1202 - PERFORMANCE GRADED ASPHALT BINDER 1200 - 6 SECTION 1202 PERFORMANCE GRADED ASPHALT BINDER 1202.1 DESCRIPTION This specification covers performan ce graded asphalt binder (PGAB). 1202.2 REQUIREMENTS
a.Provide material* that complies with the applicable requirements of SECTION 1201 and AASHTO M 320. Polymer modified binders must meet the additional requirements shown in TABLE 1202-1 . *Perform all tests after adding 0.5% high molecular wei ght amine antistripping agent (by weight) to the PGAB. Contact the Chief Chemist, Bureau of Construction and Ma terials, for a list of acceptable high molecular weight amines. TABLE 1202-1: ADDITIO NAL REQUIREMENTS Temperature Spread 1, °C 86 92 98 104 110 Separation, ASTM D 5976, ºC max. Run on Original Binder 2 2 22 2 2 Elastic Recovery, ASTM D 6084, Procedure A, % min. Run on RTFO Residue 50 60 65 75 80 1 Temperature Spread is determined by subtracting low temperature from high temperature; for example PG 64-28: 64-(-28) = 92 2For PG 70-28 RCI, separation test requirement no greater than 6.
b.Provide the grade of material designated in the Contract Documents. KDOT will not make changes in the grade of asphalt. The Contractor may substitute PGAB that complies with or exceeds the upper and lower grade designations for the grade specified. For example, if a maintenance overlay specifies a PG 58-22, a PG 64-22 or a PG 58-28 will also be accepted. Such substitutions require advance approval by the Engineer and a no-cost change order. 1202.3 TEST METHODS Test according to the app licable provisions of ASTM D 5976, D 6084 and AASHTO T 48, T 240, T 313, T 315, T 316, and R 28. 1202.4 PREQUALIFICATION Prequalify material according to SECTION 1201 . 1202.5 BASIS OF ACCEPTANCE See applicable requirements under SECTION 1201 . 1203 - EMULSIFIED ASPHALT 1200 - 7 SECTION 1203 EMULSIFIED ASPHALT 1203.1 DESCRIPTION This specification covers emulsified asphalt used for asphalt mi xes, surface sealing, microsurfacing and tack coats. 1203.2 REQUIREMENTS
a.General . Provide emulsified asphalt that is an intimate, homogenous mixture of base asphalt and emulsifying agent held suspended in water. Certain emul sified asphalt grades may contain petroleum distillates. The grade of material is designated in the Contract Documents. The KDOT reserves the right to change the grade and class as necessary due to aggregate type, road surface or weather conditions. Make the required change after being notified in writing by the KDOT. Provide emulsified asphalt that remains homogenous and stable during transportation, storage and distribution. Material that performs unsatisfactorily in any of the above situations will be rejected even if the material passes all laboratory tests.
b.Chemical and Physical Requirements . Provide emulsified as phalt that complies with TABLES 1203- 1, 1203-2 and 1203-3 . TABLE 1203-1: SPECIFICATIONS FO R ANIONIC EMULSI FIED ASPHALT RS-1H/ RS-1HP SS-1H MS-1 SS-1HP Min. Max. Min. Max. Min. Max. Min. Max. Viscosity, Saybolt Furol At 77°F, sec. . . . . . . . . . . . ----- ----- 10 100 ----- ----- 10 75 At 122°F, sec. . . . . . . . . . . . . 75 300 ----- ----- 100 400 ----- ----- Residue by Distillation, (% by Mass)……………… 65 ----- 57 ----- 65 ----- 57 ----- Oil Distillate, (% by Volume). . ----- ----- ----- ----- ----- 8 ----- ----- Storage Stability, %1 . . . . . . . . ----- 1 ----- 1 ----- 1 ----- ----- Demulsibility: 35 ml of 0.02 N CaCl 2, %. . 60 ----- ----- ----- ----- ----- ----- ----- 50 ml of 0.1 N CaCl 2, %. . . ----- ----- ----- ----- 75 ----- ----- ----- Sieve Test, % Retained. . . . . . ----- 0.50 ----- 0.50 ----- 0.50 ----- 0.1 Tests on Distillation Residue: Penetration, 77°F, 100g, 5 sec. 75 150 75 125 300 ----- 75 150 Solubility, %. . . . . . . . . . . . . . 97 .5 ----- 97.5 ----- 97.5 ----- ----- ----- Ductility, 77°F, mm. . . . . . . . . 800 ----- 800 ----- ----- ----- ----- ----- Ductility, 39°F, mm ----- ----- ----- ----- ----- ----- 100 350 Elastic Recovery @ 50°F, 20 cm elongation, % ----- ----- ----- ----- ----- 25 ----- 1 If the Contractor's storage tanks are equipped with a mechan ical propeller type agitation de vice, and the entire contents of the tank are thoroughly mixed before each day's use, th e requirement for satisfactory compliance with the storage stability test will be waived. 2 RS-1HP only 1203 - EMULSIFIED ASPHALT 1200 - 8 TABLE 1203-2: SPECIFICATIONS FO R CATIONIC EMULSIFIED ASPHALT CRS-1H/ CRS-1HP CSS-1H/ CSS-1HM CMS-1 CSS-Special Min. Max. Min. Max. Min. Max. Min. Max. Viscosity, Saybolt-Furol: At 77°F, sec. . . . . . . . . . . ----- ----- 10 60 ----- ----- ---- ---- At 122°F, sec. . . . . . . . . . 75 300 ----- ----- 100 400 ---- ---- Residue by Distillation, (% by Mass)………………… 65 ----- 57 ----- 65 ----- 64.01 66.01 Oil Distillate, (% by Volume). --- -- 3 ----- ----- ----- 8 ---- 0.5 Storage Stability, %. . . . . . . . ----- 1 ----- 1 ----- 1 ---- ---- Sieve Test, % Retained. . . . . . ----- 0.50 ----- 0.50 ----- 0.50 ---- 0.1 Tests on Distillation Residue: Penetration, 77ºF, 100g, 5 sec 75 150 50 100 300 ----- -25%2 +25%2 Solubility, %. . . . . . . . . . . . . 97 .5 ----- 97.5 ----- 97 .5 ----- ---- ---- Ductility, 77°F, mm. . . . 800 ----- 800 ----- ----- ----- ---- ---- Viscosity, Saybolt-Furol, 180°F, sec.. . . . . . . . . . ----- ----- ----- ----- 300 700 ---- ---- Elastic Recovery @50°F, 20 cm elongation, % ---- ---- ---- ---- ---- ---- ---- 1 Use modified AASHTO T 59 procedure – distillati on temperature of 350°F with a 20 minute hold. 2Penetration will be determined by the producer and submitted to the Chief Chemist at the time of prequalification. 3 CRS-1HP only TABLE 1203-3: SPECIFICATIONS FOR EMULSION BO NDING LIQUID EBL Tests on Emulsion: Min. Max. Viscosity, Saybolt-Furol @ 122ºF, sec 25 125 Storage Stability Test1, 24 h, % 1 Sieve Test2, % Retained 0.3 Residue by Distillation, % 63 Oil Distillate by Distillation, % 2 Demulsibility, % (35 ml, 0.02 N CaCl 2) (Anionic Version) Demulsibility, % (35 ml, 0.8% Dioctyl Sulfosuccinate) (Cationic Version) 60 Tests on Distillation Residue: Min. Max. Penetration, 77ºF, 100g, 5 sec 90 150 Elastic Recovery3, % 60 1 After sitting undisturbed for 24 hours, the sample sh all show no more than 5 ml of the white latex residue. 2 The sieve test is waived if successful application of the material has been achieved in the field. 3 Elastic recovery, AASHTO T 301, 50ºF, 20 cm elongation, 5 minute hold, % min., run on Distillation Residue.
c.Mixing Grade Emulsions . Formulate mixing emulsions (MS-1 and CMS-1) for use with regional aggregate types. In general, these will be crushed limest one and/or dolomite with sand for the eastern section of the state and sand-gravel with mineral filler for the central an d western sections. Formulate emulsions for use by both windrow and plant mixing methods and for either damp or dry aggregates. Provide an emulsion formulated for the intended end use if these conditions cannot be met by a single formulation. Provide an emulsion that enables material in a stockpile to easily be removed at temperatur es as low as 39ºF for an extended period of time after mixing. 1203 - EMULSIFIED ASPHALT 1200 - 9 d. Modified Emulsions, RS -1HP, CRS-1HP and CSS-1HM and CSS-Special
1.Provide anionic emulsified asphalt (RS-1HP) that complies with TABLE 1203-1 or cationic emulsified asphalt (CRS-1HP or CSS-1H M) that complies with TABLE 1203-2 .
2.Provide a modified emulsion that contains a minimum of 3.0 percent polymer solids by weight of asphalt.
3.Provide a modified emulsion that shows no more than 5 ml of the white latex residue after sitting undisturbed for 24 hours. (4) For use in Microsurfacing. Formul ate the modified emulsified asphalt so that if the paving mixture is applied at a thickness of 1 inch, and the relative humidity is not more than 50 percent with the ambient air temperature at least 75ºF, it will cure sufficiently so rolling traffic can be allowed on the pavement in 1 hour with no damage to the surface. It must show no separation after mixing. 1203.3 TEST METHODS
a.Test in accordance with the applicable provi sions of AASHTO T 44, T 49, T 51, and T 59.
b.When testing modified emulsions, test the Elastic Recovery using AASHTO T 301 . In addition, modify the distillation procedure of AASHTO T 59 as follows: “Slowly bring the temperature of the lower thermometer to 350 ± 9ºF and maintain for 20 minutes. Complete the distillation in 60 ± 15 minutes from the first application of heat.” 1203.4 PREQUALIFICATION Prequalify material under th is specification according to SECTION 1201 . 1203.5 BASIS OF ACCEPTANCE See applicable requirements under SECTION 1201 . 1204 - CUTBACK ASPHALT 1200 - 10 SECTION 1204 CUTBACK ASPHALT 1204.1 DESCRIPTION This specification covers cutback asphalt us ed for bituminous mixes and surface sealing. 1204.2 REQUIREMENTS
a.General. Provide material that complies with the applicable requirements of SECTION 1201 . Provide the grade of material designated in th e Contract Documents. The KDOT reserv es the right to change any grade of asphalt due to the characteristics of the roadbed, seasons of the year or weather conditions. This change will be to obtain a material having the characteristics of the next high er or lower grade of cutback asphalt of the same type (RC or MC). Make the required change af ter being notified in writing by the KDOT.
b.Rapid Curing Cutback Asphalt. Provide Rapid Curing Cutback Asphalt consisting of an asphaltic base fluxed with suitable petroleum distillates. Provide a material that shows no separation before use and complies with all requirements for the designated grade shown in AASHTO M 81, Table 1.
c.Medium Curing Cutback Asphalt. Provide Medium Curing Cutback Asphalt consisting of an asphaltic base fluxed with suitable petroleum distillates. Provide a material that shows no separation before use and complies with all requirements for the designa ted grade shown in AASHTO M 82, Table 1. 1204.3 TEST METHODS Test according to the applicable pr ovisions of AASHTO M 81 and M 82. 1204.4 PREQUALIFICATION Prequalify material under th is specification according to SECTION 1201 . 1204.5 BASIS OF ACCEPTANCE See applicable requirements under SECTION 1201 . 1205 - ASPHALT REJUVENATING AGENT 1200 - 11 SECTION 1205 ASPHALT REJUVENATING AGENT 1205.1 DESCRIPTION This specification covers materials to be used as an emulsified polymer-modified asphalt rejuvenating agents for the use in hot in-pl ace recycling of asphalt pavements. 1205.2 REQUIREMENTS Provide material that has a record of satisfactory performance based on the capability of the material to increase the ductility and lower the visc osity of the asphalt binde r in the pavement surface. Provide an asphalt rejuvenating agent composed of a polymer-modified asphalt emulsion. Modify the asphalt base stock with a minimum of 3.0% styrene-butadiene solution polymer. Blend the polymer modified base stock with process oils or other additives before emulsification to achieve the desired finished product properties. The material must comply with the following physical and chemical requirements in TABLE 1205-1 : TABLE 1205-1: ASPHALT REJUVENATING AGENT Property Requirement Viscosity, Saybolt-Furol at 25ºC, sec 15 – 100 Residue, % min.160 Sieve Test, % max. 0.10 Oil Distillate, % max. 2 Storage Stability, 24 hrs., % max. 1 Tests on Residue from Distillation: Asphaltenes, % max. 25 Penetration @ 4 C, 100g, 5 sec. 50 – 150 Elastic Recovery, AASHTO T 301, 4°C, 20 cm elongation, % min. Run on Distillation Residue 60 1 Use modified AASHTO T 59 proc edure – distillation temperature of 350°F with a 20 minute hold. 1205.3 TEST METHODS Test in accordance with the a pplicable provisions of AASHTO T 59, ASTM D 4402 and KT-MR20, “Chemical Analysis of Asphalt Rejuvenating Agents”. 1205.4 PREQUALIFICATION Prequalify material under th is specification according to SECTION 1201 . 1205.5 BASIS OF ACCEPTANCE See applicable requirements under SECTION 1201 . 1206 - POLYMER MODIFIED ASPHALT CEMENT FOR CHIP SEALS 1200 - 12 SECTION 1206 POLYMER MODIFIED ASPHALT CEMENT FOR CHIP SEALS 1206.1 DESCRIPTION This specification covers polymer modi fied (tire rubber and/or SBS) asph alt cement for use in chip seals. 1206.2 REQUIREMENTS Provide material that complies with the requirements shown in TABLE 1206-1 . TABLE 1206-1: ASPHALT CEMENT FOR CHIP SEALS AC-20-5TR AC-10-2TR Min. Max. Min. Max. Polymer TR & SBS(1) TR & SBS(2) Polymer Content, % 5 ----- 3 ----- Dynamic shear, G*/sin , 64C, 10 rad/s, kPa 1.0 ----- ----- ----- Dynamic shear, G*/sin , 58C, 10 rad/s, kPa ----- ----- 1.0 ----- Viscosity, 140°F, Poise 2,000 ----- 1,000 ----- Penetration, 77 F, 100g, 5sec 75 115 95 130 Elastic Recovery, ASTM D6084 50F, % Recovery, 1 hour 55 ----- 30 ----- Softening Point, F 120 ----- 110 ----- Test of Residues from RTFO Aging and PAV Bending Beam Rheometer at - 18 C, MPa Creep Stiffness ----- 300 ----- 300 m-value 0.300 ----- 0.300 -----
1.Produce the AC-20-5TR with a minimum of 5% scrap, group, whole tire rubber.
2.Produce the AC-10-2TR will a minimum of 3% polymers to include a combination of tire rubber and SBS. 1206.3 TEST METHODS Test according to the applicab le provisions of ASTM D 36 and D 6084 Procedure B, and AASHTO T 49, T 202, T 313, and T 315. 1206.4 PREQUALIFICATION Prequalify material according to SECTION 1201 . 1206.5 BASIS OF ACCEPTANCE See applicable requirements under SECTION 1201 . 1207 – WARM MIX ASPHALT ADDITIVES 1200 - 13 SECTION 1207 WARM MIX ASPHALT ADDITIVES 1207.1 DESCRIPTION This specification covers Warm Mix Asphalt (WMA) additives and processes. 1207.2 REQUIREMENTS Provide prequalified WMA additives or processes. 1207.3 TEST METHODS WMA additives and processes will be tested and evaluated by the Texas Department of Transportation following the procedures outlined in subsection 1207.4 . 1207.4 PREQUALIFICATION Obtain prequalification procedures by writing to the Texas Department of Transportation, Director of Construction and Maintenance, 125 East 11th Street, Austin, TX 78701-2483. A list of prequalified additives and processes based on the prequalification process for the Texas Department of Transportation and field performance within Kansas will be maintained by the Bureau of Construction and Materials. The KDOT prequalified list establishes the acceptable additives and pr ocesses to be incorporated into KDOT projects. Products will remain on the KDOT list provided field performance is satisfactory. Products may be removed from the KDOT list if the manufacturer requests the removal of their own product. 1207.5 BASIS OF ACCEPTANCE
a.WMA Foaming Processes.
1.Prequalification as specified in subsection 1207.4 .
2.Field observation of WMA production.
b.WMA additives.
1.Prequalification as specified in subsection 1207.4 .
2.Receipt and approval of a Type C certification as specified in DIVISION 2600 .
3.Field observation of WMA production. 1301 - MASONRY BRICK 1300 - 1 SECTION 1301 MASONRY BRICK 1301.1 DESCRIPTION This specification covers requirements for masonry brick for various types of construction. Supply masonry brick made from clay, shale, or a mixture of aggregates, water and portland cement. 1301.2 REQUIREMENTS
a.Building Brick. ASTM C 62 defines the requirements for this type of brick, except “Maximum Water Absorption by Five-hour Boiling” and “Maximum Saturation Coefficient” does not apply. Provide grade MW masonry brick unless specified otherwise in the Contract Documents.
b.Sewer and Manhole Brick. ASTM C 32 defines the requirements for this type of brick. Provide either Grade MM or MS bricks.
c.Concrete Building Brick. ASTM C 55 defines the requirements for this type of brick, except “Water Absorption” and “Moisture Content” does not apply. Provide Grade S-II concrete building brick unless specified otherwise in th e Contract Documents.
d.ADA Compliant Paving Brick. ASTM C 902 defines the requirements for this type of brick. Provide a brick that complies with Class SX, Type I, and Application PS requirements. 1301.3 METHODS OF TEST Test masonry bricks by the procedures in the ASTM standards cited with each brick type. Note the exceptions taken by the Department. 1301.4 PREQUALIFICATION None required. 1301.5 BASIS OF ACCEPTANCE Acceptance of Sewer and Manhole Brick, and Concrete Building Brick will be base d on satisfactory results of tests conducted on samples submitted to the Engineer of Tests. Acceptance of ADA Compliant Pavi ng Brick will be based on recei ving a Type A certification and satisfactory results of tests conducted on sa mples submitted to the Engineer of Tests. 1302 - CONCRETE MASONRY UNITS 1300 - 2 SECTION 1302 CONCRETE MASONRY UNITS 1302.1 DESCRIPTION This specification covers solid, concrete masonry units for manholes, catch basins and similar items. 1302.2 REQUIREMENTS Provide masonry units that comply with ASTM C 139. 1302.3 TEST METHODS Test masonry units in accordance with the methods in ASTM C 139. 1302.4 PREQUALIFICATION None Required. 1302.5 BASIS OF ACCEPTANCE Acceptance of concrete masonry units will be based on satisfactory results of tests conducted on samples submitted to the Engineer of Tests. 1303 – HOLLOW LOAD-BEARING CONCRETE MASONRY UNITS 1300 - 3 SECTION 1303 HOLLOW LOAD-BEARING CONCRETE MASONRY UNITS 1303.1 DESCRIPTION This specification covers hollow load-bearing concre te masonry units made from portland cement, water, and suitable mineral aggregates with or without the inclusion of other materials. 1303.2 REQUIREMENTS Provide normal weight, masonry units that comply with ASTM C 90 unless otherwise designated in the Contract Documents. 1303.3 METHODS OF TEST Use the methods specified in ASTM C 90. 1303.4 PREQUALIFICATION None Required. 1303.5 BASIS OF ACCEPTANCE Acceptance of hollow load-bearing conc rete masonry units will be based on satisfactory results of tests conducted on samples submitted to the Engineer of Tests. 1304 – SOLID INTERLOCKING PAVING UNITS 1300 - 4 SECTION 1304 SOLID INTERLOCKING PAVING UNITS 1304.1 DESCRIPTION This specification solid interlocking paving units (paving bricks) made from portland cement, water, and suitable mineral aggregates with or without the inclusion of other materials. 1304.2 REQUIREMENTS Provide materials that comply w ith the applicable requirements. Fine Aggregate FA-A ............................................................................................. DIVISION 1100 Concrete and Mortar ............................................................................................... DIVISION 400 Provide paving brick that complies with ASTM C 936 in the styles, dimensions and colors shown in the Contract Documents. If specified, provide commercially available edging for ed ge restraints of the type and dimensions shown in the Contract Documents. 1304.3 METHODS OF TEST Use the methods specified in ASTM C 936. 1304.4 PREQUALIFICATION None Required. 1304.5 BASIS OF ACCEPTANCE Receipt and approval of a Type D certification as specified in DIVISION 2600 . 1401 - AIR-ENTRAINING ADMIXTURES FOR CONCRETE 1400 - 1 SECTION 1401 AIR-ENTRAINING ADMIXTURES FOR CONCRETE 1401.1 DESCRIPTION This specification covers admixtures for use as air-entraining agents to be added to concrete mixtures. An air-entraining agent is defined as an admixture that is used as an ingredient of concrete, added to the batch immediately before or during mixing, for the purpose of entraining air. 1401.2 REQUIREMENTS Provide material that complies with AASHT0 M 154 fo r compressive and flexural strength, and resistance to freezing and thawing. 1401.3 TEST METHODS As specified in AASHTO M 154. Tests for bleeding, time of set, and length change are not required. 1401.4 PREQUALIFICATION
a.Each air-entraining admixture must be prequalified. Submit a written request to be evaluated for prequalification to the Bureau Chief of Construction and Ma terials. Provide the followi ng for each brand and type of material to be evaluated: (1) Name and address of the manufacturer.
2.Brand name of the material.
3.Two copies of a certified test report prepared by a laboratory regularly inspected by the Cement and Concrete Reference Laboratory (CCRL) of the National Inst itute of Standards and Technology, showing test results complying with the applicable requirements of AASHTO M 154. Also, include evidence that the laboratory is regularly inspected by CCRL. Test results are to be no more than 36 months out of date.
4.An infra-red spectrum of the admixture which was used in the laboratory tests.
5.Results of tests from the AASHTO National Tran sportation Product Evaluation Program (NTPEP). Include the most recent NTPEP test report along with eviden ce that the product being offe red is identical to the one reported in the NTPEP report.
b.A one-liter sample from production of each type of admixture being offered w ill be accepted in lieu of the NTPEP test report until June 1, 2016. Submit the sample in addition to the documentation requested above for prequalification to the Engineer of Tests. The manufacturer will be advised of the results.
c.The Bureau of Construction and Materials will maintain a list of prequalified air-entraining admixtures. Products that have been prequalified by the above procedur es will remain prequalified, as long as the formulation and manufacturing processes remain unchanged, and field experience indicates that the admixture functions appropriately. Any prequalified product that does not have a NTPEP test report on file as of January 1, 2017 will be removed from the list of prequalified air-entraining ad mixtures for concrete. Changes in the formulation, manufacturing process, or failure of the admixture to f unction appropriately will require a new prequalification. 1401.5 BASIS OF ACCEPTANCE
a.Prequalification as set forth under subsection 1401.4 .
b.Receipt and approval of a Type C certification as specified in DIVISION 2600 . 1402 - CHEMICAL ADMIXTURES FOR CONCRETE 1400 - 2 SECTION 1402 CHEMICAL ADMIXTURES FOR CONCRETE 1402.1 DESCRIPTION This specification covers chemical admixtures to be added to concrete mixtures during mixing operations for the purposes listed below:
a.Type A – Water Reducing Admixture. An admixture that reduces the quantity of mixing water required to produce concrete of a given consistency.
b.Type B – Set Retarding Admixture. An admixture that retards the setting of concrete.
c.Type C - Accelerating Admixture. An admixture that accelerates the setting of concrete.
d.Type D – Water Reducing-Set Retarding Admixture. An admixture that reduces the quantity of mixing water required to produce concrete of a given consistency, and retards the setting of concrete.
e.Type E - Water Reducing and Accelerating Admixture. An admixture that reduces the quantity of mixing water required to produce concrete of a given co nsistency, and accelerates the setting of concrete.
f.Type F – Water-Reducing, High Range Admixture. An admixture that reduces the quantity of mixing water required to produce concrete of a given consistency by 12% or greater.
g.Type G – Water Reducing, High Range, and Retarding Admixture. An admixture that reduces the quantity of mixing water required to produce concrete of a given consistency by 12% or greater, and retards the setting of concrete.
h.Type S – Specific Performance Admixture. An admixture that provides a desired performance characteristic(s) other than reducing water content, or chan ging the time of setting of concrete, or both, without any adverse effects on the fresh, hardened , or durability properties of concrete.
i.Type I – Plasticizing Admixture. An admixture that produces flowing concrete without further addition of water.
j.Type II – Plasticizing and Set Retarding Admixture . An admixture that produces flowing concrete without further addition of water, and retards the setting of concrete . NOTE: Flowing concrete is defined as having a slump equal to or greater than 7 ½ inches. 1402.2 REQUIREMENTS
a.Provide Type A, B, C, D, E, F, G, and S admixtures that comply with ASTM C 494.
b.Provide Type I and II plasticizing admixtures that comply with ASTM C 1017. 1402.3 TEST METHODS
a.Test Type A, B, C, D, E, F, G, and S admixtures as specified in ASTM C 494, with the following exception:
1.Provisional qualification, as stated in Table 1, Note C, will not be considered until at least 6 months of data has been established.
b.Test Type I and II plasticizing admixtures as specified in ASTM C 1017. 1402 - CHEMICAL ADMIXTURES FOR CONCRETE 1400 - 3 1402.4 PREQUALIFICATION
a.Each brand and type of admixture covered by this sp ecification must be prequalified. Submit a written request to be evaluated for prequalification to the Bureau Chief of Construction and Materials. Provide the following for each brand and type of ma terial to be evaluated:
1.Name and address of the manufacturer.
2.Brand name of the material.
3.Type of material as defined in subsection 1402.1 .
4.The chloride content of the admixture and whether or not chloride was added during its manufacture.
5.Recommended manner and time of adding the admixture to the concrete batch.
6.Two copies of a certified test report prepared by a laboratory regularly inspected by the Cement and Concrete Reference Laboratory (CCRL) of the National Inst itute of Standards and Technology, showing test results complying with the applicable requirements of ASTM C 494 or ASTM C 1017. Also, include evidence that the laboratory is regularly inspected by CCRL. Test results are to be no more than 36 months out of date.
7.An infra-red spectrum of the admixture which was used in the laboratory tests.
8.Results of tests from the AASHTO National Tran sportation Product Evaluation Program (NTPEP). Include the most recent NTPEP test report along with eviden ce that the product being offe red is identical to the one reported in the NTPEP report.
b.A one-liter sample from production of each type of admixture being offered w ill be accepted in lieu of the NTPEP test report until June 1, 2016. Submit the sample in addition to the documentation requested above for prequalification to the Engineer of Tests. The manufacturer will be advised of the results.
c.The Bureau of Construction and Materials will mainta in a list of prequalified chemical admixtures for concrete. Products that have been prequalified by the above procedures will remain pr equalified, as long as the formulation and manufacturing processes remain unchanged, and field experience indicates that the admixture functions appropriately. Any prequalified product that does not have a NTPEP test report on file as of January 1, 2017 will be removed from the list of prequalified chemical admixtures for concrete. Changes in the formulation, manufacturing process, or failure of the admixture to f unction appropriately will require a new prequalification. 1402.5 BASIS OF ACCEPTANCE
a.Prequalification as set forth under subsection 1402.4 .
b.Receipt and approval of a Type C certification as specified in DIVISION 2600 . 1403 - PRECURE/FINISHING AID 1400 - 4 SECTION 1403 PRECURE/FINISHING AID 1403.1 DESCRIPTION This specification covers evaporation retarding material for use in finishing concrete flatwork, and serves as a finishing aid. This material is not a substitute for regular curing compound, which must be applied after the concrete is finished. 1403.2 REQUIREMENTS
a.Provide a pigmented water based material, as described in ACI 345R, capable of producing a monomolecular film over fre shly placed concrete, which serves to retard evaporation from the surface.
b.The material may have no de leterious effects on concrete.
c.Prepare and use the material in accordance with the manufacturer's instructions. Provide a copy of those instructions to the Field Engineer prior to commencing operations. 1403.3 TEST METHODS None specified. 1403.4 PREQUALIFICATION Pre-cure/ finishing aid materials must be prequalified. For approval of proposed products, submit complete technical data and material safety data sheets to the Bur eau of Construction and Materials. The manufacturer will be notified of the acceptance or denial of the product. The Bureau of Construction and Materials will maintain a list of prequalified pre-cure/finishing aid material for concrete. Products prequalified by the above procedures will remain prequalified, as long as the formulation and manufacturing processes remain unchanged, and field experience indicates that the admixtur e functions appropriately. 1403.5 BASIS OF ACCEPTANCE
a.Prequalification as required by subsection 1403.4 of this specification.
b.Receipt and approval of a Type C certification as specified in DIVISION 2600 . 1404 - LIQUID MEMBRANE FORMING COMPOUNDS 1400 - 5 SECTION 1404 LIQUID MEMBRANE FORMING COMPOUNDS 1404.1 DESCRIPTION This specification covers liquid membrane forming compounds (also referred to as concrete curing compounds) suitable for sprayi ng on horizontal and vertical concrete surfaces to retard the loss of water during the early hardening period and subsequent curing period. 1404.2 REQUIREMENTS
a.Provide liquid membrane forming compound that complies with ASTM C 309 for Type 1-D, clear or translucent with fugitive dye, or Type 2, white pigmented compound.
b.Type 2 white pigmented compound will be further classified into Type 2 (Wax Based) and Type 2 (Other). This is to allow specifying of wax based compound for certain applications where a bond breaker is desired. Either formulation base may be supplied except when wax based is specified.
c.Do not allow water-emulsion based material to freeze. Material that has been subjected to freezing temperatures will be rejected. 1404.3 TEST METHODS Test materials in accordance with ASTM C 309. Fi ngerprinting and screening of verification samples by infrared spectroscopy is done according to ASTM E 1252. Water emulsion based material is not subject to th e long term settling test by the freeze thaw cycling method. Wax-based material for Cement Treated Base (CTB) with the following exceptions: Moisture Loss, kg /sq m (max.) ........................................... 0.60 Daylight Reflec tance (min.) ............................................... 50% 1404.4 PREQUALIFICATION Submit two 1-quart samples of material and a copy of the manufacturer’s test results on samples of the same lot of material to the Engineer of Tests. Include a copy of the Material Safety Data Sheet (MSDS). For Type 2 white pigmented compounds, include a statement regarding whether the formulation is wax based or other, unless it is specifically addressed in the MSDS. Samples will be tested for compliance with this specifi cation. The manufacturer w ill be notified of the test results on the samples submitted. Results of tests from the AASHTO National Transp ortation Product Evaluation Program (NTPEP) will be accepted in lieu of the sample requested above. Include th e most recent NTPEP test re port along with the other documentation requested. Include evidence that the product being offered is identical to the one reported in the NTPEP report. Manufacturers whose products comp ly with this specification will be placed on a prequalified list. Manufacturers will remain on the list as long as the results of verification samples and performance in the field are satisfactory. Any changes in formulation will re quire re-submittal for prequalification testing. 1404.5 BASIS OF ACCEPTANCE a . Prequalification as required by subsection 1404.4 above.
b.Receipt and approval of a Type C certification as specified in DIVISION 2600 . 1405 - BURLAP 1400 - 6 SECTION 1405 BURLAP 1405.1 DESCRIPTION This specification covers new and us ed burlap for use in curing concrete. 1405.2 REQUIREMENTS
a.General. Provide material which complies with AASHTO M 182, Class 3 (10 oz/yd) with the following additions:
1.Manila hemp may also be used to make burlap.
2.Burlap fabricated from bags may not be used.
3.Burlap may not contain any water soluble ingredient which will retard the setting time of portland cement concrete.
b.Used Burlap. Used burlap must comply with the requirements stated above, and can only have been used previously for curing concrete. "Like new" cleanliness is not expected, but contamination with any substance foreign to the concrete curing process (e.g. grease or oil) will be cause for rejection. 1405.3 TEST METHODS As specified in AASHTO M 182. 1405.4 PREQUALIFICATION None Required 1405.5 BASIS OF ACCEPTANCE
a.New burlap will be accepted on the basis receipt and approval of a Type D certif ication as specified in
Division 2600 — and a visual inspection for compliance with AASHTO M 182.
b.Used burlap will be accepted on the basis of a Contractor certification regarding the source and previous use of the material, and a visual inspection for compliance with AASHTO M 182. 1406 – SHEET MATERIALS FOR CURING CONCRETE 1400 - 7 SECTION 1406 SHEET MATERIALS FOR CURING CONCRETE 1406.1 DESCRIPTION This specification covers materials in sheet form used for covering the su rfaces of hydraulic cement concrete to inhibit moisture loss during the curing period. In the case of white reflective materials, it also reduces temperature rise in concrete exposed to radiation from the sun. Materials included are clear and white opaque polyethylene film, and white-burlap polyethylene sheet. 1406.2 REQUIREMENTS
a.General. Provide material that complies with AASHTO M 171.
b.Used Sheet Material. Used sheet material must comply with the requirements stated above, and can only have been used previously for curing concrete. "Like ne w" cleanliness is not expected, but contamination with any substance foreign to the concrete curing process (e .g. grease or oil) will be cause for rejection. 1406.3 TEST METHODS As specified in AASHTO M 171. 1406.4 PREQUALIFICATION None Required. 1406.5 BASIS OF ACCEPTANCE
a.New sheet materials will be accepted on the basis receipt and approval of a Type D certification as specified in DIVISION 2600 , and a visual inspection for compliance with AASHTO M 171.
b.Used sheet materials will be accepted on the basis of a Contractor certificati on regarding the source and previous use of the material, and a visual inspection for compliance with AASHTO M 171. 1501 - HOT JOINT SEALING COMPOUND 1500 - 1 SECTION 1501 HOT JOINT SEALING COMPOUND 1501.1 DESCRIPTION This specification covers hot joint sealing compound for use in sealing joints and cracks in asphalt and portland cement concrete pavements. 1501.2 REQUIREMENTS
a.General. Provide a joint sealing compound that is a homogeneous blend of elastomers and other plasticizers and agents blended to result in a product that seals cracks in pavements from water intrusion. The sealant must retain adhesion and flexibility during extremes of e xpansion and contraction of the crack through a temperature range of 0ºF to 140ºF. Heat and apply the material according to manufacturer’s recommendations.
b.Bond. When tested at -20oF to 200% extension of 1/2 inch to 1-1/2 inch for 3 cycles, the material exhibits no cracking, separation, or other opening that at any point is gr eater than ¼ inch d eep in the sealer or between the sealer and the mortar block. A minimum of 2 test specimens in a set of 3 representing a given sample must comply with this requirement.
c.Flow. 5 mm maximum.
d.Resilience. 50 – 80% recovery .
e.Cone Penetration. 0 oF, 150 grams, 5 seconds: 18 - 80
f.Provide material capable of a minimum 12-hour pot life at application temperature and of being re-heatable at least once (in a normal field application) without experien cing changes in application characteristics, polymer and oil separation, balling or other signs of gelling.
g.Package the material in pails or boxes clearly marked with recommended pouring temperature, maximum heating temperature, shelf life if appropriate, and batch number. The size of a batch, which is any well-defined quantity produced by essentially the same process during a designated amount or time (such as an 8-hour shift), must be a minimum of 10,000 lbs.
h.Lots from the same manufacturer may be commingled during application. Do not commingle materials from different manufacturers. 1501.3 TEST METHODS
a.Sample Preparation. ASTM D5167, sample size of 5 lbs. Maintain the material at the manufacturer's recommended pouring temperature for 6 hours for both initial and reheat, before preparing the specimens.
b.Bond. ASTM D5329, Section 9. In forming the bond test specimens, space the blocks 0.50 ± 0.01 inch apart by means of suitable spacer strips to enclose a space of 2.0 ± 0.05 inch by 2.0 ± 0.05 inch.
c.Flow. ASTM D5329, Section 8.
d.Resilience. ASTM D5329, Section 12.
e.Cone Penetration. ASTM D5329, Section 6 with the following variations:
1.Pour the sample into a 6 oz. tin flush with the top and allow to cool overnight.
2.Place the specimen in a freezer at 0 oF for 4 hours. Place the cone in the freezer for the last hour before the test. 1501 - HOT JOINT SEALING COMPOUND 1500 - 2 (3) At the end of the 4-hour period, remove the cone from the freezer, place the specimen on the stand, and penetrate immediately.
4.Return the specimen to the freezer, clean the cone, and return the cone to the freezer for 30 minutes before making each successive penetration.
f.Reheat. Allow the remainder of the sample to cool to r oom temperature until the next working day. Repeat subsections 1501.3a. through 1501.3e. Results of tests must meet requirements, and be consistent with those from the first set of specimens. 1501.4 PREQUALIFICATION
a.Manufacturers interested in prequalifying material under this specification must provide a thirty pound sample to the Engineer of Tests for laboratory testing. Incl ude a copy of the quality control test report for the batch of material the sample represents, material safety data sheets, and a complete set of heating and installation recommendations and instructions. Include any conditions a nd limits to the number of re-heating cycles for the material.
b.Results of testing from the AASHTO National Tran sportation Product Evalua tion Program (NTPEP) will be accepted in lieu of the sample requested above. Includ e the most recent NTPEP test report along with the other documentation requested. Include evidence that the product being offered is identical to the one reported in the NTPEP report.
c.The material will be evaluated for compliance with this specification, and the manufacturer will be notified of the results. The Bureau of Construction and Materials wi ll maintain a list of qualified materials. Products will remain on the prequalified list as long as the results of batc h testing and field performance are satisfactory. Report any changes in formulation to the Engineer of Tests for review and evaluation to determine if requalification is necessary. 1501.5 BASIS OF ACCEPTANCE
a.Prequalification as required in subsection 1501.4 .
b.Receipt and approval of manufacturer's certification fo r minimum pot life and reheatability requirements. The manufacturer must certify that the material is capable of a minimum 12-hour pot life at application temperature and is re-heatable at least once (in a normal field application) without experiencing changes in application characteristics, polymer and oil separation, balling or any other signs of jelling. The manufacturer must designate any conditions and limits to the number of re-heat ing cycles for the material.
c.Satisfactory results of tests c onducted at the Materials and Research Center on each batch of material. Samples will be obtained by a representa tive of KDOT and must be available for testing at the Materials and Research Center a minimum of 10 working days before the date the material is required for installation.
d.Visual observation of performance in the field. 1502 - COLD APPLIED CHEMICALLY CURED JOINT SEALANT 1500 - 3 SECTION 1502 COLD APPLIED CHEMICALLY CURED JOINT SEALANT 1502.1 DESCRIPTION This specification covers cold applied chemically cured joint sealant and backer rod to be used for filling joints in portland cement concrete pavement. 1502.2 REQUIREMENTS
a.Joint Sealant. Prequalify joint sealant before use on KDOT projects. Use either Type NS (Non Self- Leveling) or Type SL (Self-Leveling). Provide joint sealants that consist of a cold applied formulation that is self- priming and compatible with portland cement concrete. The sealants must comply with the applicable test requirements in ASTM D 5893. Acetic acid cure sealants will not be accepted.
b.Backer Rod. Furnish material that is resilient closed or open cell polyethylene fo am rod as recommended by the manufacturer of the sealant. Provide a backer rod compatible with the sealant, with no bond or reaction occurring between the rod and the sealant. 1502.3 TEST METHODS Test materials covered by this section in accordance with the applicable test methods in ASTM D 5893. 1502.4 PREQUALIFICATION
a.Laboratory Prequalification. Manufacturers interested in qualifying sealant under this specification must supply actual test data from an approved testing laboratory showing compliance with the specification. Submit test results to the Engineer of Tests.
b.NTPEP Prequalification. Results of testing from the AASHTO National Transportation Product Evaluation Program (NTP EP) will also be accepted. Submit a copy of the most recent NTPEP test report to the Engineer of Tests. Include evidence that the product being offered is identical to the one reported in the NTPEP report.
c.Prequalified List. The Bureau of Construction and Materials will include products complying with subsection 1502.2 on a prequalified list. Failure of any field instal lation in less than the anticipated life will be cause for removal of the product from prequalified status. Products removed from prequalified status will be considered for re-qualification if the manufacturer can provide evidence that the cause of failure has been positively identified, and necessary formulation changes and quality control measures ha ve been implemented to eliminate that cause. Complete prequalification under subsection 1502.4 . is required for products removed from the prequalified list. 1502.5 BASIS OF ACCEPTANCE
a.Prequalified status as required in subsection 1502.4 .
b.Receipt and approval of a Type A certification as specified in DIVISION 2600 . Report all test requirements on the certification.
c.Use the material within 6 months of the date of the certification. If the material is not used within the 6 month period, re-testing and re-certification will be required. Use re-certified material within 45 days of the re- certification. 1503 - PREFORMED EXPANSIO N JOINT FILLER FOR CONCRETE 1500 - 4 SECTION 1503 PREFORMED EXPANSION JOINT FILLER FOR CONCRETE 1503.1 DESCRIPTION This specification covers redwood board expansion join t filler (Type A) for use in sidewalks, and preformed expansion joint filler (Type B) for conc rete paving and structural construction. 1503.2 REQUIREMENTS
a.Type A. Provide redwood boards of sound heartwood. Occasional small sound knot s and medium surface checks will be permitted provided the board is free of an y defects that will impair its usefulness for the purpose intended. The redwood board joint filler is composed of only one piece of board in the length of the joint, and with dimensions as shown in the Contract Documents. Positive tolerances of 1/16 inch thickness, 1/8 inch depth (or width) and ¼ inch length are permitted. Immerse redwood board joint material in water for a minimum of 24 hours before being installed in the sidewalk. Do not allow the boards to dry out prior to installation.
b.Type B. Provide material that complies with AASHTO M 213. 1503.3 TEST METHODS
a.Type A. None specified.
b.Type B. As specified in AASHTO M 213. 1503.4 PREQUALIFICATION None required. 1503.5 BASIS OF ACCEPTANCE
a.Type A. Visual inspection for the quality and dimensional requirements.
b.Type B.
1.Receipt and approval of a Type D certification as specified in DIVISION 2600 .
2.Visual inspection at destination for condition a nd compliance with dimensional and other requirements. 1504 - PREFORMED ELASTOMERIC COMP RESSION JOINT SEALS FOR CONCRETE 1500 - 5 SECTION 1504 PREFORMED ELASTOMERIC COMPRESSION JOINT SEALS FOR CONCRETE 1504.1 DESCRIPTION This specification governs the prefor med elastomeric joint seals designed to operate under compression and intended for various applications. The specification also addresses certain components, such as lubricants and adhesives, required for in stallation of the seals. 1504.2 REQUIREMENTS
a.General.
1.Unless specified otherwise in the Contract Docume nts, provide transverse pavement joint seals that comply with TABLE 1504-1 . TABLE 1504-1: DIMENSIONS FOR PREFORME D ELASTOMERIC COMPRE SSION JOINT SEALS Joint spacing on centers. 15 feet 30 feet Allowable range of non-compressed seal width across flat contact surfaces. 0.687 0.750 inch 0.719 inch nominal width 0.812 0.875 inch 0.843 inch nominal width Vertical dimension of non-compressed seal flat contact surface, per side, minimum. 0.630 inch 0.800 inch Maximum allowable overall vertical dimension of seal when compressed to width of 3/8 inch. 1.50 inch 1.50 inch
2.Provide elastomeric seals for bridge deck expansion joints that comply with the dimensional requirements specified in the Contract Documents.
b.Material Specifications.
1.Comply with AASHTO M 220 when the intended application is pavement joints and AASHTO M 297 when the intended application is bridge deck joints. Durably label and mark seals in compliance with th e requirements of those AASHTO standards inclusive of a unique identifier such as a batch or lot number and date of manufacture. Package seals to prevent damage during transport and durably label the packaging containmen t with all information requir ed to properly identify the contents. (2) All adhesives, lubricants, cementing agents, etc., th at are required for installa tion of the seals are to be specified and provided by the manufactur er of the seal. All installation is to be in strict accordance with the specified procedures and practices of the seal manufacturer. These procedures and practices are to be provided with the component. Properly package all of these components and provide instructions for safe storage, transport, proper disposal of component and container, emergency procedures, etc. Durably label all with the name and address of the manufacturer, date of manufacture, shelf life or expiration date if applicable, a unique identifier such as a batch or lot number, and any other relevant information. 1504.3 TEST METHODS Using the applicable AASHTO material specification shown in subsection 1504.2b., conduct all tests required according to the specified procedures with the following exceptions: Pavement and bridge deck seals when compressed to a width of 80 and 85 percent of nominal are to provide a load resistance of not less than 50 pounds per linear foot. Bridge deck seals when compressed to a width of 50 percent of nominal are not to produce a load resistance that exceeds 500 pounds per linear foot. These properties are evaluated while conducting the compression deflection tests according to the procedures of the applicable AASHTO standard. 1504 - PREFORMED ELASTOMERIC COMP RESSION JOINT SEALS FOR CONCRETE 1500 - 6 1504.4 PREQUALIFICATION
a.General. All manufacturers of elastomeric seals that intend to provide seals for KDOT projects must have their products prequalified by size and design configuration. To initiate this process provide a request for the evaluation of the product to the Bureau Chief of Construction and Materials along with the following documentation: The manufacturer's corporate name and address as well as the address of the facilities that are manufacturing the seals being prequalified, The method of traceability utilized fo r quality control such as lot or batch numbers, dates of manufacture, etc., Typical material quantities represented by this method, A list of authorized distributors of the product(s) being prequalified if applicable .
b.Manufacturer Quality Control Requirements. The manufacturer must perform the quality control testing with an identified and adequately staffed section with in its organization. The laboratory must have the proper calibrated equipment with which to ade quately perform all testing required by subsection 1504.3. Provide a copy of the quality control plan to the Bureau Chief, Construction and Materials.
c.Sampling and Testing Procedure. The manufacturer is to provide a 6-foot length sample of each seal size and design configuration they desire to have evaluated for prequalification. Submit samples to the Engineer of Tests. The samples are to be represen tative of seal production and are to be provided with certified laboratory reports documenting the results of the tests required by subsection 1504.3 . The samples will be evaluated and tested by the central laboratory according to subsection 1504.3 with the results compared to those of the manufacturer.
d.Manufacturer Status. A manufacturer will be notified by written documentation of the results of their application for prequalification and in the event of any chan ge in prequalified status once it has been attained. The manufacturer is to immediately notify the Bureau of Construction and Materials of any changes in the elastomeric compound, design configuration, dimensions, installation procedures and practices, etc., of the prequalified products. The Bureau of Construction and Ma terials will review the changes and determined whether the product is to remain prequalified. If the changes disqualify the product, an application for prequalification as a new product according to the preceding requirements may be submitted. The failure of random verification samples removed from seals delivered to projects may also disqualify the product. The Bureau will maintain a list of all prequalified manuf acturers by facility and the specific seal size(s) and design(s) that have been approved. Authorized distributors of the approved products, as provided by the manufacturer, will also be maintained on the prequalified list. A distributor may be added to the prequalified list if they can provide verifiable documenta tion to The Bureau of Construction and Materials that they are supplying a prequalified product. 1504.5 BASIS OF ACCEPTANCE
a.The manufacturer by facility and the specific seal size and design must be currently prequalified.
b.Receipt and approval of a Type C certification as specified in DIVISION 2600 for the seals, adhesives, lubricants, cementing agents, and any other products specif ied by the seal manufacturer for proper installation of the seals.
c.The final disposition of all products and components will be completed at the final destination as the result of inspection for the quality of workmanship, the deli very condition, and approval of the associated required documentation. 1505 - MATERIALS FOR FILLING AND SEALING JOINTS IN PIPE 1500 - 7 SECTION 1505 MATERIALS FOR FILLING AND SEALING JOINTS IN PIPE 1505.1 DESCRIPTION This specification covers the following five types of products:
a.Joint compound for filling and sealing joints in concrete and vitrified clay pipe.
b.Flexible gasket type joint material for filling and sealing joints in concrete and vitrified pipe.
c.Factory molded joint rings for use on st andard or extra strength clay pipe.
d.Materials for sealing joints in cast iron pipe.
e.Expanded closed-cellular rubber gaskets for filling an d sealing joints in reinforced concrete pipe and boxes used for drainage and storm water lines. 1505.2 REQUIREMENTS
a.Compound Type Joint Filler.
1.General. Provide a compound that is a ready- mixed homogeneous blend of asphalt or tar, inert filler and a suitable solvent or solvents. The inert filler may incl ude polyethylene, polypropylene or cellulose fibers, mica, slate or silica flour or clay. Do not use any type of asbestos material. Mix all ingredients thoroughly at the factory to a uniform workable consistency.
2.Physical. Provide a compound that complies with TABLE 1505-1 : TABLE 1505-1: COMPOUND TYPE JOINT FILLER Property Min. Max Percent Ash ---- 30 Penetration (Standard Cone) 150g, 5 sec., 77 F 125 250
3.Packaging. Limit container size to 5 gallons of material.
4.Sampling. Sample in accordance w ith applicable provisions of KT-27.
b.Flexible Gasket Type Joint Filler. Provide a flexible plastic gasket material supplied in extruded rope form for use where infiltration or exfiltr ation is a factor in design. Produce flexible plastic gaskets from blends of refined hydrocarbon resins and plasticizing compounds re inforced with inert mineral filler and containing no solvents. Provide a gasket joint seal er that does not depend on oxidizing, evaporating or chemical action for adhesive or cohesive strength. Supply the sealer in extr uded rope form of suitable cross section and size to fill the joint space when the pipes are joined. Provide material that complies with AASHTO M 198.
c.Factory Molded Joints. Provide factory-molded joints capable of being fused to both bell and spigot ends of pipe. Provide material that produces watertight joints when the pipe is joined in the trench. The material must comply with ASTM C 425.
d.Materials For Sealing Joints in Cast Iron Pipe.
1.Packing. Provide material for packing that is twisted jute complying to the Federal Specification “Packing: Jute, Twisted” Serial No. HH-P-117-2, Type II.
2.Caulking. Provide lead caulking complying to the Federal Specification “L ead, Caulking” Serial No. QQ-C-40.
3.Rubber Seals. In lieu of lead and jute for sea ling joints, the use of specially designed rubber seals will be permitted. Install rubber seals in accor dance with the manufacturer’s recommendation. 1505 - MATERIALS FOR FILLING AND SEALING JOINTS IN PIPE 1500 - 8
e.Expanded Closed-Cellular Rubb er Gaskets for Reinforced Concre te Pipe and Precast Boxes.
1.Provide gaskets of tubular cross-section, manufactured from extruded closed-cellular rubber and complying to the physical requirements of ASTM D1056, Cla ss 2C1. Each gasket must be a single continuous part and will conform to the joint size and shape. The outer surface must be completely covered with a smooth, impermeable natural skin of the same material.
2.Gasket cross-sectional diameters and installation practices, including maximum and minimum joint gaps must be in accordance with the manufacturer’s re commendations. Provide a copy of the manufacturer’s installation instructions to the Field Engineer. Do not use this type of gasket when the pipe is installed by jacking or boring methods. 1505.3 TEST METHODS
a.Compound Type Joint Filler. Test in accordance with TABLE 1505-2 . TABLE 1505-2: COMPOUND TYPE JOINT FILLER Property Method Penetration (Standard Cone, Unworked) ASTM D 217 Use an 8-ounce gill can as the test container. Percent Ash AASHTO T 111 1505.4 PREQUALIFICATION None required. 1505.5 BASIS OF ACCEPTANCE
a.Compound Type Joint Filler. Satisfactory results of tests conduc ted at the Materials and Research Center. A representative of KDOT will sa mple each lot or batch of material. Each lot will be subjected to visual examination and testing in accordance with subsection 1505.3 and for compliance with subsection 1505.2a .
b.Flexible Gasket Type Joint Filler, Factory Mold ed Joint Rings and Materials For Sealing Joints In Cast Iron Pipe (except Rubber Seals). Receipt and approval of a Type D certification as specified in DIVISION 2600 .
c.Rubber Seals. Visual inspection by the Engineer.
d.Expanded Closed-Cellu lar Rubber Gaskets.
1.Receipt and approval of a Type D certification as specified in DIVISION 2600 .
2.Visual inspection by the Engineer for workmanship, fit and final installation practices. 1506 - POLYVINYL CHLORIDE (PVC) - PLASTIC WATERSTOP 1500 - 9 SECTION 1506 POLYVINYL CHLORIDE (PVC) PLASTIC WATERSTOP 1506.1 DESCRIPTION This specification covers extruded polyvi nyl chloride (PVC) plastic waterstop. 1506.2 REQUIREMENTS
a.General. Provide PVC waterstop with a ribb ed or serrated cross section pr ofile with center bulb that complies with all current requirements of Corps of Engineers Specification CRD-C-572.
b.Dimensions. PVC waterstop is either nominal 6 inch width or 9 inch width as shown in the Contract Documents. Other dimensions are as follows: (1) 6 inch PVC Waterstop. Center bulb 5/8 to ¾ inch outside diameter (OD) and ¼ to 3/8 inch inside diameter (ID). Minimum thickness adjacent to center bulb 0.360 inch. Waterstop may be uniform in cross-section or uniformly tapered to a minimum thickness of 3/16 inch between serrations at edges.
2.9 inch PVC Waterstop. Center bulb 5/16 inch to 7/8 inch OD and ¼ inch to ½ inch ID. Minimum thickness adjacent to center bulb 0.375 inch. Waterstop ma y be uniform in cross-section or uniformly tapered to a minimum thickness of ¼ inch between serrations at edges. 1506.3 TEST METHODS Test in accordance with the current Corps of Engineers Specification CRD-C-572. 1506.4 PREQUALIFICATIONS None required. 1506.5 BASIS OF ACCEPTANCE PVC waterstop is accepted based on receipt and appr oval of a Type D certification as specified in
Division 2600 — and visual inspection for conditions and dimensional requirements.
1507 - PRESSURE RELIEF JOINT FILLER 1500 - 10 SECTION 1507 PRESSURE RELIEF JOINT FILLER 1507.1 DESCRIPTION This specification covers material s for pressure relief joint filler and lubricant adhesive for use when installing the joint filler material. 1507.2 REQUIREMENTS
a.Polyurethane Pressure Relief Jo int Filler (4 inch Joint Opening).
1.General: This material is a flexible, low density , cellular polyurethane plank for use in pressure relief joints for concrete pavements. It is multicellular, homogeneous foam, having a specially designed cross section, which locks the filler in place. (2) Physical Properties. Provide joint filler material that complies with TABLE 1507-1 : TABLE 1507-1: POLYURETHANE PRESSURE RELIEF JOINT FILLER (4 inch Joint Opening) Property Requirements Compression (PSI): At 25% Deflection 5 ± 2 At 65% Deflection 12 ± 4 Water Absorption (% by Volume): Less than 30 Density (lbs/cu ft): 7 - 10 Recovery (Percent, Min.): 90 Dimensions: Width 4 inches Nominal Depth 7 3/4 inches Nominal* *Include a supply (equal to the length of the or der) of 1 inch X 4 inches polystyrene or polyurethane foam as spacers to insert in the bottom of the trench.
b.Polyethylene Pressure Relief Joint Filler (2 inch or 4 inch Joint Opening).
1.General: This material is a fl exible, low density, multicellular, closed cell, polyethylene plank for use as a highway pressure relief joint. Provide 2 inch or 4 inch width as sp ecified in the Contract Documents.
2.Physical Properties. The joint filler material complies with TABLE 1507-2 . TABLE 1507-2: POLYURETHANE PRESSURE RELIEF JOINT FILLER (2 or 4 inch Joint Opening) Property Requirements Compression (PSI): At 10% Deflection Less than 10 At 80% Deflection Less than 125 Water Absorption (% by Volume): Less than 0.5 Density (lbs/cu ft): 2.6 ± 0.2 Dimensions: Width 2 inches or 4 inches Nominal Depth 9 inches Nominal
c.Lubricant Adhesive. Provide a lubricant adhesive recommended by the manufacturer of the joint filler for use when installing the joint filler material. It must have workable consistency at the temperatures the filler material will be installed, be compatible with the joint filler material and the concrete, and be relatively unaffected by the moisture in concrete. 1507 - PRESSURE RELIEF JOINT FILLER 1500 - 11 1507.3 TEST METHODS
a.Polyurethane Pressure Relief Joint Filler.
1.Compression - Deflection - In accordance with ASTM D 3574 (Test C) using a rate of compression of 2 inches/minute and a sample preflexed 75%. (2) Water Absorption - In accordance with AASHTO T-42.
3.Recovery. 65% deflection recovery calculated after 1-minute relaxation from deflection return.
b.Polyethylene Pressure Relief Joint Filler.
1.Compression: In accordance with ASTM D 1056 except determine the compressive strength at 10% deflection and 80% deflection. (2) Water Absorption: In accordance with ASTM C 272 using conditioning procedure 10.1.1 at a temperature of 120 ± 5 oF.
3.Density: In accordance with ASTM D 3574 (Test A). 1507.4 PREQUALIFICATION None required. 1507.5 BASIS OF ACCEPTANCE
a.Receipt and approval of a Type D certification as specified in DIVISION 2600 .
b.Visual inspection at destination for condition and dimensional requirements. 1508 - ELASTOMERIC CONCRETE 1500 - 12 SECTION 1508 ELASTOMERIC CONCRETE 1508.1 DESCRIPTION Elastomeric concrete is composed of a two-part ra pid curing polymer binder material, aggregate and other ingredients as recommended by the binder manufacturer. Elastomeric concrete exhibits flexibility, suitable load carrying characteristics, ozone resistance, ultra-violet resi stance and is not prone to cracking or spalling when exposed to ambient air temperatures of -30oF and warmer. 1508.2 REQUIREMENTS Elastomeric concrete, when combined in the proportions and manner specified by the binder manufacturer, complies with the TABLE 1508-1 : TABLE 1508-1: ELASTOMERIC CONCRETE Property Requirements Elastomeric binder after 7-day cure. Impact Strength @ -20oF 7 ft-lb, min. Tensile Strength 500 psi, min. Ultimate Elongation 100 %, min. Tear Resistance 80 lb/in., min. Elastomeric binder after 30-day oven aging. Impact Strength @ -29oC 7 ft-lb, min. Tensile Strength 500 psi, min. Ultimate Elongation 50 %, min. Elastomeric binder-aggregate mixture after 7-day cure. Bond Strength to Concrete 300 psi, min Wet Bond Strength to Concrete 225 psi, min Compressive Stress at 5 % deflection 300 psi min, 2000 psi max. Resilience 70 %, min.
d.Use aggregates that are compatible with the elastomeri c binder, as supplied with the system, or as specified by the binder manufacturer. 1508.3 TEST METHODS
a.Preparation of Specimens. Prepare specimens by thoroughly mixing the components in the ratios specified by the manufacturer. Before mixing, heat the components to the temperatures recommended by the manufacturer during placement in order to provide a workable mixture and give an initial cure representa tive of field placement. Apply no heat after mixing. If heating is not specified, mix the components at ambient temperature. Because of the high bond strength of th ese materials, mold surfaces such as Teflon or lubricant-coated metal are recommended. Pour binder mixtures into molds as soon as possible after thorough mixing so they will flow well. Minimize entrained air during mixing. It may be removed by the use of vacuum, physical means, or passing a soft flame over the surface. Allow specimens cu re sufficiently before removal from mo lds so that they will not be damaged by removal. Cure specimens at either 73 ± 3ºF for 7 days or at 140 ± 4ºF for 30 days, and test as specified. Stamp specimens for tensile strength, ultimate elongation and tear resistance from cast sheets of the proper thickness as soon as the binder is sufficiently cured. Sand these specimens to remove irre gularities and provide true surfaces. 1508 - ELASTOMERIC CONCRETE 1500 - 13 b. Tests on the Elastomeric Binder.
1.Impact Resistance. The specimen is a cast disk 2.50 ± 0.05 inches in diameter and 0.375 ± 0.010 inches thick. Sand the faces flat and parallel . After 7 days cure, condition the specime ns for 4 hours at -20°F. Remove the specimen from the freezer and placed on a dr y machined steel plate. Immediately after placing the disk on the plate, drop a 1 pound steel ball onto the center of the specimen through a guiding tube from an initial drop height of 5 feet. The drop height is increased by ½ foot intervals until the specimen cracks, or unt il all specimens exceed the specification minimums. The result will be the average of 4 specimens. Any cr acking of a specimen will constitute failure. Repeat the procedure with 4 specime ns that have been oven cured for 30 days.
2.Tensile Strength. This test is performed acco rding to ASTM D 638 using th e Type IV specimen with dimension WO of 1 inch, which corresponds to Die C of ASTM D 412. Perform Testing after 7 days of cure. Measure the thickness and width of the specimen neck using a dial gauge or caliper, and determine the cross sectional area. Use an initial test machine jaw separation of 2 inches and a cros shead speed of 2 inches per mi nute. Load the specimen to failure. Use the maximum load to determine the tensile stre ngth. Test at least 8 specimens. Discard those with obvious flaws. Repeat the procedure with 8 specimens that have been oven cured for 30 days.
3.Ultimate Elongation. Perform this test as a part of Tensile Strength using the same specimens. Determine ultimate elongation from the initial jaw separation and the amount of crosshead travel at failure. Report results as a percent of the original gauge length. Repeat the procedur e with 8 specimens that have been oven cured for 30 days.
4.Tear Resistance. Determine tear resistance according to ASTM D 624 using the Die C specimen. Perform testing after 7 days cure. Determine the thickness of the specimen at the point of tear with a dial gauge prior to testing. Use an initial testing machine jaw separation of 2 inches, and a crosshead speed of 2 in ches per minute. Test a minimum of 5 specimens.
c.Tests on the Elastomeric Binder-Aggregate Mixture.
1.Bond Strength to Concrete. Cast the elastomeric concrete against a mortar briquette half (briquette complies to AASHTO T 132). Saw the briquette in half so that the sawed surface area equa ls approximately 1 sq in. Sandblast the surface. Place the briquette in the mold and cast the elastomeric concrete against the sawed surface. Cure the specimens 7 days in air at 73 ± 3°F. Using the Riehle briquette tester, specimen failure is considered to occur at either the bond interface or in either of the two materials. Test a minimum of 4 specimens. Determine an average tensile breaking stress based on a 1 sq in cross-sectional area.
2.Wet Bond Strength to Concrete. Prepare mortar briquette halves the same as for Bond Strength to Concrete. After a 5-day cure in air at 73 ± 3°F, immerse the specimens in 73 ± 3°F water for 2 days in a horizontal position. After the immersion period, remove the specimens fro m the water and subject them to tensile testing with the Riehle briquette tester while still damp. Test a minimum of 4 specimens. Determine an average tensile breaking stress based on a 1 sq in cross-sectional area.
3.Compressive Stress at 5 % Deflection. The test specimens are cast 1 inch cubes, prepared so as to have flat, parallel oppos ing faces free from irregularities. Cure the specimens seve n days in air at 73 ± 3°F. Determine the original thickness of the specimen within 0.001 inch wit hout a load. Place the specimen in the compression machine, apply a 100 pound load, and zero a dial gauge. Load the specime n at a rate of 0.15 inch per minute until a deflection of 0.10 inch is reached, at which point the compressive load is recorded and removed. Test a minimum of four cubes and calculate an average compressive stress based on the original 4 in.2 area.
4.Resilience. The Resilience test is a continuation of the Compressive Stress at 5 % Deflection test. After removal of the load, the specimen is allowed to recover for five minutes, after which the thickness is re-measured. Resilience is the percent recovery and is calculated as follows: Resilience = (0.10 in. + final thickness - initial thickness) X (100) (0.10 in.) 1508.4 PREQUALIFICATION
a.Manufacturers interested in prequalifying material under this specification must provide 3 sets of 2- component samples (2 for binder tests and 1 for binder-aggregate mixture tests) to the Engineer of Tests for laboratory testing. Provide 1 set of aggregate for binder-aggregate mixture testing. Include a copy of the quality control test report for the batch of material the sample represents, mate rial safety data sheets, and a complete set of mixing and installation recommendations and instructions. 1508 - ELASTOMERIC CONCRETE 1500 - 14 b. The material will be evaluated for compliance with this specification, and the manufacturer will be notified of the results. The Bureau of Construction and Materials wi ll maintain a list of qualified materials. Products will remain on the prequalified list as long as the results of ve rification testing and field performance are satisfactory. Report any changes in formulation to the Engineer of Tests fo r review and evaluation to determine if re-qualification is necessary. 1508.5 BASIS OF ACCEPTANCE
a.Prequalification as required by subsection 1508.4.
b.Receipt and approval of a Type C certification as specified in DIVISION 2600 .
c.Visual observation of performance in the field. 1509 - MEMBRANE SEALANT 1500 - 15 SECTION 1509 MEMBRANE SEALANT 1509.1 DESCRIPTION This specification covers the membrane sealant used in expansions joints as designated in the Contract Documents. 1509.2 REQUIREMENTS
a.Foam Sealant. Provide a foam sealant consisting of an open-cell high density polyurethane foam impregnated with either a polymer modified bitumen or a neoprene rubber suspended in chlorinated hydrocarbons. Precompress the foam sealant prior to packaging. Use a precompressed dimension as recommended by the sealant manufacturer to provide a water tight seal throughout a joint movement range of ±25% (minimum) from the specified joint opening dimension. Do not allow the precompressed dimension to exceed 75% of the joint opening width. Provide a foam sealant that is slowly self expandin g to permit workers ample time to install the foam before the foam exceeds the joint opening width. Supply the foam in pieces 5 feet in length or longer. Miter the ends of each piece for ease of joinin g to the adjacent pieces. Provide the foam sealant in 3 inch deep pieces (minimum). Provide foam sealant that is ultra-violet and ozone resistant. Provide the foam sealan t that meets the requirements shown in TABLE 1509-1 : TABLE 1509-1 FOAM SEALANT Property Test Method Requirements Tensile Strength ASTM D3574 21 PSI min. Elongation, Ultimate ASTM D3574 125% ± 20%. Density, Uncompressed 9 lb./cu. ft. min. Compressed Density at Joint Width 45 lb./cu.ft. min. Compression Set ASTM D3574 3% max. Softening Point ASTM D816 140 o F. min. Low Temperature Flexibility (32 oF to -10 o F) ASTM C711 No Cracking or Splitting
b.Bonding Adhesive. Provide a waterproof epoxy adhesive th at is compatible with concrete and recommended by the manufacturer of the foam sealant.
c.Splice Adhesive. Provide any polyurethane adhesive recommended by the manufacturer of the foam sealant. 1509.3 TEST METHODS Test in accordance with the requirements stated in subsection 1509.2 . 1509.4 PREQUALIFICATION None required. 1509.5 BASIS OF ACCEPTANCE Receipt and approval of a Type D certification as specified in DIVISION 2600 . Visual inspection at destination for condition and compliance with dimensional and other requirements. 1510 - STRIP SEAL ASSEMBLY 1500 - 16 SECTION 1510 STRIP SEAL ASSEMBLY 1510.1 DESCRIPTION This specification covers materials for a bridge expansion joint system using a strip seal assembly as shown in the Contract Documents. 1510.2 REQUIREMENTS
a.Type I.
1.Provide a Type I Strip Seal assembly that consists of a single continuous neoprene strip or diaphragm seal element inserted into tw o wedge grips of extruded or rolled steel that are anchored to the bridge. The Engineer will consider other configurations of locking devices or grips to retain th e diaphragm in place if the Contractor provides detailed information on the alternate device.
2.Unless shown otherwise in the Contract Documents, provide grips that comply with the requirements of ASTM A 36 or A 242. The anchoring system for the grip s must comply with the details shown in the Contract Documents.
3.Provide a Polych loroprene (Neoprene) diaphr agm that complies with the requirements of ASTM D 2628 (except for recovery requirements), or alternately, ASTM D 2000 3BC 615 A14 B14 C12 F17 (250% minimum ultimate elongation). In the preceding “line call-out”, the “15” in 615 refers to minimum tensile strength in hundreds of psi.
4.Provide a sealant for bonding the neoprene diaphragm to the steel grips that complies with the recommendations of the manufacturer of the assembly.
b.Type II
1.Provide a Type II assembly that consists of separa te units of elastomer and metal or integrally molded components cast under heat and pressure, and anchored to the bridge by bolts or studs.
2.The assembly must contain a flexible convolution or diaphragm, with or without fabric reinforcement, which links the pads and spans the expansion joint. The diaphragm must be a continuous strip, molded in an upstanding arch, which will retain its shape during the e xpansion cycle and must permit horizontal, vertical, and skewed movements while still maintaining a watertight seal.
3.Provide an elastomer manufactured from neoprene that complies with TABLE 1510-1. TABLE 1510-1: TYPE II ELASTOMER Property ASTM Test Method Requirement Tensile Strength D 412 1500 psi, minimum Elongation at Break D 412 200% minimum Hardness D 2240 4510 points, Durometer A Compression Set, 22 hrs @ 70 C D 395, Method B 35% maximum Low Temperature D 746 or D 2137 Not Brittle @ -40 C Ozone Resistance, exposure @ 100 PPHM ozone for 70 hrs. @ 40C, sample under 20% strain D 1149 No Cracks Oil Deterioration, volume increase after immersion in IRM 903 Oil for 70 hrs. @ 100 C D 471 120% maximum PPHM = Parts Per Hundred Million
4.Provide a sealant that comp lies with the recommendations of the manufacturer of the assembly.
5.Fasten the assembly to the bridge with bolts or studs that complies with details in the Contract Documents and are of a length recommended by the assembly manufacturer.
6.Provide internal reinforcement plates that comply with the requir ements of ASTM A 1011 SS Grade 36, A 36 or similar structural steel. 1510 - STRIP SEAL ASSEMBLY 1500 - 17
c.Type III
1.Provide a Type III assembly that consists of a continuous cellular or strip type neoprene seal, geometrically designed to fasten to or be clamped by the extruded aluminum frames anchored to the bridge by bolts or cast-in-place anchors.
2.Provide aluminum frame components that comply with the requirements of ASTM B 221 (Alloy 6061- T6). (3) Fasten the assembly to the bridge with bolts or studs that complies with details in the Contract Documents and are of a length recommended by the assembly manufacturer.
4.Provide an elastomer manufactured from preformed neoprene that complies with TABLE 1510-2. TABLE 1510-2: TYPE III ELASTOMER Property ASTM Test Method Requirement * Tensile Strength D 412 2000 psi, minimum Elongation at Break D 412 175% minimum Hardness D 2240 7010 points, Durometer A Compression Set, 22 hrs @ 70 C D 395, Method B 25% maximum Low Temperature D 746 Not Brittle @ -40 C Ozone Resistance, exposure @ 300 PPHM ozone for 70 hrs. @ 40C, sample under 20% strain D 1149 No Cracks Oil Deterioration, volume increase after immersion in IRM 903 Oil for 70 hrs. @ 100 C D 471 80% maximum * All test sections taken for the extruded section. PPHM = Parts Per Hundred Million 1510.3 TEST METHODS Test the materials in accordance with the ASTM standards referenced above. 1510.4 PREQUALIFICATION None required. 1510.5 BASIS OF ACCEPTANCE Receipt and approval of a Type D Certification as specified in DIVISION 2600 . Visual inspection for conditi on at the point of usage. 1511 - BRIDGE JOINT SYSTEM - PREFORMED PRESSURIZED ELASTOMERIC NEOPRENE 1500 - 18 SECTION 1511 BRIDGE JOINT SYSTEM - PREFORMED PRESSURIZED ELASTOMERIC NEOPRENE 1511.1 DESCRIPTION This specification covers material for a bridge expansion joint system using a preformed, pressurized elastomeric neoprene seal as sh own in the Contract Documents. 1511.2 REQUIREMENTS
a.Provide a polychloroprene (neoprene) elastomer profile that is preformed by extrusion and vulcanized into its definitive shape, and is supplied in several configurations and dimensions, ranging from 1/4 to 4 inches. See the Contract Documents for profile size requirements. The profile must comply with AASHTO M 297, except it must be capable of being pressurized during installation.
b.Use a double-component, epoxy-based adhesive mixed at the job-site. Apply it to thoroughly cleaned expansion gap walls and outside rough walls of the profile. Provide an epoxy-based adhesive that complies with TABLE 1511-1 . TABLE 1511-1: DOUBLE COMPONENT THIXOTROPIC PASTE Property Requirement Tensile Strength 4140 PSI Axial Compression 8760 PSI Solids Hardness 5 MOHS Pot Life 40 Minutes at 68ºF Flash Point > 200ºF Curing Time/Strong Bond Within 24 Hours Complete Cure 7 Days at 68ºF (At higher ambient temperatures, th e cure will be accelerated.)
c.Pressurization is done through a valve with a cap system. The profile is pressurized only during installation and curing time of the adhesive, to ve rify complete bonding throug hout the gap/profile surfaces. Air pressure will bleed itself with time or the air valve can be broken loose any time after 24 hours of installation. 1511.3 TEST METHODS Test the material in accordance with AASHTO M 297. 1511.4 PREQUALIFICATION None required. 1511.5 BASIS OF ACCEPTANCE Receipt and approval of a Type D Certification as specified in DIVISION 2600 . 1601 - STEEL BARS FOR CONCRETE REINFORCEMENT
1600-1 Section 1601
STEEL BARS FOR CONC RETE REINFORCEMENT 1601.1 DESCRIPTION This specification governs the steel bars for concrete reinforcement that are produced from billet steel. 1601.2 REQUIREMENTS
a.General.
1.Any plant producing steel bars for concrete reinforcement through this specification must be currently prequalified. A plant is any facility that rolls or otherwise produces the bars from the basis steel.
2.All the bars produced through this specification are to be deformed unless specified otherwise in the Contract Documents. (3) When it is required to bend and cut bars in order to produce components for a project, conduct these operations in a fabrication shop before shipment to the project. This requirement applies unless it is specified otherwise in the Contract Documents or documented approval is obtained from the Engineer’s representative. Heating of the bars to facilitate th e bending operation is not permitted.
b.Material Specifications. Carbon steel bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AASHTO M 31 Rail-steel and Axle-steel bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AASHTO M 322 1601.3 TEST METHODS Conduct all tests required by the app licable AASHTO material specification of subsection 1601.2b . 1601.4 PREQUALIFICATION Follow the instructions on the AASHTO National Transportation Product Evaluation Program’s (NTPEP) website to participate in the audit program for reinforcing steel mill. Forward an official copy of the initial (and latest) NTPEP audit report, including split sample results, to the Bureau Chief of Construction and Materials for evaluation. Producing mills that have successfully met the requirements of the audit (including test results that comply with subsection 1601.2b. ) and are listed on the NTPEP website as compliant will be prequalified. In order to maintain prequalified status, send a copy of the annual NTPEP certifi cate of compliance as soon as it is received. Producing mills th at have been removed from the NTPE P website listing will be removed from prequalified status. For producing mills that attain “provisional” status on the NTPE P website, immediately forward a description of the failing material (sizes, grade, and h eat) to the Bureau Chief of Construction and Materials. Producing mills that fail to provide the annual certificate of compliance or descriptions of failing material associated with a “provisional” NTPEP status, or are no longer in compliance with the audit requirements may be removed from prequalified status. 1601.5 PREQUALIFICATION (Alternate Method)
a.General. Contact the Bureau Chief of Construction and Materials to arrange for the required sampling, observation of testing procedures and review of the plant quality control program. The plant is to absorb all the Engineer’s representa tive expenses associated with the inspection. This includes travel, subsistence and lodging, and the expenses of shipping the selected specimen bars to the KDOT Materials and Research Center for comparison testing. It is the option of the Bureau Chief of Construction and Materials to grant approval status to a plant based upon the qualification test and inspection results of the transportation agencies of other states. A plant will be notified by written documentation in the event of any change in their approval status. The Bureau of Construction and Materials w ill maintain a list of all plants that are prequalified and approved to provide 1601 - STEEL BARS FOR CONCRETE REINFORCEMENT
1600-2 bars to KDOT projects.
b.Plant Quality Control Requirements. The plant must have a quality control section identified within its organization that is adequately staffed to perform the re quired lot by lot testing. The plant laboratory must have proper equipment, calibrated according to AASHTO T 67 (ASTM E 4) annua lly as a minimum, with which to adequately perform all testing according to subsection 1601.3 . Provide a copy of the plant quality control plan to the Engineer’s representative during the plant inspection.
c.Sampling and Testing Procedure. The Engineer’s representative will select the test samples, at random, at the plant. Provide access to all facilities necessary for the Enginee r’s representative to randomly select samples from all lots defined below. Provide plant personnel to cut and label the necessary specimens from the randomly selected bars.
1.Lot size. The lot of reinforcing bars that is s ubject to sampling includes all sizes, grades, and heats in stock. Remove the samples from 3 different bars from each of 10 heats, i.e., 30 sample bars, unless exceptions are authorized by the Bureau Chief of Construction and Materials or their designated representative. (2) The sample length needed by KDOT is 8 feet for all selected bars, #6 and smaller; 9 feet for all selected bars, #7 thru #11; and 10 feet for all selected bars larg er than #11. Please note: These are minimum lengths needed for KDOT’s use. Additional sample length will be n eeded to satisfy the plant’s testing requirements.
3.Sample preparation. Assign each sample bar a uniq ue identification number. Durably affix this number to each end of the bar. Cut each sample bar into 2 specime n preparation sections. One section is for testing by the plant and the companion section, having the length specified above, is for the comparison testing by KDOT. Conduct all sample preparation operations in th e presence of the Engineer’s representative.
4.Specimen testing. Test the speci mens according to the procedures and requirements of the applicable AASHTO specification as referenced in subsection 1601.2b . For the purpose of comparing the plant and KDOT testing laboratories, one tensile and bend test specimen se t from each sample is to be tested by each laboratory. Provide all the necessary facilities and test records required by th e Engineer’s representativ e to witness the tests. The Engineer’s representative will witness all relevant testing performed by the producer. Record the plant test results onto a KDOT form and sign the form. Pr ovide these results to the E ngineer’s representative for submittal to the KDOT central laboratory. Submit the remaining companion s ections from each sample to the KD OT central laboratory. It is mandatory that these sections each have at least one occurre nce of the plant’s unique mill marking character set that identifies the bar.
5.Comparison testing. The compan ion sections will each provide a tens ile and bend test specimen set that will be tested by the KDOT central laboratory acco rding to the procedures and requirements of subsection 1601.2b . The KDOT results will be compared to the parallel plant data from each h eat for variations and differences. These variations and differences may not exceed the followi ng, based on the KDOT values as the reference where applicable: TABLE 1601-1: STEEL BARS COMPARISON TESTING Property Individual Sp ecimen Average Specimen Yield Strength 15% 6% Tensile Strength 10% 4% Elongation, % 9 6 All variations and differences are absolute value based. A heat that fails the comparison requirements may be resampled 1 time only, and on a 2 to 1 basis. It is preferred that the resample be removed from the same heat that failed. The initial test results will be replaced by those of the resample specimens.
d.Plant Status.
1.Attainment of prequalified status. In order for a plant to be prequalified to provide bars to KDOT projects, the following requirements must be complied with:
a.With the exceptions as noted in (b) and (c) to follow, no single heat of those tested is permitted to fail to comply with the appli cable requirements referenced in subsection 1601.2b .
b.No lot tested by the KDOT may have any of the individual test results for yield strength, tensile strength, or elongation below the AASHTO specified minimum values without the 1601 - STEEL BARS FOR CONCRETE REINFORCEMENT
1600-3 deficiency also being identified by the plant quality control section.
c.It is permissible for one bend test specimen from one heat only to fail the bend test.
d.The variations from the comparison testi ng are not to exceed the values stated in subsection 1601.5c.(5) for any heat.
2.Renewal of prequalified status. The following schedule will apply to plants that have attained their initial prequalification status:
a.One year after the initial prequalification, the plant will again be evaluated according to subsection 1601.5.
b.For plants that retain prequalification after the second evaluation, the next evaluation will be required after a 2-year time interval. (c) For plants that retain prequalification after the third evaluation, the required evaluation time interval will be extended to 3 years thereaf ter providing the plant is not disqualified.
d.A prequalified plant that becomes disqualified must comply with all the requirements that apply to a plant that is attempting the initial pre qualification, with the following exception. The disqualified plant may petition for an immediate reevaluation provided it can be demonstrated to the Bureau Chief of Construction and Materials that the disqualifying deficiencies have been corrected. 1601.6 VERIFICATION
a.Samples. All prequalified plants that are currently pr oviding bars for KDOT projects will have their product quality monitored through the use of verification samples. The Regional Materials Laboratories will randomly select on average 1 verification sample per month from the bars being provide d by each prequalified plant for use on KDOT projects. Special arrangements may be considered for plants providing small quantities during the course of a year. These samples are to include all bar grades and sizes that may be available for use on KDOT projects. These samples will be obtained from various shipme nts and at any fabrication, coating, or precast facility, or warehouse selected by the Region al Materials Engineer. On occasion, it will be necessary for the Regional Materials Engineer to notify the District to obtain verification samples at a project. Samples will be submitted to the MRC for testing according to the procedures and requirements of subsection 1601.2b . Reduction in sampling will follow the criteria established in Part V, Appendix A, Multi-level Sampling Frequency Chart, with the following exception: Reduced Frequency Approved by Regional Materials Engineer with Notification to Bureau of Construction and Materials.
b.Sample testing. The verification samples are to comply with the minimum requirements of the applicable AASHTO specification of subsection 1601.2b. with the exceptions as noted in the following. It will be permissible for the test results from only one annual verification sample from each prequalified plant to be less than the following: TABLE 1601-2: STEEL BARS VERIFICATION TESTING Property Requirement Unit Weight: 99% of the specified minimum Yield Strength: 95% of the specified minimum Tensile Strength: 95% of the specified minimum Elongation, %: Specified minimum minus 2 Not more than 10% of the annual verification sample s from each prequalified plant will be permitted to have test results less than the applicable specification minimums. Not more than one annual verifica tion sample from each prequalified plant will be permitted to fail the bend test. In the event that the verification samples fail to comply with the proceeding, the Engineer’s representative may resample the failing heat(s) one time only on a 2 to 1 basis or reject the failing heat(s). The Contractor is to re place the rejected heats at no additi onal cost to the KDOT. The initial test results will be replaced by those of the resample specimens.
c.Disqualification. Failure of the verification sample bars from a plant to comply with subsection 1601 - STEEL BARS FOR CONCRETE REINFORCEMENT
1600-4 1601.6b. will result in disqualification of the plant and remova l from the prequalified source list. In the event of
disqualification, the plant is subject to the prequalification requirements of subsection 1601.5 even if originally prequalified under subsection 1601.4 . A plant that fails to comply with subsection 1601.6b. 2 times, consecutive or otherwise, will be permanently disqualified. 1601.7 BASIS OF ACCEPTANCE
a.The plant must be currently prequalified.
b.Submit for approval a Type A certification (certified mill test report), as specified in DIVISION 2600 , that governs the analysis of all bar steel heats delivered to the project.
c.The Engineer’s representative of the project must be provided with shipping orders, an invoice, or cover letter that documents the project number, bar sizes and grades, heat, job, or mill order number(s), and the total weight of each heat of the represen ted bars delivered to the project.
d.The Engineer’s representative of the project must be provided with a document stating that the bars delivered to the project comply with this specification. This documentation must bear the signature and title of an official of the plant with Contract Document binding authority, and must be notarized. This requirement may be included on the certified mill test report referenced in subsection 1601.7b .
e.Single or bound groups of bars must be tagged or otherwise marked in a durable manner. At a minimum, this identification must list the bar manufacturer’s corporat e identification and plant loca tion, the heat number, and job or mill order number. Display a copy of the plant’s un ique mill marking character set that identifies the bar on the tag.
f.The final disposition of the bars will be completed at the final destination as the result of inspection for the quality of workmanship and the delivery condition. 1602 - EPOXY COATED STEEL FOR CONCRETE REINFORCEMENT
1600-5 Section 1602
EPOXY COATED STEEL FOR CONCRETE REINFORCEMENT 1602.1 DESCRIPTION This specification covers the requirements for epox y coated steel for concrete reinforcement. The protective epoxy coating is applied to the reinforcing steel by the electrostatic spray or th e electrostatic fluidized-bed method. 1602.2 REQUIREMENTS
a.General.
1.Appendices to the standards cited below that are identified as non-mandatory information in those standards, are to be considered mandatory information for the purposes of this specification. (2) Applicators must be certified under the Concre te Reinforcing Steel Institute (CRSI) Epoxy Coating Plant Certification program.
b.Epoxy Coated Steel Bars.
1.Unless shown otherwise in the Contract Docume nts, use uncoated steel bars that comply with SECTION 1601 for straight bars or SECTION 1604 for helical reinforcement.
2.Apply an epoxy coating that complies with ASTM A 775.
3.Fabricators must comply with the provisions of ASTM D 3963, “Standard Sp ecification for Fabrication and Jobsite Handling of Epoxy-Coated Reinforcing Steel Bars."
c.Epoxy Coated Steel Wi re and Welded Wire Fabric.
1.Unless shown otherwise on the Contract Documents, use material which complies with SECTION 1603 for welded wire fabric or SECTION 1604 for steel wire.
2.Apply an epoxy coating that complies with ASTM A 884, Type 1 with Class A coating thickness. Prestressed beams may utilize preformed welded wire fabric having an ASTM A 884, Type 2 coating. Do not re-bend after applying the Type 2 coating.
d.Dowel Bars and Straight Tie Bars* for Pavement.
1.Use steel bars that comply with SECTION 1601 .
2.Apply an epoxy coating that complies with ASTM A 775. (3) Coating or patching material need not be applied to the cut end faces of the bars. For dowel bars to be mounted in baskets, coating will not be required within 2 inches of the end that will be fixed in the supporting basket by welding. (4) Cut the bars by a method that minimizes heat input and surface da mage and results in no appreciable deformation of the ends. * Refers to straight bars that are not bent after being epoxy coated. For field straightened tie bars (delivered bent), provide uncoated Grade 40 st eel bars that comply with SECTION 1601 . Do not use epoxy co ated steel for field straightened tie bars. 1602.3 TEST METHODS As specified in the ASTM standards referenced above. 1602.4 PREQUALIFICATION
a.Applicators. Epoxy coating applicator plants supplying material to KDOT projects must be prequalified. Follow the instructions on CRSI’s website to participate in the Epoxy Coating Plant Certification program. Send a copy of the most r ecent yearly certification, gr ade sheets and inspection notes, as well as audit responses when applicable, to the Bureau of Construction and Materials for review. In order to maintain prequalified status, send copies of the yearly certification, grade sheets and inspection notes, as well as audit response when applicable, each year as soon as they are received from CRSI. Failure to
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 709–750 of 978.