL for the element of air voids is equal or greater than 70, full production may resume; or

in the last 200 tons will be tested for volumetric properties. After construction of the test section, production shall be halted until the testing is complete and element QLs are calculated. If the QL for VMA or AC is equal to or greater than 65 or the QL for the element of air voids is equal to or greater than 70, full production may resume. If the QL for VMA or AC is less than 65 or the QL for the element of air voids is less than 70, the material shall be removed and replaced at no cost to the Department. The time count will continue, and any delay to the project will be considered to have been caused by the Contractor and will not be compensable. The costs associated with mix designs shall be solely at the Contractor’s expense. If the Contractor fails to verify the new mix design per A or B, then production shall be halted until a new mix design has been completed per CP 52 or CP 54, a new Form 43 issued, and the Contractor demonstrates they are capable of producing a mixture meeting the verification requirements per A or B.

production resumes, three additional volumetric field verification tests shall be performed, and the test results evaluated per the above requirements. The test frequency shall be one per day unless altered by the Engineer.

above is complete and production continues, the sample frequency will revert back to a minimum of 1/10,000 tons. The Engineer has the discretion to conduct additional verification tests at any time.

Table 106-1.

Quality Level (MQL). The MQL will be calculated per the procedure in CP 71 for Determining Quality Level (QL). The MQL will be calculated using only acceptance tests. The MQL will be calculated on tests 1 through 3, then tests 1 through 4, then tests 1 through 5, then thereafter on the last five consecutive test results. The MQL will not be used to determine pay factors. The three reference conditions and actions that will be taken are described as follows:

106.05

maintained, and the past five consecutive test results are within the specification limits.

process is established because of changes in materials or the job-mix formula, following an extended suspension of work, or when the MQL is less than 90 and equal to or greater than 65. Once an element is at condition green, if the MQL falls below 90 or a test result falls outside the specification limits, the condition will revert to yellow or red as appropriate.

shall be notified immediately in writing and the process control sampling and testing frequency increased to a minimum rate of 1 per 250 tons for that element. The process control sampling and testing frequency shall remain at 1 per 250 tons until the process control QL reaches or exceeds 78. If the QL for the next five process control tests is below 65, production will be suspended. If gradation is the element with MQL less than 65, the Department will test one randomly selected sample in the first 1250 tons produced in condition red. If this test result is outside the tolerance limits, production will be suspended. (This test result will not be included as an acceptance test.) After condition red exists, a new MQL will be started. Acceptance testing will stay at the frequency shown in Table 106-1. After three acceptance tests, if the MQL is less than 65, production will be suspended. Production will remain suspended until the source of the problem is identified and corrected. Each time production is suspended, corrective actions shall be proposed in writing by the Contractor and approved in writing by the Engineer before production may resume. Upon resuming production, the process control sampling and testing frequency for the elements causing the condition red shall remain at 1 per 250 tons. If the QL for the next five process control tests is below 65, production will be suspended again. If gradation is the element with MQL less than 65, the Department will test one randomly selected sample in the first 1,250 tons produced in condition red. If this test result is outside the tolerance limits, production will be suspended.

106.06

Table 106-1 Schedule for Minimum Sampling And Testing for HMA

Process Control Element Acceptance*, # Check (CTP)

Asphalt Content 1/500 tons 1/1000 tons 1/10,000 tons Gradation 1/Day 1/2000 tons 1/20,000 tons Theoretical 1/1000 tons, 1/1000 tons, Maximum 1/10,000 tons minimum 1/Day minimum 1/Day Specific Gravity In-place Density 1/500 tons 1/500 tons 1/5000 tons 1 core/2500 linear 1 core/5000 linear 1 core/50,000 linear Joint Density feet of joint feet of joint feet of joint Aggregate 1/2000 tons, Percent minimum 1/Day 1/2000 tons Not applicable Moisture ^ Percent Lime ^,+ 1/Day Not applicable Not applicable Table 106-1 Notes: * The minimum number of acceptance tests will be: 5 asphalt content, 3 gradation, 10 in-place density and 5 joint density tests, for all projects. # When unscheduled job mix formula changes are made (Form 43) acceptance of the elements, except for in-place density, will be based on the actual number of samples that have been selected up to that time, even if the number is below the minimum listed in the schedule. At the Engineer’s discretion, additional random in-place density tests may be taken in order to meet scheduled minimums, provided the applicable pavement layer is available for testing under safe conditions. Beginning with the new job mix formula, the quantity it will represent shall be estimated. A revised schedule of acceptance tests will be based on that estimate. ^ Not to be used for incentive or disincentive pay. Test according to CP-33 and report results from Form 106 or Form 565 on Form 6. + Verified per Contractor’s PC Plan

106.06Sampling and Testing of Portland Cement Concrete Paving. All Portland Cement

Concrete Pavement, Item 412, shall be tested per the following process control and acceptance testing procedures:

of all elements listed in Table 106-3. Process control testing shall be performed at the expense of the Contractor. The Contractor shall develop a process control plan (PCP) per the following:

adequate details to ensure that the Contractor will perform process control. The Contractor shall submit the PCP to the Engineer at the Pre- construction Conference. The Contractor shall not start any work on the project until the Engineer has approved the PCP in writing.

sampling frequency, which shall be equal to or more frequent than that shown in Table 106-3. The process control tests shall be independent of

106.06

acceptance tests.

volume, and tolerance limits shall be plotted. The chart shall be posted daily at a location convenient for viewing by the Engineer.

The QL shall be calculated per the procedure in CP 71 for Determining Quality Level. The QL shall be calculated on tests 1 through 3, then tests 1 through 4, then tests 1 through 5, and then thereafter the last five consecutive test results. The area of material represented by the last test result shall correspond to the QL.

the Contractor using CP 61. The location where material samples will be taken shall be indicated in the PCP.

followed. Acceptable standards are Colorado Procedures, AASHTO and ASTM. The order of precedence is Colorado Procedures, AASHTO procedures and then ASTM procedures. The compressive strength test for process control will be the average strength of two test cylinders cast in plastic molds from a single sample of concrete, cured under standard laboratory conditions, and tested three to seven days after molding.

process control testing shall be identified in the PCP. This person shall be present on the project and possess one or more of the following qualifications:

paving experience.

with three years of paving experience.

or higher in the subfields of Transportation Engineering Technology, Highway Materials, or Construction Materials Testing Engineering Technology, Concrete and four years of paving experience.

Colorado Procedure 10.

testing shall conform to the standards specified in the test procedures and be in good working order., For projects with greater than 50,000 SY of PCCP or projects that do not have a certified lab within 40 miles of the project limits then the Contractor shall provide the following equipment and supplies, which will not be paid for separately but shall be included in the work:

106.06

usable space. This facility shall be used exclusively for the molding, storage and testing of concrete test specimens as required. This facility shall be provided in addition to other facilities required in Section 620. The storage facility shall have sufficient water storage capacity for curing all required test specimens. The storage facility shall provide separate storage tanks for each type of required testing. Each storage tank shall have a continuously recording thermometer and sufficient blank charts for the project. Temperatures of each storage tank shall be recorded for the duration of the project.

machine shall meet the requirements of ASTM C39 and shall have a minimum capacity of 250,000 lbs. The machine shall have a digital monitor capable of displaying load rate and total load. The following or an approved equal by the Region Materials Engineer may be used:

Both the Contractor and the Engineer may use this machine for testing concrete specimens. After the machine has been certified and accepted by the Engineer it shall not be moved until all portland cement concrete paving and compressive strength acceptance tests have been completed.

associated test plates when pavement thickness acceptance is based on magnetic pulse induction (MPI).

tests to the Engineer electronically at least once per day. The Contractor shall assemble a process control (PC) notebook and update it daily. This notebook shall contain all worksheets, test results forms, test results charts and quality level charts for each of the elements listed in Table 106-3. The Contractor shall submit examples of worksheets, test result forms and test results charts per CP 12B as part of the Contractor’s Process Control Plan (PCP). The Contractor shall submit the PC notebook electronically to the Engineer for review once a month on the date agreed to at the Pre-construction Conference. A list of recognized deficiencies will be returned to the Contractor within two workdays after submittal. Deficiencies may include but are not limited to, the failure to submit the notebook on time or an absence of the required reports. For any month that deficiencies are identified, the PC notebook will be submitted for review two weeks after the PC notebook is returned. Upon the second recognized deficiency, the Engineer will notify the Contractor, and the pay estimate shall be withheld until the Contractor submits, in writing, a report detailing the cause of the recognized deficiency. The report shall include how the Contractor plans to resolve the deficiencies. Additional recognized deficiencies will result in a delay of the pay

106.06

estimate until the Contractor has identified and resolved the deficiency along with revising and resubmitting his PCP to address these issues. Once the Engineer has reviewed and approved the revised PCP the estimate may be paid. Upon submittal of the PC notebook for the semi-final estimate, the PC notebook shall become the property of the Department. The Contractor shall make provisions such that the Engineer can inspect process control work in progress, including PC notebook, sampling, testing, plants, and the Contractor’s testing facilities at any time.

shall perform PC Testing for each aggregate source. All aggregates furnished for the project shall conform to the range of tolerances listed in Table 106-2 when compared to the approved mix design gradations. Individual gradation testing shall be at a minimum frequency of 1/day or 1/1,000 tons, whichever is greater, as aggregate is delivered to the batch plant and incorporated into the stockpile. If material does not meet the listed tolerances, the area of the stockpile represented by the sample may be remixed and retested. If material fails to meet the tolerances a second time, it shall be rejected. If multiple batch plants are being utilized, aggregates at each plant shall be tested separately. Testing and Tracking methods shall be included in the Contractor’s Process Control Plan. Table 106-2 Individual Aggregate Gradation Tolerances Sieve Size Tolerance (%) ≥No. 4 ±6 No.8 – No. 30 ±4 No. 50 ±3 No. 100 ±2 No. 200 ±1

aggregate gradation (CAG) when an Optimized Gradation (OG) is used for Class P Concrete. A sample of the combined aggregate from the first 100 cubic yards of concrete shall be tested; then one test per 750 cubic yards shall be performed. The frequency shall be a minimum of one per day if production is less than 750 cubic yards per day. The Department will perform one gradation test each day which may be a split of one of the PC samples. This data will not be used to determine the acceptability of the material but as information only.

The Contractor’s gradation test data will be used to evaluate the gradation optimization based on the mix design optimization.

When the Contractor’s gradation test results fail to meet their optimization range, the Contractor shall immediately make corrections to bring the aggregate gradation optimization into range and notify the Engineer. If two or more consecutive test results for any single day or two successive days are found to fall outside the optimization range, the Contractor shall immediately suspend production and provide a written corrective plan to the Engineer for approval before resuming production.

106.06

Upon being allowed to resume production, the Contractor shall follow the daily sampling frequency. If the next two consecutive gradation tests indicate that they meet the optimization range, the Contractor may continue production. If the first two aggregate samples do not meet the optimization range, production shall be suspended.

Before resuming production, the Contractor shall sample the individual aggregate stockpiles at two or more locations to determine the range of variability within each stockpile, make appropriate adjustments to the percentages for each aggregate component, and discharge and sample the combined aggregates. The combined aggregate gradation shall be tested to determine if the optimization range is met. Production can resume if the optimization range is met.. Production will continue to be suspended for additional evaluation of stockpiles and aggregate feed rates until gradation sampling and testing indicate the optimization range is met.

All gradation test information during production shall be provided to the Engineer daily. The Contractor shall immediately report all gradation test data to the Engineer for evaluation during periods when production is suspended or upon resuming production. The Contractor will be notified in writing in all cases when production may resume or shall remain suspended.

100 cubic yards of concrete shall be tested; then one test per 750 cubic yards shall be performed. The frequency shall be a minimum of one per day if production is less than 750 cubic yards per day. The moisture content sample maybe the same sample used for gradation PC testing. Moisture content of each aggregate shall be tested per CP 33. As they become available, results shall be immediately input into the batching computer and reflected on batch tickets.

When Recycled Concrete Aggregate (RCA) is used, the moisture content of the RCA shall be at or above the absorption of the RCA. When the moisture content of the RCA is lower than the absorption of the RCA, the Contractor shall immediately suspend production and provide a written corrective plan to the Engineer for approval before resuming production

perform a Box Test in accordance with CP-63 at the beginning of each day’s paving. The Box Test shall show no more than 30 percent surface voids and an edge slump less than 1/4 inch. When the Box Test results fail to meet these requirements, the Contractor shall immediately make corrections and notify the Engineer. After corrective actions have been completed, the Contractor shall perform a Box Test. The Box Test shall show no more than 30 percent surface voids and an edge slump less than 1/4 inch. If two or more consecutive Box Test results fail to meet these requirements, the Contractor shall immediately suspend production and provide a written corrective plan to the Engineer for approval before resuming production.

106.06

supplier all compressive- strength PC data for the concrete supplied to the project. The Contractor shall distribute the PC compressive strength data within two business days of the 7-day and 28-day compressive strength testing. The data shall include the compressive strength and batch ticket number at a minimum.

Acceptance) in the Department’s Field Materials Manual. Acceptance sampling and testing procedures will be per the Department’s Field Materials Manual with the following exceptions and inclusions: A split sample from an acceptance test shall not be used for a process control test. The Engineer will designate the location where samples are to be taken. Samples shall be taken by the Contractor per CP 61. The Engineer will be present during the sampling and take possession of all acceptance samples. Samples transported in different containers will be combined and mixed before molding specimens. All materials are subject to inspection and testing at all times. Pavement thickness acceptance will be determined by cores or magnetic pulse induction (MPI). Acceptance tests for thickness using MPI shall be the Contractor’s process control tests. MPI testing shall be per AASHTO T359. When compressive strength testing is specified, the Engineer will distribute electronically to the concrete supplier all compressive strength Owner Acceptance

compressive strength data within two business days of the 7-day and 28-day compressive strength testing. The data will include the compressive strength and batch ticket number at a minimum. The Contractor shall not have a valid dispute or claim as a result of any action or inaction by the Department related to the distribution of test results. The compressive strength test for acceptance will be the average compressive strength of three test cylinders cast in plastic molds from a single sample of concrete and cured under standard laboratory conditions before testing. If the compressive strength of any one specimen differs from the average by more than 10 percent, that specimen will be deleted, and the average strength will be determined using the remaining two specimens. If the compressive strength of more than one specimen differs from the average by more than 10 percent, the average strength will be determined using all three specimens. Each set of three cylinders will be tested at 28 days after molding.

testing will not be required for PCCP repairs and projects with less than 1,000 square yards of PCCP or when designated by the Region Materials Engineer. The check testing program will include a pre-pave conference held between the Project Engineer, the Contractor, Contractor's and Department's testers. Items discussed will include methods, procedures, and equipment for compressive strength testing, air content, and slump. Check testing shall be completed before any PCCP is placed. A set of three cylinders will be molded by both the Contractor’s and the Department’s project testers from a split sample. The specimens will be sampled, molded and cured for seven days and tested for compressive strength according to the procedures of Section 106. The Department’s Independent Assurance Tester will also mold, cure and test a set of three cylinders, but the Independent Assurance Test results will not be entered in the check testing analysis. If the results of the check tests do not meet the following criteria, then the check testing will be repeated until the

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following criteria are met:

Department’s strength test results shall be within 10 percent of the average of all strength test results.

strength test results.

When compressive strength criteria is indicated, a check test must also be conducted on the sand equivalent test. A set of 5 sand equivalents will be run by both the Contractor’s and the Department’s project tester, from a split sample. The average of the absolute differences between tests taken by the process control personnel and the acceptance testing personnel will be compared to the acceptable limits shown in Table 13-1 of CP 13. The CTP will be continued until the acceptance and process control test results are within the permissible ranges shown in Table 13-1 of CP 13.

During production, split samples of randomly selected acceptance tests will be compared to the permissible ranges shown in Table 13-1 of CP 13. The minimum frequency will be as shown in Table 106-3.

If production has been suspended and then resumed, the Engineer may order a CTP between tests taken by process control and acceptance testing persons to ensure the test results are within the permissible ranges shown in Table 13-1 of CP 13. Check test results shall not be included in process control testing. The Region Materials Engineer shall be called upon to resolve differences if a CTP shows unresolved differences beyond the ranges shown in Table 13-1 of CP 13.

Contractor’s process control test. The Department’s representative performing verification tests shall also use a split sample of the Contractor’s process control test and participate in the IAT.

quality level formulas per Section 105 will be selected by a stratified random process.

106.07

Table 106-3 PC Testing Schedule - Item 412 Portland Cement Concrete Pavement

Element Minimum Testing Frequency Contractor’s Process Control Aggregate Gradation each Minimum of 1/day, then 1 per 2500 cu. yds. source or combined When an OG is used, follow 106.06(a) 9 gradation Slump and Air Content First three loads each day, then as needed for control Compressive Strength, Slump Minimum of 1/day, then 1/2500 sq. yds. Air Content, Yield, and Sand Equivalent Pavement Thickness Per subsection 412.21 Minimum of six transverse and six longitudinal joint locations for the first 2,500 linear feet, then three transverse and three Pull Test Joints longitudinal joints thereafter Load Transfer Dowel Per subsection 412.13(b)2 Bar Placement Average Texture Depth 1 per 528 linear feet in each lane and shoulder wider than 8 feet Water Cement Ratio First three loads each day, then 1/500 cu. yds. Box Test Minimum of 1/day when a slipform paver is used at the beginning of each day’s paving. Aggregate Moisture Per subsection 106.06(a) 10 Content

106.07Material Inspection at Plant. If the Engineer inspects the materials at the source, the

following conditions shall be met:

producer.

production of the materials being furnished.

The Department reserves the right to retest all materials that have been previously tested or inspected. The retesting may be before or after incorporation of the materials into the work. Those materials inspected and tested after delivery on the project or after incorporation into the work, that do not meet the requirements of the Contract will be rejected or accepted with an adjustment in price per the requirements of subsection 105.03.

106.08Storage of Materials. Materials shall be stored to assure the preservation of their

quality and fitness for the work. Stored materials, even though conditionally approved before storage, will be subject to inspection and testing before incorporation into the work. Stored materials shall be located to facilitate prompt inspection. With prior approval, portions of the right of way may be used for storage of materials and equipment, and for the Contractor’s plant. Any additional space required shall be provided at the Contractor’s expense. Stored materials will be paid for per subsection 109.07. Private property shall not be used for storage purposes without written permission of the owner or lessee. If requested, copies of such written permission shall be furnished to the Engineer. All storage sites shall be restored to their original condition at the Contractor’s expense.

106.09

106.09Handling Materials. All materials shall be handled so their quality and fitness for

the work is preserved. Aggregates shall be transported to the work in vehicles constructed to prevent loss or segregation of materials.

106.10Department Furnished Materials. Material furnished by the Department will be

made available to the Contractor at the points specified in the Contract.

The cost of handling and placing materials after they are made available to the Contractor shall be included in the contract price for the item.

The Contractor will be held responsible for all material received until it is incorporated into the work and accepted.

Demurrage charges resulting from the Contractor’s failure to accept the material at the designated time and point of delivery will be deducted from monies due the Contractor.

106.11Buy America (BA) and Build America, Buy America (BABA) Requirements

applicable version of the Special Notice to Contractors Section of the CDOT Field Materials Manual (FMM), and the requirements therein, in effect at the time of bidding. The Special Notice to Contractors Section of the FMM, and the requirements therein, shall be considered a contractual document when this specification is included.

categories:

ii. Manufactured products; iii. Construction materials; or iv. Section 70917(c) materials.

categories. In some cases, an article, material, or supply may not fall under any of the categories listed in paragraph (b)(1) of this section. The classification of an article, material, or supply as falling into one of the categories listed in paragraph (b)(1) must be made based on its status at the time it is brought to the work site for incorporation into an infrastructure project. In general, the work site is the location of the infrastructure project at which the iron, steel, manufactured products, and construction materials will be incorporated.

the Buy America Preference for only the single category in which it is classified.

coating, for all steel or iron products permanently incorporated in the work shall have occurred in the United States of America. All manufacturing processes include the processes that change the raw ore or scrap metal into a finished steel or iron product.

106.11

The Contractor shall obtain and maintain on file Buy America certifications that every process from either the original smelting or melting operation, including the application of a coating, performed on steel or iron products either has or has not been carried out in the United States of America. These Buy America certifications apply to every steel and iron product that requires pre-inspection, pretesting, certified test results, or a certificate of compliance. Shipping invoices, bar lists, and mill test reports shall accompany the Buy America certifications. These Buy America certifications shall be obtained from each supplier, distributor, fabricator, and manufacturer that has handled each steel or iron product. These Buy America certifications shall create a chain of custody trail for every supplier, distributor, fabricator, and manufacturer that handled the steel or iron product and shall include certified mill test reports with heat numbers from either the original smelting or melting operation. Prior to the permanent incorporation or payment for the steel or iron products, the Contractor shall also provide a copy of these certifications to the Project Engineer. The Contractor shall allow the State, FHWA, and their representatives access to the Buy America certifications including supporting documentation upon request. The lack of these certifications will be justification for rejection of the steel or iron product.

Before the permanent incorporation into the project and before payment for steel or iron products, the Contractor shall also provide the following for every iron or steel product that is delivered:

certify in writing that the Contractor has received and reviewed the Buy America certifications and supplied them to the Project Engineer; the certification(s) and supporting documentation is on file and complies with the Buy America requirements; and the Contractor has submitted the required documentation to FHWA or other CDOT representatives.

a document that summarizes the date and quantity of all steel and iron material delivered to the project. This summary document shall include the pay item, quantity of material delivered to the project, delivered cost of the pay item, and the quantity of material installed by the monthly progress payment cutoff date. The summary document shall reconcile the pay item for the material delivered to the project to the Buy America certifications. The summary document shall also include the delivered cost of all foreign steel or iron delivered and permanently incorporated into the project, if applicable. The Contractor shall also submit a summary document for each month that no steel or iron products are incorporated into or delivered to the project. The Contractor shall submit the summary document to the Engineer by the monthly progress payment cutoff date.

The Contractor shall obtain and maintain on file Buy America certifications that every process from either the original smelting or melting operation, including the application of a coating, performed on steel or iron products either has or has not been carried out in the United States of America. These Buy America certifications apply to every steel and iron product that requires pre-inspection, pretesting, certified test results, or a certificate of compliance. Shipping invoices, bar lists, and mill test reports shall accompany the Buy America certifications. These Buy America certifications shall be obtained from each supplier, distributor, fabricator, and manufacturer that has handled each steel or iron product. These Buy America certifications shall create a chain of custody trail for every supplier, distributor, fabricator, and manufacturer that handled the steel or iron product and shall include certified mill test reports with heat numbers from either the original

106.11

smelting or melting operation. Prior to the permanent incorporation or payment for the steel or iron products, the Contractor shall also provide a copy of these certifications to the Project Engineer. The Contractor shall allow the State, FHWA, and their representatives access to the Buy America certifications including supporting documentation upon request. The lack of these certifications will be justification for rejection of the steel or iron product.

This requirement will not prevent a minimal use of foreign steel or iron, provided the total cost, including delivery to the project, of all such steel and iron products does not exceed 1/10 of one percent (i.e., 0.1%) of the total contract cost or $2,500, whichever is greater. When there is foreign steel or iron permanently incorporated into the project, the Contractor shall provide documentation of the project delivered cost of that foreign steel or iron to the Project Engineer.

https://www.fhwa.dot.gov/construction/contracts/831125.cfm) waive the application of Build America, Buy America requirements for manufactured products that do not include steel and iron components. However, Buy America requirements apply to steel or iron components of manufactured products (i.e. steel wire mesh or steel reinforcing components of precast reinforced concrete products).

pavement marking shall have been manufactured from North American glass waste streams in the United States of America. The bead manufacturer shall submit a COC in accordance with subsection 106.12 confirming that North American glass waste streams were used in the manufacture of the glass beads.

following construction materials incorporated into infrastructure projects. Each listed construction material is followed by material-specific manufacturing process criteria that is necessary to be considered “produced in the United States.”

through final shaping, coating, and assembly, occurred in the United States;

building materials, and polymers used in fiber optic cables). All manufacturing processes, from initial combination of constituent plastic or polymer-based inputs, or, where applicable, constituent composite materials, until the item is in its final form, occurred in the United States;

melting of raw materials through annealing, cooling, and cutting, occurred in the United States. See section 106.11(d) of the CDOT Specifications for additional requirements related to glass beads for pavement marking;

ribboning (if applicable), through buffering, fiber stranding and jacketing, occurred in the United States. All manufacturing processes also include the standards for glass and optical fiber, but not for non-ferrous metals, plastic and polymer-based products, or any others;

through the completion of the draw, occurred in the United States;

106.11

planing, occurred in the United States;

constituent materials until the wood product is in its final form, occurred in the United States; and

plaster and additives through cutting and drying of sandwiched panels, occurred in the United States.

Except as specifically provided, only a single standard under paragraph (f) of this section should be applied to a single construction material.

Before the permanent incorporation into the project and before payment for all eligible construction materials, the Contractor shall obtain a certification from each supplier, distributor, fabricator, and manufacturer that has handled the construction material and submit it to the Project Engineer. This certification shall identify that every material- specific manufacturing process as listed above either has or has not been carried out in the United States of America and shall attest specifically to Build America, Buy America compliance.

In the case that eligible construction materials are permanently incorporated into the project, the Contractor shall maintain and submit on a monthly basis, CDOT Form #1600, Contractor’s Certificate of Compliance summarizing the Item Description, CDOT Bid Item Number, Manufacturer Name, Date, and Quantity Received, Date and Quantity Installed, Bid Item Unit, and delivered cost of all eligible construction materials. The completed Form #1600(s) shall be kept in the project files and shall be submitted as part of the material final documentation package.

In the case that no eligible construction materials are permanently incorporated into the project, the Contractor shall maintain and submit on a monthly basis, CDOT Form #1610, Non-Applicable Projects: Build America, Buy America (BABA), certifying that no construction materials subject to Build America, Buy America requirements as defined in this section will be permanently incorporated into the project. The completed Form #1610(s) shall be kept in the project files and shall be submitted as part of the material final documentation package.

Form #1600 or Form #1610 does not relieve the Contractor of providing the necessary Build America, Buy America supplier certifications prior to permanent incorporation into the project or before payment for the material. The Contractor shall allow the State, FHWA, and their representatives access to the Buy America and Build America, Buy America certifications and supporting documentation upon request. The lack of these certifications will be justification for rejection of the construction material.

This requirement will not prevent a minimal use of foreign construction materials, provided the total cost of non-compliant materials, including delivery to the project, of all such construction materials does not exceed $1,000,000 or five percent of the total applicable project costs, whichever is lesser. Total applicable project costs are defined as the cost of materials (including the cost of any manufactured products) used in the project that are subject to Buy America and/or Build America, Buy America requirements. When there are foreign construction materials permanently incorporated into the project, the Contractor

106.12

shall provide documentation of the project delivered cost of the non-compliant materials to the Project Engineer before permanent incorporation or payment. Form #1600 shall be used to track the total applicable project cost of all materials subject to Buy America and/or Build America, Buy America requirements. The foreign construction material minimal use threshold percentage of five percent shall not be exceeded in any given month.

such as stone, sand, or gravel; and aggregate binding agents or additives are not subject to Build America, Buy America requirements.

and approving all waivers, including waivers requested by recipients and on behalf of subrecipients. More information on Buy America waivers can be found in the Field Materials Manual Special Notice to Contractors.

If a Contractor desires to pursue a waiver they shall notify the CDOT Project Engineer in writing who will then submit it to the CDOT Materials & Geotechnical Services Unit, Pavement Design and Documentation Services Program. The Pavement Design and Documentation Services Program will review it and forward it to the FHWA Division Office for consideration.

A Contractor’s decision to pursue any waivers on the project shall not waive or otherwise nullify any provisions of the Contract. In addition, the time to obtain a waiver shall be considered a non-excusable, non-compensable delay and Liquidated Damages (per Subsection 108.09) will be enforced should the Contract Time (original or as amended) expire due to the approval or non-approval of a waiver.

The Contractor will not be entitled to an extension of contract time due to the approval or non-approval of a waiver and no such claim will be considered.

106.12Certificates of Compliance. The Contract will designate products and assemblies

that can be incorporated in the work, if accompanied by Certificates of Compliance. The Certificate of Compliance shall be a legible copy or an original document from the manufacturer, and shall include, under penalty of perjury, the original or electronic signature (including corporate title) of a person having legal authority to act for the manufacturer. It shall state that the product or assembly to be incorporated into the project has been sampled and passed all specified tests in conformity to the plans and specifications for the project.

The Contractor’s original signature and certification shall be added to the manufacturer’s document, as directed below.

Each certificate shall include:

106.12

product or assembly. Certificates shall reference the actual tests conducted on samples taken from the same lot, heat, or batch, and shall include a statement that the product or assembly to be incorporated into the project was fabricated per and meets the applicable specifications.

The Contractor shall certify and sign the manufacturer’s original Certificate of Compliance as directed below. The quantity certified by the Contractor shall be that which has been delivered to the project at that time and is represented by that COC. For products with multiple delivery dates, multiple Certificates of Compliance will be required. One legible copy of the fully signed Certificate of Compliance shall be furnished to the Engineer before installation of material. The original shall be provided to the Engineer before payment for the represented item will be made. Both the legible copy and the fully signed Certificate of Compliance shall include the Contractor’s certification and signature. Each product or assembly delivered to the project must contain the lot, heat, or batch number identical to that on the accompanying Certificate of Compliance.

The following certification, signed by a person having legal authority to act for the Contractor:

I hereby certify under penalty of perjury that the material listed in this Certificate of Compliance represents __________ (quantity and units) of pay item __________ (pay item number and Description) that will be installed on project number __________________. _________________________ __________________ Contractor and Date

Failure to comply with the above requirements may result in delays to the project or rejection of the materials. Products or assemblies furnished on the basis of Certificates of Compliance may be sampled and tested by the Department, and if determined not to meet the applicable specifications will be rejected or accepted according to subsection 105.03.

106.13

106.13Certified Test Report. The Contract will designate products and assemblies that can be

incorporated in the work if accompanied by Certified Test Reports. The Certified Test Report shall be a legible copy or an original document from the manufacturer, and shall include, under penalty of perjury, the original or electronic signature (including corporate title) of a person having legal authority to act for the manufacturer or the independent testing laboratory. It shall state that the test results show that the product or assembly to be incorporated into the project has been sampled and passed all specified tests in conformity to the plans and specifications for this project. Each report shall include:

Each certificate shall include:

Department specifications. Test results shall be from tests conducted on samples taken from the same lot, heat, or batch.

The Contractor shall certify and sign the manufacturer’s original Certified Test Report as directed below. The quantity certified by the Contractor shall be that which has been delivered to the project at that time and is represented by that Certified Test Report. For products with multiple delivery dates, multiple Certified Test Reports will be required. One legible copy of the fully signed Certified Test Report shall be furnished to the Engineer before installation of material. The original shall be provided to the Engineer before payment for the represented item will be made. Both the legible copy and the fully signed Certified Test Report shall include the Contractor’s certification and signature. Each product or assembly delivered to the project must contain the lot, heat, or batch number identical to that on the accompanying Certified Test Report.

The following certification, signed by a person having legal authority to act for the Contractor:

I hereby certify under penalty of perjury that the material listed in this Certified Test Report represents __________ (quantity and units) of pay item __________ (pay item number and Description) that will be installed on project number __________________. _________________________ __________________ Contractor, Date

Failure to comply may result in delays to the project or rejection of the materials. Products or assemblies furnished on the basis of Certified Test Reports may be sampled and tested by the Department, and if determined not to meet the applicable specifications will be rejected or accepted according to subsection 105.03.

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107.01