1902 - QUALITY CONTROL PROGRAM FOR PRECAST CONCRETE PRODUCTS
1900-3 (3) Two lift holes, not exceeding 4 inch es in diameter, will be permitted in each section. After placement,
fill lift holes with a suitable concrete mortar , unless directed otherwise by the Engineer.
d.Manholes, Inlets, and Boxes for Storm Water Drainage . Fabricate manholes, inlets, and boxes for storm water drainage complying with the KDOT approved shop drawings, including rein forcement, ab sorption, and concrete strength.
e.Manholes, Inlets, and Boxes for Sanitary Sewer Drainage. Fabricate manholes, inlets, and boxes for sanitary sewer drainage complying with the KDOT approved shop drawings and ASTM C 478. 1902.3 TEST METHODS
a.The following current test methods and property requirements, AASHTO or the ASTM equivalent are to be applied to procedures refe renced in this specification.
1.AASHTO T-22, “Compressive Strength of Cylindrical Concrete Specimens.” Apply the single operator precision statement for field conditions from ASTM C-39.
2.AASHTO T-23, “Making and Curing Co ncrete Test Specimens in the Field.”
3.AASHTO T-24, “Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.”
4.AASHTO T-119, “Slump of Hydraulic Cement Concrete.”
5.AASHTO T-121, “Weight per Cubic Foot, Yield and Air Content (Gravimetric) of Concrete.”
6.AASHTO R-39, “Making and Curing Concrete Test Specimens in the Laboratory.” (7) AASHTO T-196, “Air Content of Freshly Mixed Concrete by the Volumetric Method.”
8.AASHTO T-152, “Air Content of Freshly Mixed Co ncrete by the Pressure Method.” Not applicable, without special calibration, in the following conditions: Slump ≤ 2 inches. A mid-range or high-range water-reducer is used. An air-entraining agent other than a vinsol resin is used. Non-plastic concrete such as commonly used in the manufacture of pipe and concrete masonry units.
9.AASHTO T-231, “Capping Cylindrical Concrete Specimens.” For unbonded neoprene caps, ASTM C- 1231, “Use of Unbonded Caps in Determination of Compressive Strength of Hardened Concrete Cylinders.”
10.ASTM C-497, “Concrete Pipe, Manhole Sections, or Tile.” (Suggested minimum amplitude of 5 mils.)
11.ASTM C 1567, “Determining the Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accel erated Mortar-Bar Method).”
12.Kansas Test Method KTMR-29, “Wetting and Drying Test of Steam Cured Reinforced Concrete Pipe with Fly Ash.”
b.Cylinders are to be 4 X 8-inch, however 6 X 12-inch cylinders will also be approved.
c.Compressive strength testing of a minimum of three 28-day laboratory cured cylinders is required for each mix design of a producer. The five lo t moving average will apply to each mix design.
d.Cure optional shipping strength cylinders under the same conditions as the product they represent. Test a minimum of 2 cylinders for shipping strength at the same age. Attain a minimum of 80 percent of the specified 28-day compressive strength for the pro duct on each cylinder before shipping. These products are still subject to the requirements of this section and final approval at the project site. Note in the monthly report which products are shipped after 28 days of age, therefore not requiring shipping strength data. When shipping strength cylinders are utilized, a minimum of 1 set is to be produced at the same time period and from the same concrete batch as the 28-day comp ressive strength cylinders. Additional shipping strength cylinders may be produced at other times from different concrete batches and tested if desired. Submit all shipping strength data to KDOT and provide availability to the inspector at the production site.
e.Whether internal or external to the producing facility, the individuals conducting quality control sampling and testing for all producers are to be certified by ACI, or a KDOT approved equivalent, in the appropriate method(s) of sampling and testing, or the laboratory must be AASHTO accredited. Provide copies of the certifications to KDOT. Notify KDOT within 2 months of any changes in certification status or QC testing personnel. 1902 - QUALITY CONTROL PROGRAM FOR PRECAST CONCRETE PRODUCTS 1900-4
f.KDOT reserves the right to require the producing facility hire a laboratory to perform verification sampling and testing for KDOT, with all associated cost s paid for by the producing facility. All laboratories performing verification sampling and testing must be accred ited by AASHTO for all the accreditation available test methods shown in subsection 1902.3 . In addition, all laboratories performing verification sampling and testing must be approved by KDOT, and must report all test results directly to KDOT. 1902.4 PRODUCER PREQUALIFICATION
a.Becoming Prequalified.
1.Notify KDOT of desire to prequalify. Produce 5 lots of concrete that would be used on KDOT products. Provide 28-day compressive strength test data fo r all 5 lots. Allow KDOT to sample and test 1 of the 5 lots. This sample will be a split sample, with KDOT and Producer testing essentially the same product. The maximum variation between the average of the Producer’s 5 lots and KDOT’s test results is 10%.
2.Demonstrate that all highway and bridge construction industry related products manufactured at each facility are produced under a Quality Control Program. Present a Quality Control Plan to the Bureau Chief of Construction and Materials for evaluation and disposition. The plan must provide the following information as the minimum requirements: Name and location of the producer's facility. Name, telephone number, level of authority (organizational chart), and qualifications of the persons and alternates directing quality control at the facility. One of these individuals must be present during production at the facility. The name and location of the laboratory, whether internal or external to the facility, conducting the quality control testing for th e producer. A listing of any accreditatio n of the laboratory as well as the frequency of NIST traceable equipment calibrations is required. Except as described in subsection 1902.4a(4) , a lot is defined as the production from each mix design during the 7 consecutive day period beginning Sunday and ending Saturday of each week. Test 1 lot from each mix design used at the facility during th is 7-day period. Lot size is 7 consecutive days regardless of the size or type of product or whether the mix is used only once during that 7-day period or each of the 7 days. List the QC tests to be performed, including which tests are used for shipping strength. Define the method for obtaining random samples for each test and the number of samples to be tested per lot. The frequency of submitting quality control summary reports. This is not to be less than 1 report per month.
3.The program will be reviewed, an d if found acceptable, the producer's facility will be placed on a list of prequalified precast product sources maintained by the Bureau of Construction and Materials.
4.Upon approval by the Engineer, Producers that demonstrate a continually low monthly production rate, or do not continually provide products to KDOT may base their lots on a per unit basis, not to exceed 1 month. Producers of manholes, inlets, boxes and other project specific products that choose this option must notify the Bureau of Construction and Materials when producing K DOT products. KDOT may also choose to decrease the frequency of verification sampling, testing and production monitoring for any Producer.
b.Maintaining Prequalified Status.
1.Monitor on a lot by lot basis for each mix design or product the 5 lot moving average of compressive strength, tX; the n - 1 weighted standard deviation of the 5 test values used to determine the moving average, St; the quality index, QL; and the associated percent within limits (PWL) as referenced in the Terminology and Definitions. Notify KDOT of changes in mix designs, concrete materials sources, mixing equipment, or sources of concrete. Changes that significantly a ffect the control charts may constitute a new mix design and therefore require a new five lot moving average. Produce 5 successive lots complying with the minimum strength requirements for each new mix design. Selection of the production lot or test number, t is im portant since it determines the 5 test moving average. Since t is an integer, it is suggested that for the firs t lot, set t = 1, increment by 1 for each successive lot. A producer, at their option, may impose a more stringent quality control requirement than the five lot moving average. Inform KDOT as to the frequency of qu ality control testing, the PWL, the production quantity 1902 - QUALITY CONTROL PROGRAM FOR PRECAST CONCRETE PRODUCTS
1900-5 represented by the test or tests, other types of contro l monitoring such as attributes, variables, tracking and
traceability methods, etc. The Producer and KDOT must mutually agree upon this program. The frequency of sampling and testing may be decreased with the approval of KDOT if proficiency in maintaining the quality control of the products is demonstrated to the satisfaction of KDOT.
2.Clearly mark the lot when any single cylinder test value for that lot has a final strength of less than 85 percent of the specified minimum 28-day compressive strength. Clearly mark this material to prevent it from being included in a KDOT project and store it se parately from the ap proved material.
3.Comply with a 90 percent within limits (PWL) requirement relative to the minimum specified 28-day compressive strength for the 5 lot moving average. The Lower Spec Limit (LSL) for each product is that product's required 28-day compressive strength. Notify KDOT i mmediately whenever the 5 lot moving average falls below 90 PWL, and comply with the following. Produce 5 successive lots complying with the minimum strength requirements as agreed upon by KDO T and the Producer, and provide documentation that corrective action has been taken and that compliance has been reestablished.
4.Maintain optional control charts of tX, St; and PWL vs. test number t.
5.Display plant name, initials, or logo, date manufactured, AASHTO class when applicable, and size on all inventories. Clearly mark all prod ucts not intended for KDOT use. Main tain traceability of all products shipped to KDOT projects. (6) The producer's facility will be randomly visited to inspect the place ment of the steel and other necessary requirements fo r the project.
7.Provide KDOT with the current week's production schedule at the beginning of each week. Verification samples will be taken at a minimum of once every 5 lots for each product. This may include, but is not restricted to, any combination of cylinders, core samples, and, for pipe, 3-edge bearing tests. The same statistical parameters ( tX,St; and PWL) will be developed from th e verification test data of the cy linders. Under normal conditions, no more than 10 pieces of pipe per year will be tested to u ltimate strength when the 3-edge bearing test is used for verification testing.
8.A minimum of 5 of the KDOT's verification test re sults will be compared with the associated producer’s quality control tests through the F and t statistical test to determine if they represent the same population. Continual deviations will be rectified with the Producer.
9.Any unacceptable practices witnessed by KDOT pers onnel at the producer’s facility may result in loss of Prequalified Status if not corrected or eliminated after notification.
c.Terminology and Definitions. Refer to 5.2.1 in Part V for terminology and definitions concerning QC/QA and Statistical Analysis.
d.Monthly Report Requirements
1.Include the following information in the quality control summary reports. Clear and consistent identification of each mix design and test samples. Use only 1 producer defined lower specification limit for each mix design. The date the sample, product, or cylinders were produced and the dates tested for both shipping strength and 28-day compressive strengths of laboratory cured cylinders. Include documentation when products are not shipped before 28 days, therefore waving the shipping strength requirements. The load at failure, compressive strength, applicable correction factor, and co rrected strength, for each individual sample tested as per subsection 1902.3c . The statistical analysis of this data as described in subsection 1902.4b(1) and the optional control charts.
2.Do not send QC Reports for products that are not normally used in the highway and bridge construction industry.
3.Reports that are more than 2 months late will cause a loss of Prequalified Status for a 6-month period. Further delinquent reports may cause pe rmanent loss of Prequalified Status.
4.Make available the actual test data and reports, including shipping strength data, to the inspector at the production site. Test reports are to bear the names and signatures of the certified technicians or representative of the laboratory conducting the sampling and testing. For pre cast facilities that are performing their own QC testing, actual data records are to be initialed by the certified t echnicians conducting the testing. Make available for inspection the shipping reco rds for KDOT projects. 1902 - QUALITY CONTROL PROGRAM FOR PRECAST CONCRETE PRODUCTS
1900-6 1902.5 Basis of Acceptance
Delete the basis of acceptance in AASHTO M 170 , AASHTO M 206 and AASH TO M 207, and replace with the following:
a.Prequalification as required by subsection 1902.4.
b.Receipt and approval of a Type C certification as specified in DIVISION 2600 .
c.All products governed by this special provision are subject to final visual inspection for shipping damage, fit and other visual defects, and disposition when delivered to the project site.
d.Receipt and approval of a written statement from the producer certifying that iron and steel used in the production of all product delivered to the job site comp lies with all provisions of the Buy America Act. See subsection 106.1c. for a definition of “Buy America” materials. 1903 - CAST IRON AND DUCTILE IRON PIPE
1900-7 Section 1903
CAST IRON AND DUCTILE IRON PIPE 1903.1 DESCRIPTION This specification governs pipe, fittings, and accessory items produced from malleable, gray, or ductile (nodular) cast iron and intended for various piping system applications, including drainage systems. 1903.2 REQUIREMENTS
a.General . Provide pipe, fittings, and accessory item castings that comply with the design, dimensions, alloy designation and thermal treatment, requirement for su pplemental corrosion protection, and specific fabrication requirements as specified in the Contr act Documents. Provide co mpliant components of pipe systems that are open to atmospheric pressure complying with subsection 1903.2b . Provide compliant clos ed systems that can be pressurized with the specification(s) selected from AS TM A 377 that is (are) appropriate for the intended application. The selected specification(s) is (are) denoted in the Contract Documents.
b.Material Specifications . Provide compliant components of open systems complying with ASTM A 48 when produced from gray cast iron or ASTM A 536 when produced from duc tile cast iron. Accessory items may also be produced from ferritic malleable cast iron in comp liance with ASTM A 47. Provide compliant pipe, fittings, and accessory items for these piping systems with ASTM A 74. The mechanical property requirements of ASTM A 74 determine the class or grade of cast iron required. 1903.3 TEST METHODS Conduct all tests required by the applicable ASTM or other specification of subsection 1903.2b according to the procedures specifi ed in that standard. 1903.4 PREQUALIFICATION Not applicable. 1903.5 BASIS OF ACCEPTANCE Receipt and approval of a Type D certification as specified DIVISION 2600 . Inspection by field personnel of all products and components for compliance with dimensional and supplemental corrosion protection coating requirements when corrosion protection is specified, quality of workmanship, delivery condition, approval of the required associated documentation, and any other requirements as may be specified in the Contract Documents. 1904 - CORRUGATED METAL PIPE AND END SECTIONS
1900-8 Section 1904
CORRUGATED METAL PIPE AND END SECTIONS 1904.1 DESCRIPTION This specification governs corrugated steel pipe, arches, corrugated aluminum alloy pipe, arches, and the associated end sections and accessory items for use in drainage systems and other applications. 1904.2 REQUIREMENTS
a.General . Provide pipe, arches, end sections, and acce ssory items that comply with the design, dimensions, alloy designation and thermal treatment, requirement for supplemental corrosion protection, and specific fabrication requirements as specified or in the Cont ract Documents. The componen ts of pipe systems are to comply with subsection 1904.2b . The selected specification(s) is (are ) denoted in the Contract Documents.
b.Material Specifications.
1.Comply all corrugated steel (g alvanized and aluminized) pipe, pipe -arches, and accessory items with AASHTO M 36. Comply all steel sheet utilized to fabr icate the pipe and pipe-arc hes with AASHTO M 218 when zinc coated, or AASHTO M 274 when aluminum alloy coated. The type of pipe, and type and class of coating will be specified in the Contract Documents. Provide only continuous helical (lock or welded) seams. Do not interconnect components with differing coating types within a piping system.
2.Comply all corrugated aluminum alloy pipe, pipe-arches, and accessory items with AASHTO M 196. The type of pipe will be specified in the Contract Document s. Provide only continuous helical lock seams. Do not interconnect metal aluminum alloy pipe with metal steel pipe or accessory items except as permitted through M 196.
3.Repairs to the high frequency resistance welded (HFRW) seam in steel continuous welded helical corrugated metal pipe (CMP) are to be adherent to the following guidelines:
a.For pipes with a nominal diameter of 24 inches or greater, the maximum allowable total length of manual weld repair for the helical weld seam in a section of steel CMP is ½-inch of weld per 1- inch of nominal pipe diameter per 20 feet (or fraction thereof) of pipe section length.
b.For pipes with a nominal diameter of less than 24 inches, the maximum allowable total length of the manual weld repair referenced in (a) is 12 inches.
c.For pipes with a nominal diameter of 24 inches or greater, the maximum allowable length of a single weld repair for the helical weld seam in a section of steel CMP is 1/4 -inch of weld per 1- inch of nominal pipe diameter , not to exceed 18 inches.
d.For pipes with a nominal diameter of less than 24 inches, the maximum allowable length of the single weld repair referenced in (c) is 6 inches.
e.Do not space repair welds closer than 1 helix length of welded seam. One helix length is the distance traversed by a point on the weld seam during 1 revolution of the pipe.
f.Repair welds are not permitted within the re-r oll areas at the ends of a steel CMP section.
g.No visible discontinuities, e.g., hot or cold cracks, porosity, entrapped slag, voids, etc., are permitted within the total weld length, repair and coil splice welds included, of the finished section of steel CMP.
h.The preferred weld repair method is, but not restricted to, gas metal arc welding (GMAW). Any method that utilizes a ferrous based filler me tal compatible with th e parent coil steel and provides an acceptable repair weld is adequate. Weld repair without the us e of filler metal, such as by Gas Tungsten Arc Welding (GTAW) , is also acceptable when practical.
i.Minimize the number of plant co il splices within a section of steel CMP. This is subject to the judgment of the KDOT inspector and based on the steel CMP section size. In no instance is the number of coil splices to exceed 3 per steel CMP section.
4.Produce end sections from the same metal and provid e with the same coating as the pipe to which they are to be attached. Comply with the desi gn and dimension requirements as stated in subsection 1904.2a . However, the thermal treatment, denoted by the temper designatio n for aluminum alloys, must not reduce the ductility of the metal to the degree that forming tears or cracks occur during production of the end section. A section of CMP that is an integral component of the end section is subject to subsection 1904.2b . 1904 - CORRUGATED METAL PIPE AND END SECTIONS
1900-9 1904.3 Test Methods
Conduct all tests required by the applicable AASHTO, AS TM or other specification of subsection 1904.2b according to the procedures specified in that standard. 1904.4 PREQUALIFICATION Not applicable. 1904.5 BASIS OF ACCEPTANCE
a.Receipt and approval of a Type A certification as specified in DIVISION 2600 for all corrugated metal pipe (CMP) and the associated end sections and acces sory items provided thro ugh this specification.
b.Inspection, and testing when app licable, by field personnel of CMP and end sections and accessory items for compliance with corrosion protection coating thickness requirements when applicable, mechanical or welded seam quality, and dimensional requirements.
c.The final disposition of CMP and end sections an d accessory items will be completed at the final destination as the result of inspectio n for the quality of workmanship, th e delivery condition, and receipt and approval of the associated required documentation. Corrugated metal pipe and end sections and accessory items may also require inspection during the production process at the fabrication facility. 1905 - STRUCTURAL PLATE FOR PIPE, PIPE ARCHES, AND ARCHES
1900-10 Section 1905
STRUCTURAL PLATE FOR PIPE, PIPE ARCHES, AND ARCHES 1905.1 DESCRIPTION This specification governs the steel and aluminum alloy structural plat e and accessory items utilized in the construction of pipe, pipe arches, and arches. 1905.2 REQUIREMENTS
a.General . Provide pipe, pipe arches, arches, and acce ssory items that comply with the design, dimensions, alloy designation and thermal treatment, requirement for supplemental corrosion protection, and specific fabrication requirements as sp ecified in the Contract Documents. Comply with AASH TO LRFD Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications. Properly form the components required to construct th ese units to facilitate and expedite their assembly. When the end of an assembly is required by the Contract Documents to comply with the finished fill slope angle; precut the end components so the end of the assembled unit complies with this indicated angle.
b.Material Specifications .
1.Provide compliant components and accessory items pr oduced from steel metal for pipe, pipe arches, and arches with AASHTO M 167.
2.Provide compliant components and accessory items pr oduced from aluminum alloy metal for pipe, pipe arches, and arches w ith AASHTO M 219.
3.Do not interconnect steel metal components and accessory items with aluminum alloy metal components and accessory items except as permitted th rough the specifications previously referenced. 1905.3 TEST METHODS Conduct all tests required by the applicable AASHTO, AS TM or other specification of subsection 1905.2b according to the procedures specified in that standard. 1905.4 PREQUALIFICATION Not applicable. 1905.5 BASIS OF ACCEPTANCE
a.Receipt and approval of a Type A certification as specified in DIVISION 2600 for all steel and aluminum alloy components and accessory items utilized in the construction of pipe, pipe arches, and arches.
b.Inspection, and testing when app licable, by field personnel of th e components and accessory items for compliance with corrosion protection coating thickness requir ements when applicable, place ment of fastener holes, uniformity of corrugations, dimensional requirements, and any other specification requirements considered pertinent to the construction of the final product.
c.The final disposition of all steel and aluminum alloy components and accessory items utilized in the construction of pipe, pipe arches, and ar ches will be completed at the final destination as the result of inspection for the quality of workmanship, the de livery condition, and receipt and appr oval of the associated required documentation. Inspection durin g the production process of components an d accessory items at the manufacturing or fabrication facility may also be required. 1906 - ASPHALT COATED CORRUGATED METAL PIPE, PIPE ARCHES, COUPLING BANDS AND STRUCTURAL PLATE
1900-11 Section 1906
ASPHALT COATED CORRUG ATED METAL PIPE, PIPE ARCHES, COUPLING BANDS AND STRUCTURAL PLATE 1906.1 DESCRIPTION This specification covers asphalt co ated corrugated metal pipe, pipe arches, coupling bands and structural plate. The following four t ypes of treatments are included: Type A. Fully Asphalt Coated Type B. Half Asphalt Coated with Paved Invert Type C. Fully Asphalt Coated with Paved Invert Type D. Fully Asphalt Coated and 100%t Paved or Lined 1906.2 REQUIREMENTS
a.Provide “Type A” coated pipe unless otherwise specified in the Contract Documents.
b.Supply asphalt coated corrugated metal pipe, pipe arches, coupling bands and structural plate complying with AASHTO M 190 with the following revisions or additions:
1.Asphalt coat only corrugated metal pipe, pipe arches, coupling bands and structural plate that comply with the applicable SECTIONS 1904 and 1905 .
2.Do not apply the Imperviousness Test in AASHTO M 190.
c.As an alternate, coat corrugated structur al plate in accordance with AASHTO M 243. 1906.3 TEST METHODS Test in accordance with the methods shown in AASHTO M 190 and/or M 243. 1906.4 PREQUALIFICATION None Required 1906.5 BASIS OF ACCEPTANCE Asphalt coated corrugated metal pipe, pipe arches, coupling bands and structural plates are accepted based on receipt and approval of a Type D certification as specified in DIVISION 2600 and visual inspection for conditions and dimensional requirements. 1907 - PLASTIC PIPE FOR UNDERDRAINS, OUTLETS AND DRAIN TILE
1900-12 Section 1907
PLASTIC PIPE FOR UNDERDRAINS, OUTLETS AND DRAIN TILE 1907.1 DESCRIPTION This specification covers polyvinyl chloride (PVC) pipe for use in underdrain, pavement edge drain, and outlet installations. Polyethylene (PE) is also permitted for edge drains. 1907.2 REQUIREMENTS
a.Underdrain Pipe . Provide perforated polyethylene or polyvinyl chloride underdrain pipe and fittings in the diameter shown in the Contract Do cuments that complies with ASTM F 891 for polyvinyl chloride, except the minimum pipe stiffness required is 100 psi, at 5% deflection, for PVC pipe.
b.Outlet Pipe . Provide a smooth interior walled pipe in the diameter shown in the Contract Documents that complies with ASTM F 891 for polyvinyl chloride, except the minimum pipe stiffness required is 100 psi, at 5% deflection, for PVC pipe.
c.Drain Tile . Provide perforated polyethylene drain tile and fittings in the diameter shown in the Contract Documents that complies with AASHTO M 252 or M 294 for perforated polyethylene pipe. 1907.3 TEST METHODS Test pipe supplied for this specification according to the procedures referenced and outlined in AASHTO M 252, AASHTO M 294, and ASTM F 891. 1907.4 PREQUALIFICATION None Required. 1907.5 BASIS OF ACCEPTANCE Receipt and approval of a Type D certification as specified in DIVISION 2600. Visual inspection for conditions and dimensional requirements. 1908 - POLYETHYLENE (PE) PIPE
1900-13 Section 1908
POLYETHYLENE (PE) PIPE 1908.1 DESCRIPTION This specification covers polyethylene pipe for storm sewers and culverts. 1908.2 REQUIREMENTS
a.Polyethylene Pipe. Provide polyethylene (PE) pipe for stor m sewers and culverts that complies with one of the following:
1.AASHTO M 294 (Corrugated Pipe) with the following additions or exceptions: Only Type S is acceptable. Rotational Molded Pipe will not be accepted.
2.ASTM F 894 (Ribbed, Profile) with the following additions or exceptions: AASHTO LRFD Bridge Design Specifications, SECTION 12, 50 year life requirements. Minimum Cell Class per ASTM D 3350 of 334433C or 335434C. Minimum section properties as noted in SECTION 12.
3.ASTM F 714 (Smooth Wall) with the following additions or exceptions: A DR of 21 or less will be required. AASHTO LRFD Bridge Design Specification, SECTION 12, 50 year life requirements. Minimum Cell Class per ASTM D 3350 of 335434C.
4.Soil tight joints are required (AASHTO LRFD Bridge Construction Specifications, SECTION 26). Maximum opening is 1 inch. For openings over 1/8-inch, exceed the channel length by four times the length of the opening. Channel length is the length of the path that the soil must infiltrate. The D 85 soil size to size of opening ratio must be 0.3 for medium to fine sand and 0.2 for uniform sands. D 85 is the sieve size that 85% of the backfill material is smaller than.
b.Joints. To obtain soil tight joints, manufacture the pipe joints to comply with the following: Maximum opening is 1 inch. For openings over ⅛-inch, exceed the channel length by 4 ti mes the size of the opening. Channel length is the length of the path that the soil must infiltrate.
c.End Sections. Provide culvert end sections that comply with the sizes and dimensions in the Contract Documents. Fabricate end sections fr om materials that comply with these specifications. Corrugated metal or concrete end sections are also acceptable. Connect dissi milar materials using a soil-tight connection approved by the Engineer.
d.Deflection . Maximum deflection (reduction of the barrel base inside diameter) is 5%. Measurement will be made using a mandrel or other method as approved by the Engineer not less than 30 days following the installation. Deflections in excess of 5% may require th e pipe to be removed and reinstalled, or replaced if permanently deformed or damaged in any way. 1908.3 TEST METHODS Test materials in accordance with th e AASHTO and ASTM standards cited in subsection 1908.2 . 1908 - POLYETHYLENE (PE) PIPE
1900-14 1908.4 Prequalification
Follow the instructions on the AASHTO National Transportation Product Evaluation Program’s (NTPEP) website to participate in the audit program for polyethylene (PE) pipe plants. Forward an official copy of the initial (and latest) NTPEP audit report to the Bureau Chief of Construction and Materials for evaluation. Include copies of the mo st recent six months of quality control test results. In order to maintain prequalified status, send a copy of the annual NTPEP certifi cate of compliance as soon as it is received. Plants that have been removed from the NTPEP website listing will be removed from prequalified status. Plants that fail to provide the annu al certificate of compliance or are no longer in compliance with the audit requirements may be removed from prequalified status. 1908.5 BASIS OF ACCEPTANCE Prequalification as specified in subsection 1908.4 . Receipt and approval of a Type C certification as specified in DIVISION 2600 . Visual inspection for condition and dimensional requirements. Successful testing with a mandrel as outlined in subsection 817.3b . 1909 - POLYVINYL CHLORIDE (PVC) PIPE
1900-15 Section 1909
POLYVINYL CHLORIDE (PVC) PIPE 1909.1 DESCRIPTION This specification covers polyvinyl chloride pipe (PVC) for storm sewers and culverts. 1909.2 REQUIREMENTS
a.Polyvinyl Chloride Pipe . Provide polyvinyl chloride (PVC) for storm sewers and culverts that comply with one of the following:
1.AASHTO M 304 (Profile Wall) with the following additions or exceptions: Seamless construction will be required; sp iral wound pipe will not be allowed. ASTM D 1784, use only Cell Classification of 12454C.
2.AASHTO M 278 (Smooth wall), or ASTM F 679 (Large Diameter Sewer Pipe). ASTM D 1784, use only Cell Classification of 12454.
b.Joints. To obtain soil tight joints, manufacture the pipe joints to comply with the following: Maximum opening is 1 inch. For openings over ⅛-inch, exceed the channel length by 4 ti mes the size of the opening. Channel length is the length of the path that the soil must infiltrate.
c.End Sections. Provide only corrugated metal or precast concre te end sections that comply with the sizes and dimensions in the Contract Documents, and applicable SECTION 1902 or 1904 . Connect the dissimilar materials using a soil tight connection approved by the Engineer. 1909.3 TEST METHODS Test materials in accordance with th e AASHTO and ASTM standards cited in subsection 1909.2 . 1909.4 PREQUALIFICATION Follow the instructions on the AASHTO National Transportation Product Evaluation Program’s (NTPEP) website to participate in the audit program for polyvinyl chloride (PVC) pipe plants. Forward an official copy of the initial (and latest) NTPEP audit report to the Bureau Chief of Construction and Materials for evaluation. Include copies of the mo st recent six months of quality control test results. In order to maintain prequalified status, send a copy of the annual NTPEP certifi cate of compliance as soon as it is received. Plants that have been removed from the NTPEP website listing will be removed from prequalified status. Plants that fail to provide the annu al certificate of compliance or are no longer in compliance with the audit requirements may be removed from prequalified status. 1909.5 BASIS OF ACCEPTANCE Prequalification as specified in subsection 1909.4 . Receipt and approval of a Type C certification as specified in DIVISION 2600 . Visual inspection for condition and dimensional requirements. Successful testing with a mandrel as outlined in subsection 817.3b . 2001 - PORTLAND CEMENT AND BLENDED HYDRAULIC CEMENT
2000-1 Section 2001
PORTLAND CEMENT AND BLEN DED HYDRAULIC CEMENT 2001.1 DESCRIPTION This specification governs the requirements for portland and blended hydraulic cement utilized in the production of concrete. 2001.2 REQUIREMENTS
a.General. Cement types are to be designated according to the classifications of AASHTO M 85 for portland and AASHTO M 240 for blended cement. Utilize Type I, IP(x), IS(x), IT(Ax)(By), II(MH), or III cement as allowed in SECTION 401 . The “x” and “y” in the previous sentence equals the targeted percentage of pozzolan or slag cement in the product expressed as a whole number by mass of final blended product. Likewise , “A” and “B” are either “S” for slag cement or “P” for pozzolan with “A” being the larger mate rial by mass and “B” the smaller. A cement type and source must be prequalified before it can be utilized in KDOT projects. Cements of differing types and or sources cannot be intermixed within any singular component of a structure. A contractor must have moisture protective facilities to store the cement required for 3 active construction days. The Engineer’s representative may waive this requ irement if it is determined that a well-regulated supply from the cement producer can be mainta ined. Any cement that has been contam inated by moisture or reclaimed by any method is not acceptable. Previously approved cement bulk stored at the source plant or terminal for over 6 months or in bulk or packaged and stored at a contractor or distributor facility fo r over 3 months after the initial test date is subject to re- sampling, testing, and the requirements of this subsection. Cement stored at facilities, other than those described in the foregoing, before the initiation of construction or delivered to such facilities during construction of KDOT pr ojects is to be sampled and tested and is subject to the requirements of this Section. This requirement may be waived if certifications documenting that the cement is a prequalified type from a prequalified source are provided to the Engineer's representative.
b.Portland Cement. Provide Type I, Type II(MH), and Type III portland cement that comply with all applicable requirements (including the optional chemical and physical requirements, annexes, and appendices) of AASHTO M 85, except as modified by the following: (1) The time of setting may be determined by use of the Gillmore needles met hod (AASHTO T 154), or the Vicat needle method (AASHTO T 131). Identify which method is being used on the report. KDOT will test using the Gillmore method. (2) Optimized SO 3 – Provide supporting expansion data whenever SO 3 results exceed the requirements stated in AASHTO M 85, Table 1.
3.If processing additions are used, report the perc entage, composition, and the source of the additions in writing to KDOT.
4.Heat of hydration requirements as stated in AASHTO M 85, Table 4 will not be enforced.
c.Blended Hydraulic Cement . Supply blended hydraulic cements Type IP(x), Type IS(x), and Type IT(Ax)(By) that comply with AASHTO M 240 except as modified by the following:
1.Provide a written statement specifying the proportions and materials being blended to produce the blended hydraulic cement, and that the amount of pozzolan or slag cement in the finished cement will not vary more than ± 5.0% by weight of the finished cement from lot to lot or within a lot.
2.Report the amount retained on the No. 325 sieve, and the fineness by the air permeability method in accordance with the procedures specified in ASTM C 204 at the time of shipment.
3.Mortar expansion of the finished cement must be within the limits included in Table 2 of AASHTO M240 or the job specific mixture requirements in subsection 2001.2d.(1)(d).
4.The equivalent alkalis, as de fined in Table 2 of AASHTO M 85, may not exceed 1.5% in any application. For prequalification, or to increase the equivalent al kalis above current production levels, submit results from ASTM C 441 testing showing mortar expansion within the limits in Table 2 of AASHTO M 240 for the maximum 2001 - PORTLAND CEMENT AND BLENDED HYDRAULIC CEMENT
2000-2 equivalent alkalis level intended for production. Submit a sa mple to the Engineer of Tests for verification testing.
Monthly quality control test reports will be monitored to verify the equivalent alkalis level of regular production remains below this maximum level. If production at a hi gher level is desired, co mplete requalification which establishes a new maximum limit will be required.
d.Field Blended Cements.
1.Cements for use in concrete that are blended in the field by substituting any pozzolan or slag cement for portland cement whether in the mixer or otherwise, must comply with the following:
a.Provide a written statement specifying the proportions and materials being blended to produce the total cementitious content, and that the amount of pozzolan or slag cement will not vary more than ± 1.0% by weight of the total cement from batch to batch.
b.Use portland cement or blended hydraulic cement from sources prequalified under this specification.
c.Use pozzolan or slag cement from approved or prequalified sources.
d.Test and provide project mix design results complying with SECTION 401 .
e.Concrete made with these mixtures is subject to strength and other requirements detailed in other parts of the specifications.
2.Silica fume, which is specified elsewher e, is excluded from the requirements in subsection 2001.2d.(1) .
3.Refer to SECTION 401 for more specific information regarding the substitution of any pozzolan or slag cement for portland cemen t as a field blended cement. 2001.3 TEST METHODS Conduct all tests required by the applicable AASHTO, ASTM or other specifications of subsection 2001.2 according to the procedures specified in that standard. Field sample cement in accordance with the procedures of Part V, KT-29. Obtain all other cem ent samples in accordance with the requirements an d procedures of ASTM C 183. 2001.4 PREQUALIFICATION
a.Becoming Prequalified.
1.Submit the following to the Engineer of Tests:
a.A copy of the quality control plan for the source. The plan should include information on what cement types are produced, where and how sampling is done, frequency, and what standards (AASHTO, ASTM, et c.) are applied.
b.A 2-gallon sample of each cement type produ ced by the source and permitted through this Section that is representative of the pro duct intended for use on KDOT projects.
c.Certified quality control test results of cement, by type, that was produced by the source during the 6 months immediately before the prequalification request. Provide the high, low and average values or statistical analysis for each month.
d.Documentation of the sour ce nominal cement production levels, by quantity of each type produced, for the 6 months preced ing the prequalification request.
e.Documentation of routine Cement and Concrete Reference Laboratory (CCRL) inspection of the source laboratory performing the cement quality control testing. Include the results of the most recent evaluation.
f.The names of the individuals responsible for the quality control for cement production at the source.
2.Submit monthly quality control reports for all prequalified cement Types within 2 weeks after completion of testing. Include supporting expansion data whenever SO 3 results exceed the requirements stated in AASHTO M 85, Table 1. Also include a summary of the amount, composition, and source of all processing additions used for each type of cement manufactured during the month. If none were used, report that fact also.
3.Prequalification of a cement source, by type, w ill be based on cement produced when the source is utilizing specific materials, equipment and processes. Any change in materials, materials sources, equipment or processes voids the source prequalification, and a new prequalifica tion will be required. 2001 - PORTLAND CEMENT AND BLENDED HYDRAULIC CEMENT
2000-3 b. Maintaining P requalified Status. After a cement source has acquired prequalified status, the source
will be permitted to provide cement, by prequalified type, for use on KDOT projects provided the following conditions are complied with:
1.The quality-monitoring program meets the minimum sampling and testing frequencies established in ASTM C 183. This frequency may be altered somewhat with the approval of the Bureau Chief, Construction and Materials.
2.Submit monthly quality control reports for a ll prequalified cement types within 2 weeks after completion of the testing. Include a summary of the amount, composition and source of all process additions used under ASTM C 465 for each type of cement manufactured during the month. If none were used, report that fact also. (3) Utilize an approved laboratory to conduct quality control tests. The laboratory will be considered approved if it is properly equipped, has the capabilities to perform the tests required through this subsection and is routinely inspected through the CCRL program. Continued approval of the control laboratory and the source, by cement type, will depend on satisfactory comparison of its te st results with the results obtained by the Materials and Research Center on random verification samples of cement produced by the source. (4) The source has not changed materials, material sources, equipment, or processes since prequalification. 2001.5 BASIS OF ACCEPTANCE
a.Prequalification as specified in subsection 2001.4 .
b.A proper certification must accompan y each shipment of cement. Provide a copy of the bill of lading which includes the following certification statement and th e signature of a responsible source representative to the Field Engineer responsible for the project. Certification Statement The material herein has been sampled and test ed as prescribed by KDOT and complies with the applicable specification requirements fo r Type __ cement in ac cordance with the requirements of AASHTO . Date________________ Signed_______________________________ If a processing addition is used in the manufacture of the cement, include the following as a part of the certification statement: A processing addition, consisting of __% of ______________ and complying with the requirements of AASHTO M 85, has been used in the manufacture of this cement.
c.Identify the bills of lading with a project number, and denote the cement source, the type, and the quantity in the shipment. Retain this copy at the project or Contractor or distributor facility for the Engineer's representative’s records.
d.In the case of more than one project being supplie d by a contractor or distributor facility, the facility must provide the Engineer's representative either a copy of the bill of lading, or a signed listing of the bills of lading representing the cement, by type and so urce, incorporated into each project. Note: Verification samples will be obtained by KDOT pers onnel at the project site. Test results that do not comply with the specifications of this subsection may be co nsidered sufficient cause to rescind approval to furnish cement, by type, on a certification basis.
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 857–872 of 978.